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Blast Chiller

1. the default values change for each phase shown on the individual screen during the creation of a cycle minimum blast chiller freezer temperature set point to maximum blast chiller freezer Conservation set point 6 b a Blast chiller freezer temperature set point in conservation C temperature set point 2 0 0 not used 1 start conservation time between defrost 2 time set time between defrost Defrost scheduler 6 b b Type of defrost scheduler 3 time set 1 Monday to Sunday Mon to Day E 6 bb Day of activation of the first defrost Fri Mon to Sat weekends Hours and minutes of the first defrost The next will be run after the time between defrosts or at the time set for the second defrost according to the 0 to 23 0 Time of the first defrost 6 b b settings of the defrost scheduler parameter 0 to 59 0 Time of the eighth 0 to 23 0 defrost 6b Hours and minutes of the eighth defrost 0 to 59 0 Evaporator fan control set point Parameter active only if the fans are controlled in relation to the temperature that is depending on the deviation Minimum fan control set point Evap fan control set between the blast chiller freezer temperature and the evaporator to Maximum set point control point 6 b c temperature PC fans 5 0 D switch fans off 6 b c Fans off when door closed YES NO YES Fans during defrost 6 b c Fans during defrost Off On On Type of HACCP threshold 6 b d Type of HACCP alarm threshold Relative Absolute Relative Mi
2. Defrost Y Time Time between defrosts variable dn Defrost duration less than Ts dn d ZZ Defrost duration higher than 100 P Fig 4 14 Combination of variable time between defrosts and skip defrost 4 5 5 Manual defrost Parameters type of defrost maximum defrost duration fan operation during defrost dripping duration post dripping duration 030220851 rel 1 5 09 12 2008 26 Description of the function The manual defrost can be activated by the user from the Conservation menu right side of the bar at the bottom regardless of whether the conservation phase is in progress The manual defrost only involves the activation of the evaporator fans according to the setting of the fan operation during defrost parameter for the maximum duration set or until the user stops it manually The dripping and post dripping phases if set are performed Note for this type of defrost the evaporator probe is not normally envisaged nonetheless if this is configured the start and end defrost thresholds can be set Note the manual defrost can 4 6 HACCP Hazard Analysis and Critical Control Point Input blast chiller freezer temperature probe Parameters blast chiller freezer HACCP high temperature alarm threshold alarm blast chiller freezer high temperature delay HACCP alarm delay maximum blackout duration during a cyde maximum blackout duration during conservation type of HACCP threshold Description of th
3. A 7 Ba Maintenance Information I l I I e Maintenance settings i Q9 I Aa 22N o o a Config serial Forts i o 2 i zu b Set or hours 887 cu mus c Calibrate Probes DOS o Si d Temperature control ES Y C Manual management I I I I d Default Pu2 Alarms F a a a a st a a a E a T A E EEA E E EEE EE I Li BU o 8 e Configuration I e T lt I B oS f 1 0 configuration ba D BESCU Manufacturer settings em we h 1 0 test I I if E 1 Initislisstion FW3 s NM clock Fo 2 Es Data 109 HACCP 4 pe a Alarma i c Bi Print Il i1 14 2f Lock keyrad 030220851 rel 1 5 09 12 2008 29 Fig 5 2 Fig 5 1 The Blast Chiller screen can be divided nto 4 main areas containing different This shows the information on the type of the cycle by time by temperature hard soft na f on the other hand no cyde is running on accessing this menu three submenus are displayed REPEAT STANDARD and CUSTOM the first row of the display shows the Menu branch accessed by the user where the address of the screen string CYCLE the various submenus are indicated by specific icons relating to the menu map may be displayed in the top right corner see Fig 5 5 5 2 2 Repeat 2 Main sa SISTERS If entering branch 2 a of the functions tree a screen Is displayed showing information on 3 8 q the last cycle completed with th
4. NTC input precision PT1000 input precision 0 1V input precision 0 10V input precision 030220851 rel 1 5 09 12 2008 0 55C ESE 3mV 30mV CAREL 0 5V input precision 15mV 0 20 mA input precision 0 06 mA Important the 21Vdc available at the Vdc terminal J2 can be used to power any active probes The maximum current is 150 mA thermally protected against short circuits To supply the 0 to 5 V ratiometric probes use the 5V available at terminal 5Vref 124 The maximum current is 60 mA Digital inputs Type optically isolated no of optically isolated inputs at 24 Vac 50 60 Hz or 24Vdc Total Maximum number EXP 8 Normally open open closed open 200 ms Normally closed closed open closed 400 ms 230 Vac or 24 Vac 50 60 Hz 10 15 Power supply to the inputs External 24Vdc 10 20 Classification of the measurement circuits Category 1 24 Vac Vdc Minimum digital input impulse detection time IEC EN 61010 1 Category 2 230 Vac Analogue outputs Type optically isolated Maximum number 4 x0to 10 Vdc outputs Y1 Y4 SMALL Power supply 24 Vac Vde outputs Y1 Y4 2 of full scale Precision outputs Y5 Y6 2 5 of full scale Resolution 8 bit outputs YI Y4 2s zeige outputs Y5 Y6 2s or 15s selected via software Maximum load 1 KQ 10mA Digital outputs The outputs can be divided into groups Between groups cells in the table there is double insulation and consequently these may have different v
5. Parameter the name of the parameter Type indicates the function the various parameters relate to Screen the identification number of the screen for accessing the parameter in question menu branch followed by the index of the screen if available Description short description of the parameter UOM unit of measure Range the range of values available for the parameter Default the default value of the parameter Temperature control and compressors E ol Inputs outputs Menu Parameter Type screen Description UOM Range Default Cyde Current cycle Cyde running Product temperature the highest or the average value if more than one probe is used depending on the value set for the blast chiller temp probe Product temperature management C 500to 90 0 Blast chiller freezer temperature the highest or the average value if more Blast chiller freezer than one probe is used depending on the value set for the blast chiller temperature M temp probe management C 50 0 to 90 0 maximum cycle duration to Timer Time remaining until the conclusion of the cycle min 9999 Signals Alarms HACCP alarms product probe error conservation phase setting to Cycle terminated correctly cycle terminated after Cycle status Information concerning the end of the cycle maximum time Conservation Blast chiller freezer temperature the highest or the average value i
6. 2 5 5 Connecting product probes with heaters The probes with heater codes NTCINFO340 and PT1INFO340 require the four wires to be connected to the Blast Chiller pCO board the wires with different colours are indicated in the following figure by the numbers described in the table wire colour 182 Red 384 White 030220851 rel 1 3 09 12 2008 15 This represents just one of the possible configurations for the connections The inputs and outputs effectively used depend on the configuration of the software On the Blast Chiller pCO Small model the white wire indicated as number 3 can be connected to the GND terminal as in the figure or BC4 or BC5 white wire number 4 on the other hand can be connected to B1 B2 or B5 or B4 or B5 LW I UW Y 78 88 Sl 185888 5 mel E S g COD ii BE J11 service card Endl lili Damn se de mcam cioe ae se A ez 23 sape alle ee MM ile lt ae KD E wm T Fa rn nn nto nan a m a m m m m m m m m m m m mi La ES 24 Vac On the Blast Chiller pCO model the white wire represented in the following figure as number 4 can be connected in addition to B1 also to B2 or B3 or BA Serial Card Note if using NTC or PT1000 probes without heater the wires indicated by numbers 1 and 2 will not be present 2 3 4 Connecting the analogue inputs selected as ON OFF The pCO allows some analogue i
7. Access parameter settings Stop Access auxiliary output control E Access conservation phase settings 5 5 Conservation 273 y A E E O AE ne Access continuous operation This menu can be used to start or modify the conservation phase The screen displayed de Access defrost settings and control is similar to the one shown in Fig 5 2 and is used to set the main parameters E Access light control Pause 5 4 Sterilisation tart gt DI Access this menu to start the blast chiller sterilisation procedure The display shows the F Repeat cycle screen in Fig 5 3 this screen is only visible however if the corresponding output has zus Save been enabled otherwise the display shows the message NOT AVAILABLE Sel Start standard cycle Note indicates that only one option is available while E shown if the user can choose between various options available 5 1 W on off This menu is used to switch Blast Chiller on off that is from OFF status to ON and vice versa To change status press for 5 seconds Fig 5 5 f The first row shows the string STERILISATION while in the middle of the screen are the 5 2 Cycle temperature of the blast chiller and the duration of the sterilisation process The icon Willie flashes if the process is running The last two rows focus the user s attention on any causes that prevent the sterilisation process from starting or other information concerning the end of the procedure The icons at
8. Differential Set point Zo gt Fig 4 8 ON OFF evaporator fan control 030220851 rel 1 3 09 12 2008 ENG Control based on the diff between blast chiller temp and evaporator temp Maximum output Minimum output Blast chiller freezer temp Set point Differential Evaporator temp lt ___ gt Control based on the evaporator temperature Maximum output Minimum output Evaporator temp Set point Differential lt Fig 4 9 Modulating evaporator fan control Note if the version fitted on the pCO board is being used a PWM analogue output can be managed If output Y3 is configured for the evaporator fans these must also be managed by the parameters relating to maximum and minimum phase shift triac pulse width and mains frequency In this mode the following hardware modules can be connected FCS CONVONOFF CONVO 10A0 or MCHRT series 4 4 2 Condenser fans Input Condenser temperature Parameters condenser fan off temperature set point condenser fan off differential condenser fan start delay at power up Output condenser fans Description of the function the condenser fans can be managed in modulating mode described in Fig 4 11 or on off mode Fig 4 10 if both the condenser fan temperature probe and the output have been configured First start Condenser temperature Set point lt NR Differential Fig 4 10 ON OFF condenser fan
9. Esc returns to the previous screen scrolls a list upwards or increases the value shown Up on the display scrolls a list downwards or decreases the value V Down shown on the display enters the selected submenu or confirms the value Enter set oor Pn Cycle Repeat button to quickly access the Repeat Cycle menu buttons only available on the membrane interface The membrane terminal has three additional LEDs which have the following meaning alarm As the corresponding Alarm button on the membrane does not light up as is the case on the panel display this LED is used to visually signal that Red an alarm has been activated Green 5 chiller On Off Green P cyde running button to quickly access the On Off menu CAREL 4 1 Chill and freeze cycles Blast chill cycles are the main function of the Blast Chiller and can be divided into two categories chill cycles and freeze cydes A chill cyde significantly reduces the time the food remains in the critical temperature band from 10 C to 65 C where there is high probability of bacteria proliferation A freeze cyde on the other hand tends to reduce the formation of macrocrystals of ice inside the frozen product such macrocrystals when forming affect the organoleptic properties of the food The standard values of these cycles are as follows Chill cyde Freeze cycle 90 C 18 C 240 min Initial product temperature Final product tempera
10. if the electronic controller is fitted with standard Carel NTC sensors it is compliant with standard EN13485 on Thermometers for measuring the air temperature in applications on units for the conservation and sale of refrigerated frozen and deep frozen food and ice cream 030220851 rel 1 5 09 12 2008 12 CAREL 1 6 Product probe Blast Chiller can be fitted with the following probes for specific uses 1 6 1 Piercing probe without handle NTC probe code NTCINFO600 1 6 2 Piercing probe with handle NTC probe code NTCINF0610 NTC probe with heater NTCINFO340 and PT1000 probe with heater PT1INF0340 030220851 rel 1 5 09 12 2008 15 CAREL 2 1 2 1 1 General installation instructions Installation procedure Environmental conditions Avoid assembling the pCO and the terminal in environments with the following characteristics temperature and humidity that do not conform to the rated operating data of the product strong vibrations or knocks exposure to aggressive and polluting atmospheres e g sulphur and ammonia fumes saline mist smoke so as to avoid corrosion and or oxidation strong magnetic and or radio frequency interference there avoid installing the units near transmitting antennae exposure of the pCO to direct sunlight and to the elements in general large and rapid fluctuations in the room temperature environments containing explosives or mixes of flammable gases exposure to dust for
11. in relation to its advanced level of technology requires setup configuration programming commissioning to be able to operate in the best possible way for the specific application The failure to complete such operations which are required indicated in the user manual may cause the final product to malfunction CAREL accepts no liability in such cases Only qualified personnel may install or carry out technical service on the product The customer must only use the product in the manner described in the documentation relating to the product In addition to observing any further warnings described in this manual the following warnings must be heeded for all CAREL products e Prevent the electronic circuits from getting wet Rain humidity and all types of liquids or condensate contain corrosive minerals that may damage the electronic circuits In any case the product should be used or stored in environments that comply with the temperature and humidity limits specified in the manual e Do not install the device in particularly hot environments Too high temperatures may reduce the life of electronic devices damage them and deform or melt the plastic parts In any case the product should be used or stored in environments that comply with the temperature and humidity limits specified in the manual e Do not attempt to open the device in any way other than described in the manual e Do not drop hit or shake the device as the internal
12. terminals CAREL Q Note the terminal on the Blast Chiller pCO board relating to the PWM analogue outputs can only be used for the evaporator or the condenser fans and not connected to the steriliser lamp Note the power supply to the circuit measuring the zero crossing is at terminal SYNC on the pCO and must be 24 Vac in phase with the power supply to the actuator for three phase power supply use the same phase to power the pCO and the actuator 2 5 3 Optional modules The module is used to convert a PWM output 5 V pulses to a linear O to 10 V and 4 to 20 mA analogue output code CONVO 10A0 The control signal at the input terminals optically isolated from the rest of the module must have a maximum amplitude of 5V and a period between 8 ms and 200 ms The 0 to 10 V output voltage can be connected to a maximum load of 2 kQ with a maximum ripple of 100 mV The 4 to 20 mA output current can be connected to a maximum load of 280 Q with maximum overshoot of 0 5 mA The mechanical dimensions of the module are 87x56x60 mm 2 DIN modules with IP20 index of protection Module for converting a 0 to 10 V analogue output to an SPDT digital output code CONVONOFFO The module is used to convert a 0 to 10 V analogue output Yn to an ON OFF relay output The control signal Yn at the input terminals optically isolated from the rest of the module to ensure the switching of the relay from OFF to ON must have a maximum amplitude
13. 0 0 Wo n a ik n Probe B5 offset 7 b c bc03 Offset in the reading of probe B5 G 9 9 to 9 9 0 0 Blast chiller freezer a temperature diff 7 b d bd01 Blast chiller freezer temperature diff C 0 0 to 90 0 2 0 Device connected to See Chap 9 digital output 1 vo 7 c c01 Device connected to digital output 1 CONFIGURATIONS compressor Operating mode 7 C01 Operating mode of digital output 1 Auto Manual Auto Digital output 1 in manual operating mode 7 c C01 Digital output 1 in manual operating mode On Off Off Device connected to See Chap 9 digital output 8 7 c c08 Device connected to digital output 8 CONFIGURATIONS defrost Operating mode 7 6 c08 Operating mode of digital output 8 Auto Manual Auto Digital output 8 in manual operating mode 7 c c08 Digital output 8 in manual operating mode On Off Off Device connected to See Chap 9 analogue output 1 7 c c09 Device connected to analogue output 1 CONFIGURATIONS Steril Operating mode of analogue output 1 7 C09 Operating mode of analogue output 1 Auto Manual Auto 030220851 rel 1 5 09 12 2008 56 CAREL Analogue output 1 in 0 manual operating mode 7 c09 Analogue output 1 in manual operating mode 0 to 100 0 Device connected to See Chap 9 analogue output 3 7
14. 24Vdc Total Normally open open closed open 150 ms Minimum digital input impulse detection time Normally closed closed open closed 400 ms Power supply to the inputs internal Analogue outputs Type Not optically isolated 2 x0 to 10 Vdc outputs Y1 and Y2 and Power supply internal Precision outputs Y1 Y2 3 of full scale Resolution 8 bit Settling time outputs Y1 Y2 25 Maximum load 1 KQ 10mA for 0 to 10 Vdc and 4700 10mA for PWM gt Note the synchronicity for the PWM phase control output is taken from SYNC and GO The PWM output Y3 can become a pulse modulation input pulse duration proportional to the analogue value by setting the software The PWM may be in synchronicity with the SYNC signal or have a fixed cycle of 2 ms Digital outputs The outputs can be divided into groups Between groups cells in the table there is double insulation and consequently these may have different voltages There is also double insulation between each terminal of the digital outputs and the rest of the controller The relays belonging to the same group individual cell in the Insulation distance table have basic insulation and therefore can have the same power supply 24 Vac or 230 Vac Makeup of the groups Reference for the relays with the same insulation Group3 CI OC 5 030220851 rel 1 3 09 12 2008 11 CAREL Type of relay Type A Type A Type A Number of changeover contacts 1 output 5 SPDT 2000VA 250Vac 8 A resistive UL873 2 5 A resi
15. 5 HACCP alarms NO YES NO Print last 10 HACCP 9 C Print last 10 HACCP alarms NO YES NO Print last cyde 9 c Print last cycle completed NO YES NO Print last 3 cycles m 9 c Print last 3 cycles completed NO YES NO Print last 10 cycles 9 c Printlast 10 cycles completed NO YES NO Lock keypad EE main menu Lock keypad El 10 Used to lock the keypad See paragraph 5 10 Note all the temperatures can be expressed in degrees C or F depending on the setting of the corresponding parameter unit of measure 6 d The values in the column Range are referred to C 030220851 rel 1 3 09 12 2008 40 CAREL The table below shows the list of alarms signalled by Blast Chiller These each have a code shown in the first column and a message that is displayed third column Parameters high temperature alarm threshold low temperature alarm threshold temperature alarm differential type of temperature alarm threshold high temperature alarm delay low temperature alarm delay enable high temperature alarm enable low temperature alarm Description of the function the high and low temperature alarm thresholds may be either absolute or relative to the set point depending on the settings made for the type of temperature alarm threshold The management of the high and low temperature alarms is displayed in Figure 7 1
16. O test Used to check the status and the operation of the input and output channels 5 7 1 Initialisation PW3 This screen is used to restore the default parameter values set by CAREL choosing CAREL default cancels all the custom settings made and reboots Blast Chiller restoring with the initial settings In addition password PW3 can be changed 5 8 W clock This menu is used to set the date and time of the Blast Chiller dock Note the type of date and time display may be selected using the corresponding parameter 59 E Data log The data log menu is used to access the list of HACCP alarms the other alarms and print the HACCP reports This screen in fact features three submenus e 9a HACCP displays the HACCP alarms e Ob Alarms displays all the other alarms e OcPrint used to print the last ten HACCP alarms and the last ten cydes completed 5 10 El Lock keypad Used to lock unlock the keypad To lock unlock the keypad press ESC and Y together To prevent unauthorised personnel from changing the Blast Chiller settings 030220851 rel 1 3 09 12 2008 32 once the keypad has been locked it can only be unlocked by entering one of the three passwords PW1 PW2 or PW3 CAREL The following table shows all the parameters divided by the functions they refer to the columns in the table show Key to the type of parameters main E Defrost eis Fans V HACCP alarms s B Alarms Cycle and custom cyde
17. The printer must have a standard RS232 serial interface e Forthe connection between the printer and the pCO use the BMS or FieldBus serial port the latter available on the pCO controllers In addition the RS232 serial option must be installed on the pCO controllers e The printer must support at least one of the communication speeds available on the pCO 1200 2400 4800 9600 and 19200 bps The communication settings are 8 data bits no parity 1 stop bit no flow control e The connection cable between the printer and the pCO must be acquired or made according to the signals available on the pCO connector as follows Pin Name Direction Use Printer error detection BMS ONLY 1 DCD Input SERIAL Data reception Data transmission DTR 0 pCO ready signals CONNECTED TO PIN 7 INTERNALLY ON THE 4 DIR Output BOARD 5 CND f Earth pin CONNECTED TO PIN 4 INTERNALLY ON 7 RTS Output THE BOARD Pins 6 8 and 9 are not connected Connector board 1 5 QOOO0O00 OOOO0 G 9 Note data can be printed corresponding to the last ten cycles completed and to the last ten HACCP alarms activated The following data are saved and therefore printed date time type of cycle value read by the probes at the start and the end of the cycle duration of the cycle 4 7 Lights Input door switch brightness sensor day night switch Parameters day hours and minutes the light is switched on day hours and minutes the li
18. al delay after open door 7 8 g05 High temperature alarm delay after opening door S 0 to 9999 30 Antifreeze alarm L threshold 7 g g06 Antifreeze alarm threshold C 50 0 to 90 0 25 0 Antifreeze alarm delay 7 g Antifreeze alarm delay S 0 to 9999 30 External al delay 7 8 g07 External alarm delay S 0 to 9999 30 Low press al delay start 7 8 g07 Low pressure alarm delay when starting S 0 to 9999 30 Low press al delay steady 7 8 g07 Low pressure alarm delay in steady operation S 0 to 9999 30 High cond temp threshold 7 8 g08 High condenser temperature alarm threshold C 50 0t0900 40 0 High cond temp differential 7 g g08 High condenser temperature alarm differential C 50 0 to 90 0 4 0 High cond temp al delay 7 g g08 High condenser temperature alarm delay S 0 to 9999 30 Min blast chiller temp setp 7 g g09 Minimum blast chiller freezer temperature set point C 1 99 9 to 99 9 40 0 Max blast chiller temp setp 7 g 809 Maximum blast chiller freezer temperature set point C 1 99 9 to 99 9 10 0 Min product temp setp 7 g g10 Minimum product temperature set point C F999to 99 9 40 0 Max product temp setp 7 g gl0 Maximum product temperature set point C 999t0999 10 0 Set point delta with day night switch 7 g gll Set point variation with day night switch C 00to 90 0 2 0 Diff delta with day night 7 g gll Differential variation with day night switch C 00to 90 0 1 0 Min evap fan setp 7 2 812 Minimum ev
19. c c11 Device connected to analogue output 3 CONFIGURATIONS Operating mode of analogue output 3 7 cll Operating mode of analogue output 3 Auto Manual Auto Analogue output 5 in manual operating mode 7 c c11 Analogue output 3 in manual operating mode 0 to 100 0 Manufacturer default 7 d Reset the manufacturer default settings NO YES NO New maintenance EN password 7 d New maintenance password 0 to 9999 1234 Reset alarms 7 d Reset the data for the alarms saved NO YES NO Number of compressors 7 e e01 Number of compressors managed 0t02 1 Compressor parallel op E 7 e e01 Enable parallel compressor operating mode in NO YES NO Enable compressor rotation 7 e e01 Enable compressor rotation NO YES NO 0 not used 1 none Type of evaporator fan 2 on evaporator temperature control 7 e e02 Type of evaporator fan control 3 on temperature diff None Printer fitted 7 e e04 Printer fitted NO YES NO DCD manual status 7 e 05 Status of the DCD manual signal NO YES NO Err control EN 7 e e05 Disable print error control NO YES YES Man error reset 7 e e05 Manual print error reset NO YES NO Remove empty lines 7 e e06 Remove empty lines by the print NO YES NO Disable print queue 7 e e06 Disable print queue NO YES NO User light contr E 7 e e07 Enable light control by the user NO YES NO User output contr m 7 e e07 Enable auxiliary output control by the user NO YES NO See Chap 9 Config dig input 1 71 f01 Device connected to digital input 1 CONFIGU
20. circuits and mechanisms may be irreparably damaged e Do not use corrosive chemicals solvents or aggressive detergents to clean the device e Do not use the product for applications other than those specified in the technical manual All of the above suggestions likewise apply to the controllers serial boards programming keys or any other accessory in the CAREL product portfolio CAREL adopts a policy of continual development Consequently CAREL reserves the right to make changes and improvements to any product described in this document without prior warning The technical specifications shown in the manual may be changed without prior warning The liability of CAREL in relation to its products is specified in the CAREL general contract conditions available on the website www carel com and or by specific agreements with customers specifically to the extent where allowed by applicable legislation in no case will CAREL its employees or subsidiaries be liable for any lost earnings or sales losses of data and information costs of replacement goods or services damage to things or people downtime or any direct indirect incidental actual punitive exemplary special or consequential damage of any kind whatsoever whether contractual extra contractual or due to negligence or any other liabilites deriving from the installation use or impossibility to use the product even if CAREL or its subsidiaries are warned of the possibility
21. dripping and post dripping phases are skipped 45 1 Defrost scheduler Parameters type of defrost scheduler day hours and minutes of the first defrost day hours and minutes of the eighth defrost Description of the function the defrost can be programmed in three different ways shown in Fig 4 13 1 first defrost at the start of the conservation phase and the next defrosts planned in the intervals between defrosts 2 first defrost at a certain time preset and the next defrosts planned in the intervals between defrosts 3 defrosts at set times up to 8 Start storage Y y y A rr ee Time between defrosts Time lt Time between defrosts T hh mm Y Y Y Time between defrosts Time between defrosts Time gt lt gt hh mmi hh2 mm2 hh3 mm3 hh4 mm4 Time Fig 4 13 Defrost scheduler Note the interval between defrosts must always be set as it is used if there are Time problems with the internal clock Real Time Clock 25 CAREL 4 5 2 Advanced defrosts Parameters select type of advanced defrost nominal defrost duration proportional factor in the time variation between defrosts Description of the function there are three types of advanced defrost which can be set using the corresponding parameters 1 variable time between defrosts with this type of defrost the time between defrosts is increased or decreased depending on the duration of the previous defrost The def
22. modify the value and confirms and moves to the next step 6 perform the same operations described in point 5 for phase 2 and phase 5 7 choose Yes or No to set a conservation phase at the end of the cycle and set the corresponding set point 8 in addition a defrost phase can be set before the cycle and or before any conservation phase 9 thena final screen is displayed for saving the custom cycle with a name up to 15 alphanumeric characters and the symbols and space plus a cyde identifier number from 1 to 10 10 pressing for 5 seconds saves the cyde 11 return to the main menu gt Cycle gt Custom cycle 12 this submenu includes the list of all the custom cycles created a cycle can be selected from the list and run using the same procedure as for any standard cyde Note up to 10 custom cycles can be saved after the tenth Blast Chiller overwrites one of the other custom cydes already configured with the new cyde created 4 1 1 Probe errors and overstock Input blast chiller freezer temperature probes and product temperature probes Parameters probe differential not entered correctly probe delay out of range overload check period blast chiller freezer set point and product set point maximum duration of the cyde Description of the function there are three items relating to the value measured by the probes e product temperature out of range e product temperature probe not inserted correctly e produc
23. most common settings Contents 1 INTRODUCTION as li o 7 1 1 METE alU Ss a dede A A A AR DUE A A A 7 1 2 Models NOTES AUTO Sa ee RES 7 1 3 Components and ACCSSS OMS sen a a AS AAA ao 7 1 4 Doscripliomol tus po O SmallBoard s a unse ne ld D ha 7 1 5 E PCO OA D E E ee es ne nme ri see 10 1 6 O 13 2 INSTALLATION ea RADIALI a 14 2 1 Generalinstallationinstrucio scene lalla else 14 2 2 POWER SUDD M PP PE 14 2 3 Connecingihe analogue lin DUNS aa E EE TDI ee ae 14 2 4 Connecting he digtalinputS erson E a EEG 16 2 5 Connecting The analogueoulpl Sar A A A Lo 16 2 6 Gonnecung he digital OU DUIS e st LS AS A ote id ls Lala 17 3 Miss db TERA Ernst es ee bebo ca iS 18 3 1 Graphic Simi A 18 3 2 E a ae u A 19 4 FUNGHONS EM CM case nace ne a ee T ror Ro oM e ii RP 20 4 1 Chill and ireeze voir cella ac eI e cu eres ala era 20 4 2 Temperaire CONTO lustro ora 22 4 3 Compressor MAN ATENAS 22 4 4 Fan managemen pe ts a lt 23 4 5 Deci RR nr O H ROT 25 4 6 HACCP Hazard Analysis and Catical Control Point o oor obe eee run ai ee 26 4 7 E RR RS A fo N AN eB A E C IO onc Ob koc ei IE RIT 27 4 8 Auxhary OU UT oor ed 27 4 9 PEC O20 uicit en ae DUE Pe IO TEASER NIU le MM LEI AIR ALIA ILARIA 27 ATO ONORE P c ERES 27 4 11 SIEH ISA ON aceto dudo cM D cl MM ted I LU Ud M M iL LM IL ML
24. of such damage DISPOSAL INFORMATION FOR USERS ON THE CORRECT HANDLING OF WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT WEEE In reference to European Union directive 2002 96 EC issued on 27 January 2003 and the related national legislation please note that e WEEE cannot be disposed of as municipal waste and such waste must be collected and disposed of separately e the public or private waste collection systems defined by local legislation must be used In addition the equipment can be returned to the distributor at the end of its working life when buying new equipment e the equipment may contain hazardous substances the improper use or incorrect disposal of such may have negative effects on human health and on the environment e the symbol crossed out wheeled bin shown on the product or on the packaging and on the instruction sheet indicates that the equipment has been introduced onto the market after 15 August 2005 and that it must be disposed of separately e in the event of illegal disposal of electrical and electronic waste the penalties are specified by local waste disposal legislation KEY TO THE ICONS NOTE to bring attention to a very important subject in particular regarding the practical use of the various functions of the product d IMPORTANT to bring critical issues regarding the use of the Blast Chiller to the attention of the user pm TUTORIAL some simple examples to accompany the user in configuring the
25. of the digital inputs Important note do not connect other devices to the IDn inputs The sizes of the cables for the remote connection of the digital inputs are shown in the following table size mm for length up to 50 m size mm for length until 100 m 0 25 0 5 If the product is installed in industrial environments application of the EN 61000 6 2 standard the length of the connections must be less than 50 m This length shouldn t be exceeded in any case to avoid measurement errors 2 5 Connecting the analogue outputs 2 5 1 Connecting the O to 10V analogue outputs The pCO provides 0 to 10 V optically isolated analogue outputs powered externally at 24Vac Vdc Fig 4 n shows the electrical connection diagram the OV zero of the power supply is also the reference for the output voltage The table below shown summarises the distribution of the analogue outputs according to the version available no of analogue outputs reference Y1 Y2 Y3 Y4 VGO CO N Important on the pCO the outputs are not optically isolated Remember on the other hand that the pCO power supply is insulated pCO terminals pCO terminals 2 5 2 Connecting the PWM analogue outputs The pCO provides a PWM analogue output for phase cutting speed controllers The following figure shows the wiring diagram and the two most common connection examples 5VREF no of analogue reference outputs pCO terminals not available pCO
26. on real time clock temperature controlled defrost differential Output defrost relay Description of the function the defrost function can be activated in the cases following e before running a cycle if set before starting the conservation phase if set in the conservation phase if the time between defrosts has expired in the conservation phase if set using the scheduler in the conservation phase if called by the defrost activation digital input e in the conservation phase if started from the keypad e in the conservation phase if called by the supervisory system e Manual The defrost can be managed in one of the following modes depending on the settings of the corresponding parameters e by temperature with electric heater e by temperature with reverse cycle hot gas e bytime using electric heater e by time with reverse cycle hot gas e bytime with electric heater and temperature control The defrost by temperature can only be run if the evaporator temperature probe has been configured otherwise the defrost can only be run in time mode Defrosts with temperature control can also only be only be run if the evaporator temperature probe is installed and is working correctly In this case the relay is closed when the temperature reaches the end defrost temperature threshold and is open when the temperature is lower than the end defrost temperature threshold minus the temperature controlled defrost differ
27. piercing probe 90 with handle 6 m cable range 501200 C PTIINFO340 printer kit BCOPZPRNOO 1 4 Description of the pCO Small board 9 9 03 12 g Key power supply connector G GO OI AAA AAN yellow power LED and 3 status LEDs mar ml ii Blast Chiller N IN J11 additional power supply for the terminal and 0 to 5 V ratiometric probes universal analogue inputs NTC 0 to 1 V 0 to 5 V ratiometric 0 to 10 V O to 20 mA 4 to 20 mA passive analogue inputs NTC PT1000 ON OFF 0 to 10 V analogue outputs 24 Vac Vdc digital inputs 230 Vac or 24 Vac Vdc digital inputs connector for the display panel external with direct signals service card WO Jo ITN ID Joss input 24 V V max power 40 VA 50 to 60 Hz ERU field card serial card connector for all standard pCO series terminals and for downloading the 10 application program 11 relay digital outputs 12 connector for connection to the I O expansion board 13 pLAN network connector 14 cover for inserting the supervisor and telemaintenance option 15 cover for inserting the field card option 030220851 rel 1 3 09 12 2008 7 CAREL 1 4 1 Meaning of the inputs outputs on the pCO Small board Connector Signal 1 1 112 2 1 122 123 12 4 12 5 33 1 152 133 33 4 J4 1 J4 2 VGO a3 J4 4 J4 5 J4 6 35 1 52 15 3 35 4 15 5 15 6 ie 35 7 15 8 is 15 9 Jo 110 lese di n J11 2 113 112 1 1122 112
28. point connections without graphics and to configure the pCO The default address is 32 The address of the terminal can only be set after having connected to power You supply via the RJ12 connector To enter configuration mode press together for at least 5 seconds the terminal will display a screen similar to the following with the cursor flashing in the top left corner To change the address of the terminal Display address setting proceed as follows in sequence 1 Press once the cursor will move to the Display address setting field 2 Selectthe desired value using and dy and confirm by pressing E again 3 Ifthe value selected is different from the one saved previously the following screen will be displayed and the new value will be saved to permanent memory If the address field is set to 0 the terminal communicates with the pCO board using the Local terminal protocol and the I O Board address field is no longer shown having no meaning CAREL To change the list of terminals private and shared associated with a pCO board proceed as follows in sequence 4 enter configuration mode see above pressing all and E at the same time for at least 5 seconds 5 press twice the cursor will move to the I O Board address field 6 selectthe address of the pCO board being configured and confirm by pressing The pCO will then start the configuration procedure sending a screen simi
29. powered at 24 Vac Vdc with a maximum power Pmax 10 W 24 VacN dc e Sec Sle U u A 588 Ye e are Es Be Jas ja J15 SSR relay reference Ahn FER pCO terminals pCO terminals 4 5 Important the load of the SSR relay is powered at 24 Vac Vdc thus all the other terminals in the group from 1 to 6 must be powered at 24Vac Vdc due to the absence of double insulation within the group Moreover terminals from 1 to 6 can be powered 050220851 rel 1 5 09 12 2008 17 at 110 230 Vac using a safety transformer Class 2 for the power supply to the 24 Vac Vdc load of the SSR relay 2 6 4 Summary table of digital outputs according to the versions available NO NC contacts changeo total SSR contacts ver no contacts outpu ts a qo O SE TEO 4 Se Hib qp 2089 2 6 5 Remote connection of the digital outputs The sizes of the cables for the remote connection of the digital outputs are shown in the following table pCO terminals pCO terminals AWG 20 15 14 Current Size mm If the product is installed in industrial environments application of the EN 61000 6 2 standard the length of the connections must be less than 30 m This length shouldn t be exceeded in any case to avoid measurement errors CAREL 3 1 Graphic terminals Blast Chiller features of two types of graphic terminal one version for flush mounted or panel installation wi
30. program resident in the flash memory The connection diagram is shown below CAREL input 24 V V 50 to 60 Hz max power 40 VA 15 W field card V term I QP Fono N ISP 5V ref C iir Controller pCO terminals NTC sensor cable pco GND BC4 BC5 BC9 BC10 1 B1 B2 B5 B4 B5 B6 B7 B8 B9 BIO 2 pco l B1 B2 B3 B4 2 N Important the two wires of the NTC sensors are equivalent as they have no polarity therefore it is not necessary to follow any specific order when connecting to the terminal block 2 3 2 Connecting the PT1000 temperature sensors The pCO pCO version only can be connected to 2 wire PT1000 sensors for all high temperature applications the range of working is 100 to 200 C The inputs must be pre configured for PT1000 signals by the application program resident in the flash memory The connection diagram is shown below input 24 V V 50 to 60 Hz max power 40 VA 15 W field card am 2 gt c AA Controller PT1000 sensor cable pCO sensor sensor2 sensor3 probe4 BC4 BC5 BC9 BCIO 1 B4 B9 B10 2 pco not avallable AN Important e for correct measurements using the PT1000 sensor each sensor wire must be connected to an individual terminal as shown in Figure 4 c e thetwo wires of the PT1000 sensors are equivalent as they have no polarity therefore it is not necessary to follow any specific order when connecting to the terminal block
31. temperature control follows the diagram in Fig 4 3 the differential and the set point for each phase are the same and the second phase is activated after having waited the delay time between the start of different compressors if on the other hand parallel operating mode has not been selected then temperature control follows the diagram in Fig 4 4 the differential for each phase is half of the control differential while the set point for the second phase is equal to the control set point plus half of the control differential Blast chiller temperature Set point Cont diff 2 Control differential Fig 4 4 Temperature control with second phase If there is more than one blast chiller freezer probe the value is calculated considering the values read by the various probes and the settings defined for the type of calculation which may be Highest the temperature of the blast chiller is the highest of the values read Average the temperature of the blast chiller is the average of the values read Note the set point and the differential can be adjusted by a set point deviation with day night switch and a differential deviation with day night switch when the digital input is active the set point used then is the set plus the set point deviation and the differential is the differential plus the differential deviation 4 3 Compressor management Parameters number of compressors parallel operating mode of the com
32. the bottom right are used to Used to display the cycle in progress or run a cycle selected from the last completed or the standard or custom cycles set The Blast Chiller displays the following screen when running a cycle start stop the sterilisation process pressing for 3 seconds and change its duration At the end of the process the last two rows of the display show a message telling the user that operation is complete STERILISATION COMPLETED and pressing menu or ESC Blast Chiller returns to the main menu If for any reason the sterilisation procedure was not completed correctly for example if the door of the blast chiller is opened during the procedure the last two rows of the display show the string 030220851 rel 1 3 09 12 2008 40 CAREL STERILISATION NOT COMPLETED If while sterilisation is running the user returns to the main menu but wants to know the status of the process simply return to the corresponding menu Note pressing menu or ESC and thus returning to the main menu cancels all the information relating to the end of the sterilisation process 5 5 Heat probe This menu is used to access the heat probe function piercing probe the screen is however only visible if the corresponding function has been enabled otherwise the display shows NOT AVAILABLE The icon on the display flashes if heating is in progress while the last two rows of the display inform the user when the temperature has reached
33. the value set for the blast chiller Product temperature 2a temp probe management parameter blast chiller C 50 0 to 90 0 Blast chiller freezer temperature the highest or the average value if more Blast chiller freezer than one probe is used depending on the value set for the blast chiller temperature 2a temp probe management parameter blast chiller C 50 0 to 90 0 Timer 2a Duration of the last cycle completed min 0to 9999 Standard cycles 2b Standard cycles 1t08 1 Custom cydes 2 c Custom cycles 1 to 10 1 Conservation LA main menu Blast chiller freezer temperature the highest or the average value if more than one probe is used depending on the value set for the blast chiller Product temperature temp probe management parameter blast chiller C 50 0 to 90 0 Blast chiller freezer temperature the highest or the average value if more Blast chiller freezer than one probe is used depending on the value set for the blast chiller temperature di temp probe management parameter blast chiller C 150 0 to 90 0 minimum blast chiller freezer temperature set point to maximum blast chiller freezer Set point 3 Blast chiller freezer temperature set point C temperature set point Alarms HACCP alarms product probe error conservation phase setting Signals
34. with relative thresholds the operating principle is the same for the absolute thresholds considering the appropriate values The high and low temperature alarms can be disabled by setting the enable disable high and low temperature alarm parameters 030220851 rel 1 5 09 12 2008 4 Code Description Type of reset Notes HA HACCP alarm high temperature Manual Disabled if the door remains open for a preset time HF HACCP alarm blackout during conservation Manual HC HACCP alarm blackout during cyde Manual HD HACCP alarm cycle ended after maximum time due to probe error Manual HE HACCP alarm cycle ended after maximum time Manual If only one probe is fitted or both are faulty the duty setting function cannot be E01 Blast chiller freezer temperature probe 1 not working Automatic activated if enabled E02 Blast chiller freezer temperature probe 2 not working Automatic As for alarm ED1 E03 Blast chiller freezer temperature probe 3 not working Automatic As for alarm ED1 E51 Product temperature probe Q not working Automatic If only one probe is fitted or both are faulty the cycle cannot end by temperature E52 Product temperature probe 2 not working Automatic As for alarm E51 E53 Product temperature probe 3 not working Automatic As for alarm E51 El Evaporator temperature probe not working Automatic Fans on E2 Antifreeze temperature probe not working Automatic E6 Condenser temperature probe not working Automatic Fans on All the devices are off ex
35. 100 000 EN 60730 1 30 000 UL 873 Class A Category 2 24 Vac 10 15 50 60 Hz and 28 to 36 Vdc 10 20 40 VA Vac 15 W Vdc with male female plug in connectors 250Vac max 8 A max min 0 5 mm max 2 5 mm H8S2320 16 bit 24 MHz 2 2 MB Dual Bank x 16 bits 512 KB x 16 bits 13 KB 32 KB not visible from the pLAN network 0 25 standard Product certification IEC EN 50155 standard Railway applications Electronic equipment used on rolling stock UL 873 and C222 No 24 93 Temperature Indicating and Regulating Equipment EC regulations 57 2005 of 12 January 2005 in particular if the electronic controller is fitted with standard Carel NTC sensors it is compliant with standard EN13485 on Thermometers for measuring the air temperature in applications on units for the conservation and sale of refrigerated frozen and deep frozen food and ice cream Key 1 Power supply connector G GO 24 Vac or 20 60 Vdc Input 24 Vac for phase control and NTC 0 1 V 0 5 V 0 20 mA 4 20 mA analogue inputs 5Vref for power supply to 5V 2 ratiometric probe and 24Vdc power to active probes 3 0 to 10 V analogue outputs and PWM phase control output 4 Digital inputs with voltage free contact Connector for all standard pCO series terminals and for downloading the application 5 program 6 pLAN network connector 7 tLAN terminal connector 8 tLAN network or MP Bus connector 9 Relay digital outputs with one comm
36. 3 112 4 112 5 113 1 11322 1133 313 4 1135 114 1 1142 1143 115 1 1152 1153 124 1 1242 1243 Description 24 Vdc or 24 Vac power supply power supply reference universal analogue input 1 NTC 0 to 1 V 0 to 10 V 0 to 20 mA 4 to 20 mA universal analogue input 2 NTC 0 to 1 V 0 to 10 V 0 to 20 mA 4 to 20 mA universal analogue input 5 NTC 0 to 1 V 0 to 10 V 0 to 20 mA 4 to 20 mA common for analogue inputs 21 Vdc power supply for active probes maximum current 200 mA passive analogue input 4 NTC PT1000 ON OFF common for analogue input 4 passive analogue input 5 NTC PT1000 ON OFF common for analogue input 5 power to optically isolated analogue output 24 Vac Vdc power to optically isolated analogue output 0 Vac Vdc analogue output no 1 0 to 10 V analogue output no 2 0 to 10 V analogue output no 5 0 to 10 V analogue output no 4 0 to 10 V digital input no 1 24 Vac Vdc digital input no 2 24 Vac Vdc digital input no 3 24 Vac Vdc digital input no 4 24 Vac Vdc digital input no 5 24 Vac Vdc digital input no 6 24 Vac Vdc digital input no 7 24 Vac Vdc digital input no 8 24 Vac Vdc common for digital inputs from 1 to 8 negative pole for DC power supply 8 pin telephone connector for connection to a display panel 6 pin telephone connector for connection to the standard user terminal RX TX connector for connection over RS485 to the pLAN network RX TX connector for connec
37. 3 defrost fans compressors to Sterilisation Eid main menu Output 4 Value of the sterilisation analogue output 0 to 100 0 Blast chiller freezer temperature the highest or the average value more than Blast chiller freezer one probe is used depending on the value set for the blast chiller temp temperature 4 probe management parameter blast chiller C 50 0 to 90 0 0 to maximum sterilisation Timer 4 Time remaining until the conclusion of the sterilisation process min duration 100 EE Door open sterilisation completed sterilisation not Sterilisation status 4 Sterilisation status completed 0 to maximum sterilisation Sterilisation duration 4 Sterilisation duration set point min duration 20 Output 4 Sterilisation analogue output set point 0 to 100 0 0 to maximum sterilisation Sterilisation duration 4 Sterilisation duration min duration 1000 Heat probe Lf main menu Product temperature the highest or the average value if more than one probe is used depending on the value set for the blast chiller temp probe Product temperature Ta 5 management parameter blast chiller C 50 0 to 90 0 Probe heating completed temperature in the heart too Probe heating status 5 Probe heating status high Settings kell main menu Password 6 User password 0 to 9999 1234 End cycle LS 6 aa Selecttype of end cycle temperature time Temperature minimum blast chiller freezer temperature set point to maximum blast chiller fre
38. 79 836 Enable negative temperature cycles NO YES YES Dig in 1 status m 7 h h01 Status of digital input 1 Off On Digital input 1 logic 7 h h01 Logic of digital input NO NC NC z B ns ks Dig in 8 status 7 h h04 Status of digital input 8 Off On Dig in 8 logic 7 h h04 Logic of digital input 8 NO NC NO An input value 7 h h05 Value read by analogue input 1 pe 4 to 20 mA 0 to 10 V NTC An input type 7h Type of probe 1 PT1000 NTC 030220851 rel 1 3 09 12 2008 39 CAREL gt 7 h m An input 5 value 7 h ho7 Value read by analogue input 5 C DE 4to 20 mA 0 to 10 V NTC An input 5 type 7 h h07 Type of probe 5 PT1000 to NTC Device connected to dig See Chap 9 out 1 7 h h08 Device connected to digital output 1 CONFIGURATIONS compressor Dig out 1 operation 7 h h08 Operating mode of digital output 1 Auto Manual Auto Dig out 1 status in manual mode 7 h h08 Status of digital output 1 in manual operating mode On Off Off i 7 h Device connected to dig See Chap 9 out 8 7 h h15 Device connected to digital output 8 CONFIGURATIONS compressor Dig out 8 operation 7 h h15 Operating mode of digital output 8 Auto Manual Auto Dig out 8 status in manual mode 7 h h15 Status of digi
39. Analogue output 3 71 25 Device connected to analogue output 3 CONFIGURATIONS Cond fan Min value 7 125 Minimum value of analogue output 3 0 0 to 100 0 0 0 Max value 71 125 Maximum value of analogue output 3 0 0 to 100 0 100 0 Blast chiller temp calculation 7 8 g01 Calculate blast chiller freezer temperature when multiple probes used Average highest Average Prod temp calculation 7 8 g01 Calculate product temperature when multiple probes used Average highest Average 030220851 rel 1 3 09 12 2008 5 CAREL Type 7 8 g02 Type of blast chiller freezer temperature threshold Relative absolute Relative Enable high temp al 7 8 g05 Enable high temperature alarm NOJ YES YES High temp al threshold 7 8 203 High temperature alarm threshold C 500to 90 0 5 0 High temp al delay 7 8 203 High temperature alarm delay S 0 to 9999 0 Enable low temp al 7 g g04 Enable low temperature alarm NO YES YES Low temp al threshold 7 g g04 Low temperature alarm threshold C 500to 90 0 3 0 Low temp al delay 7 g g04 Low temperature alarm delay S 0 to 9999 0 High temp al delay after defrost 7 8 g05 High temperature alarm delay after defrost S 0 to 9999 30 High temp
40. Blast Chiller CAREL Blast chiller controller ENG User manual ERR THESE INSTRUCTIONS Integrated Control Solutions amp Energy Savings IMPORTANT CAREL bases the development of its products on decades of experience n HVAC on the continuous investments in technological innovations to products procedures and strict quality processes with in circuit and functional testing on 100 of its products and on the most innovative production technology available on the market CAREL and its subsidiaries nonetheless cannot guarantee that all the aspects of the product and the software included with the product respond to the requirements of the final application despite the product being developed according to start of the art techniques The customer manufacturer developer or installer of the final equipment accepts all liability and risk relating to the configuration of the product in order to reach the expected results in relation to the specific final installation and or equipment CAREL may based on specific agreements acts as a consultant for the positive commissioning of the final unit application however in no case does it accept liability for the correct operation of the final equipment system The CAREL product is a state of the art product whose operation is specified in the technical documentation supplied with the product or can be downloaded even prior to purchase from the website www carel com Each CAREL product
41. C MD M IA EE 28 A2 HAGA PODO ERE I ETE LLLI UT LEE 28 5 PESCA P TON OF TRHEMENUS a illo ia olio 29 5 1 E DON ON M M Ke em 30 5 2 Qo PR O NORTE E RI ER II E IO RI ERRORI III TNT 30 Di GONservallon eee ne es 30 5 4 A ill 30 5 5 LEN Heat ole A A LI I AL 31 5 6 SEIUNGS IO AO CUE Igel ASD 31 5 7 Maintenance EN t m muc 31 5 8 0 COCK Mes see Nele Bessere ee ee eee 32 5 9 E A A t E E ET T EUM 32 5 10 E OCIS VIO ACU ai bon 32 6 TABLE OF PARAMETER Seas ne ee nen dae 33 7 ABLEOPALAPBIVIS zieren re ct RI MEE ee IMMUNE I M MAIN ee ee IMP EMI EE E 41 7 1 Bigriand tow tempelkatlulexalatTiq iesus E A RI IMPONE ALITO sears dub VR uA MA VLA ERU SEDE dI ARM PU NEN I I 41 8 TABBE OF VARIABLES SENT TO THE SUPERVISOR istrian a BEI Ense 42 9 CONFIGURATIONS 322222 ee ee use lee 45 CAREL 1 1 Main features Blast Chiller is a complete range of controllers and user terminals for managing the blast chilling blast freezing and conservation of foodstuffs in compliance with the relevant standards in force Additional features include blast chill cydes that are completely customisable by the user smart defrosts and optimum time management using the built in dock Blast Chiller is based on the pCO series programmable platform one version on the pCO Small and one on the pCO and features a graphic interface pGD1 series and a simple and user friendly menu for navig
42. Fahrenheit temperature measure unit Pause too long during cycle Door opened during cycle Reset alarm history Fan overload alarm Overload alarm High pressure alarm Room temperature probe 1 Room temperature probe 2 Room temperature probe 3 Product temperature probe 1 Product temperature probe 2 Product temperature probe 3 Evaporator temperature probe Condenser temperature probe Antifreeze temperature probe Evaporator fan analog output Condenser fan analog output Sterilization analog output Product setpoint Product temperature Product setpoint during phase 1 Product setpoint during phase 2 Product setpoint during phase 3 Room setpoint Room setpoint during phase 1 Room setpoint during phase 2 Room setpoint during phase 3 Room temperature Antifreeze alarm threshold Condenser fan differential Condenser fan setpoint Differential of the condenser high temperature alarm Condenser high temperature alarm threshold Fvaporator fan setpoint Evaporator fan differential High temperature alarm threshold HACCP Room temperature alarm differential High temperature alarm threshold Low temperature alarm threshold Room temperature regulation differential Room setpoint offset with day night End defrost temperature probe Start defrost temperature Conservation room temperature setpoint Working hours of the compressor 1 high part Working hours of the compressor 1 low part Working hours of the compressor 2 high part W
43. O Small pCO Y Sterilisation Sterilisation Y2 Evaporator fans Evaporator fans Y3 Condenser fans Condenser fans PWM Y4 CAREL reserves the right modify or change its products without prior warning 030220851 rel 1 3 09 12 2008 46 NOTES 030220851 rel 1 3 09 12 2008 4 030220851 rel 1 3 09 12 2008 48 030220851 rel 1 3 09 12 2008 49 030220851 rel 1 3 09 12 2008 50 CAREL CAREL S p A Via dell Industria 11 35020 Brugine Padova Italy Tel 39 049 9716611 Fax 39 049 9716600 http www carel com e mail carel carel com 030220851 rel 1 5 09 12 2008
44. RATIONS On Off Relay logic 75 101 Logic of digital input 1 NO NC NO Tf See Chap 9 Config dig input 8 7 108 Device connected to digital input 8 CONFIGURATIONS High press Relay logic 71 108 Logic of digital input 8 NO NC NC See Chap 9 Conf an input 7 f f09 Device connected to analogue input 1 CONFIGURATIONS Blast chiller temp 1 4 to 20 mA 0 to 10 V NTC Type 71 109 Type of probe 1 PT1000 to NTC Min value 71 Minimum value of probe 1 E 99 9 to 99 9 0 0 Max value 74 Maximum value of probe 1 99 9 to 99 9 0 0 71 to to See Chap 9 Conf an input5 7 f f14 Device connected to analogue input 5 CONFIGURATIONS Antifreeze temp 4 to 20 mA 0 to 10 V NTC Type 7 f f14 Type of probe 5 PT1000 to NTC Min value 7 1 F14 Minimum value of probe 5 C 99 9 to 99 9 0 0 Max value m 7f f14 Maximum value of probe 5 Ze 99 9 to 99 9 0 0 See Chap 9 Config Dig output 1 7 115 Device connected to digital output 1 CONFIGURATIONS compressor Relay logic 7 115 Logic of digital output 1 NO NC NO i a See Chap 9 Config Dig output 8 71 122 Device connected to digital output 8 CONFIGURATIONS defrost Relay logic 74 122 Logic of digital output 8 NO NC NO Config analogue output See Chap 9 1 71 2253 Device connected to analogue output 1 CONFIGURATIONS sterilisation Min value 71 123 Minimum value of analogue output 1 0 0 to 100 0 0 0 Max value 75 123 Maximum value of analogue output 1 0 0 to 100 0 100 0 i See Chap 9
45. SC at any time returns to the previous step Note on the page for setting the parameters the first row of the display shows the name of the submenu relating to the parameter being set as shown in Fig 5 4 030220851 rel 1 5 09 12 2008 3 Fig 5 4 5 6 C Operating hours This shows the operating hours of all the main devices connected to Blast Chiller so as to monitor periodical maintenance and Y scroll the list of the various devices while ES returns to the higher level menu 5 6 d Change language The user can select one of the languages loaded in the Blast Chiller memory in addition the unit of measure can be chosen between SI International system and Imperial temperature expressed in C or in F and the date expressed as dd mm yy or yy mm dd The other function available in this menu is the possibility to change password PWI The screen is navigated in the same way as described for the other screens 5 7 EM Maintenance The menu can only be accessed when entering a password depending on the password entered and the access level different screens will be displayed e password PW2 accesses the maintenance level screens only e password PW3 accesses all the screens on the Blast Chiller manufacturer level Some screens are displayed only if the corresponding function is available The main feature of the maintenance menu screens 7 is that the first row of the display on the right shows the a
46. able auto start compressor during pump down NOJ YES NO Max pump down time 7 8 g29 Maximum pump down duration min Oto 9999 D Comp on time with generic alarm 7 8 g30 Compressor operating time with generic alarm min Oto 9999 5 Comp off time with generic alarm 7 8 g50 Compressor off time with generic alarm min Oto 9999 10 Evap fan with comp off 7 8 831 Evaporator fan behaviour with compressor off Always on on with comp Always on Cond fan setp 7 8 831 Temperature set point to stop condenser fans C 50 0 to 90 0 35 0 Cond fan diff 7 8 831 Temperature differential to stop condenser fans C 00to 90 0 2 0 Min phase control 7 8 832 Minimum phase shift for PWM output 0 to 100 25 Max phase control 7 8 832 Massimo phase shift for PWM output 0 to 100 15 Triac pulse width 7 g g32 Triac pulse width for PWM output ms 10 0 to 10 0 2 5 Mains frequency 7 8 832 Mains frequency for PWM output Hz 50 60 50 Off time with light sensor 7 8 g53 Off time with light sensor min 0to 9999 5 Light activation in Off status EM 78 833 Light activation in OFF status ON OFF OFF Aux activation in Off status 7 2 833 Auxiliary output activation in OFF status ON OFF OFF Maximum sterilisation 4 duration an 7 2 834 Maximum sterilisation duration min 0to 9999 500 Probe heater time rn 7 8 835 Maximum probe heater duration min Oto 10 2 Probe heater threshold 7 8 835 End probe heater threshold C J00to 90 0 4 0 Enable negative temp cycles E
47. able below shows the variables sent to the supervisor Type address R W Description Digital 1 R Product temperature 1 probe error Digital 2 R Product temperature 2 probe error Digital 3 R Product temperature 3 probe error Digital IA R Room temperature 1 probe error Dgta 5 R Room temperature 2 probe error Digital IR Room temperature 3 probe error Digital 7 IR Condenser temperature probe error Digital 8 R Evaporator temperature probe error Digital Antifreeze temperature probe error Digital Compressor maintenance required Digital Compressor 2 maintenance required up 2 e i uo Digital 12 IR Condenser fan maintenance required Digital 15 R Evaporator fan maintenance required Digital 14 R UV light maintenance required Digital 15 R System maintenance required Digital 16 R High condenser temperature warning Digital 17 RL Condenser high temperature alarm Digital 18 R Defrost maximum time Digital 19 SR Door opened during conservation PR ee ee PRO ESP ETA Digital Low pressure alarm Digital Antifreeze alarm Digital Compressor 1 alarm Digital Digital Black out during conservation phase HACCP Digital Black out during cycle execution HACCP Digital 26 R Controller error Digital 127 RL High temperature alarm HACCP Digital 28 R Cyde ended by maximum time for probe error HACCP Digital 29 R Cycle ended after maximum
48. anaged with different priorities by digital input user interface and the supervisor the digital input has the highest priority If the device has been switched off from a digital input it cannot be switched on in the other ways On the other hand the control from the keypad or the supervisor remains enabled if the digital input has not been configured During OFF status the following are disabled e running cycles e temperature control e all the functions relating to the management of the fans and compressors e defrost e _ HACCP monitoring e _ Saving and displaying the alarms In addition by setting the related parameters the lights and the auxiliary output can also be enabled or disabled in this status During OFF status e allthe parameters can be displayed and saved e the alarms relating to the probes remain active e the compressor protection times are observed e _ the pump down procedure is performed if enabled e _ the defrost and continuous operating modes are terminated When switching ON e the compressor protection times must be observed CAREL e the compressor and fan start delays are ignored 4 11 Sterilisation Input door switch Parameters sterilisation duration maximum sterilisation duration percentage of power Output sterilisation Description of the function the sterilisation process can operate in ON OFF mode or modulating mode depending on the output configured Sterilisati
49. aporator fan control set point C 50 0 to 90 0 0 0 Max evap fan setp 7 g g12 Maximum evaporator fan control set point C 50 0 to 90 0 50 0 Evaporator fan control differential Parameter active only if fans controlled Evap fan diff 7 8 g13 according to the temperature C 0 0to 90 0 2 0 Fan speed up time 7 8 813 Fan speed up time S 0 to 999 0 Min HACCP temp setp 7 2 814 Minimum HACCP high temperature set point C 50 0t0900 2 0 Max HACCP temp setp 7 8 g14 Maximum HACCP high temperature set point C 500to 90 0 5 0 HACCP alarm delay E 7 8 814 HACCP temperature alarm delay min Oto 9999 120 Blackout duration during cyde 7 8 15 Allowing duration of HACCP blackout when running a cycle min 0to 9999 5 Blackout duration during conservation 7 8 gl5 Alowing duration of HACCP blackout during the conservation phase min 0to 9999 1 Door open duration during cycle 7g gl6 Alowing duration of door open when running a cycle S 0 to 9999 30 Pause duration during cyde 7 2 gl6 Allowing pause duration when running a cycle S 0 to 9999 30 Probe out of range delay 7 8 817 Time in which the probe error is ignored before a cycle min Oto 9999 5 Probe not inserted differential 7 g g17 Differential for control probe not inserted C 0 0 to 20 0 3 0 Sample time 7 8 817 Time for checking incorrect probe insertion and product overload min 0to 9999 5 0 not used 1 temperature with heater 2 temperature with gas ES 3 time with he
50. arting from one of the standard cycles made up of two phases or alternatively using the complete option made up of three phases all configured by the user 1 quick chill 2 controlled chill 3 quick freeze Temperature V quick chill 2 controlled chill 3 quick freeze Product temperature probe Unit temperature probe Fig 4 2 Complete cycle Phase 1 is used to quickly chill food that has just been cooked phase 2 to avoid the formation of ice on the surface of the products and phase 3 to freeze quickly Each phase has the following parameters e blast chiller temperature set point AT A2 A3 in Fig 4 2 e duration cycle by time or maximum duration cycle by temperature T1 T2 T5 in Fig 4 1 e product temperature set point for the final phase cycle by temperature P1 P2 P3 in Fig 4 2 If one of the time parameters T1 T2 T3 is set to zero the corresponding phase is skipped If a cycle is being managed by time the product set points P1 P2 and P3 are not evaluated if on the other hand a cycle is managed by temperature the time parameters T1 T2 and T3 are used as maximum duration of the three phases if the set point P3 is not reached throughout the cycle T1 T2 T3 this does not end but rather continues until the set point is reached with an alarm signalling the event If at the end of the cycle a conservation phase is set Blast Chiller brings and maintains the blast chiller freezer at the se
51. at 4 time with gas 5 temp con w heat Type of defrost 7 2 818 Type of defrost 6 manual Start defrost t 7 2 g18 Start defrost threshold set point 2C 50 0 to 90 0 3 0 End defrost t 7 8 818 End defrost threshold set point C 500to 90 0 4 0 Defrost activation delay 7 2 g19 Start defrost delay after reaching the threshold S 0 to 9999 180 Defrost delay output 7 2 g19 Defrost output activation delay S 0 to 9999 10 Min time between def 7 2 820 Minimum time between different defrosts min Oto 480 30 Min defrost duration 7 2 g20 Minimum defrost duration S 0 to 9999 120 Max defrost duration 7 8 g20 Maximum defrost duration min Oto 480 10 030220851 rel 1 5 09 12 2008 58 CAREL Time between defrosts 7 2 g21 Time between different defrosts h 0 to 999 8 Dripping time 7 2 g21 Dripping duration S 0 to 9999 120 Post Dripping time EX 72 821 Fan off time after dripping min 01015 1 Comp prot priority over def 7 8 822 Compressor protection or defrost priority Comp Defrost Comp Defrost differential with temperature control 7 8 822 Temperature controlled defrost differential C 00to 90 0 2 0 0 not used 1 none ES 2 variable time 3 skip defrost Advanced defro
52. ation through three levels of access protected by password Unlike traditional controllers Blast Chiller guarantees a reduction in electricity consumption thus bringing cost reductions and helping to protect the environment 1 2 Models and features platform pCO Small pco code BCOOSMWOOO BCOOSPWOO0 BCOOXMWOOO BCOOXPWO000 keypad faceplate membrane keypad faceplate analogue inputs up to 4 NTC digital inputs up to 6 digital outputs up to 5 analogue outputs up to 3 standard cycles X custom cycles X conservation phase X graphic display X languages gt real time clock X HACCP report X programming with key X supervision X printer X buzzer X RS485 option X X X X certification CE UL languages available ITA ENG FRA ESP DEU 1 5 Components and accessories description code Blast Chiller pCO with display panel mounting with plastic faceplate BCOOXPWOOO Blast Chiller pCO with display rear panel assembly with membrane keypad BCOOXMW000 Blast Chiller pCO with display panel mounting with plastic faceplate BCOOSPWOOO Blast Chiller pCO with display rear panel assembly with membrane keypad BCOOSMW000 telephone connection cable display panel with plastic faceplate S90CONNOO see paragraph 3 1 1 NTC piercing probe 6 m cable range 50T110 C NTCINFO600 NTC piercing probe 90 with handle 6 m cable range 50T110 C NTCINFO610 NTC piercing probe 90 with handle 3 m cable range 50T110 C NTCINFO340 PT1000
53. ature 1 product temperature1 evaporator temperature condenser temperature product temperature 2 product temperature 3 blast chiller condenser temperature product temperature 2 product temperature 3 blast B2 temperature 2 blast chiller temperature 3 antifreeze chiller temperature 2 blast chiller temperature 3 antifreeze Blast chiller temperature 1 product temperature1 evaporator temperature Blast chiller temperature 1 product temperature1 evaporator temperature condenser temperature product temperature 2 product temperature 3 blast chiller condenser temperature product temperature 2 product temperature 3 blast B3 temperature 2 blast chiller temperature 3 antifreeze chiller temperature 2 blast chiller temperature 3 antifreeze Blast chiller temperature 1 product temperature1 evaporator temperature Blast chiller temperature 1 product temperature1 evaporator temperature condenser temperature product temperature 2 product temperature 3 blast chiller condenser temperature product temperature 2 product temperature 3 blast BA temperature 2 blast chiller temperature 3 antifreeze chiller temperature 2 blast chiller temperature 3 antifreeze Blast chiller temperature 1 product temperature1 evaporator temperature condenser temperature product temperature 2 product temperature 3 blast chiller B5 temperature 2 blast chiller temperature 3 antifreeze Digital inputs No pCO Small pCO On Off external alarm door switch
54. cept for the lights and auxiliary outputs which follow the settings of the related parameters the pump down cannot be performed Compressors Da External alarm active Manual and fans follow the settings of the related parameters The following functions cannot be run sterilisation compressors evaporator fans dor Door open during conservation Automatic cycles continuous operating mode and defrost DP Door open during the cycle Automatic The cycle is interrupted PL Pause too long during the cycle Automatic The cycle is interrupted LP Low pressure Automatic The compressors and pump down are disabled HP High pressure Manual Compressors off OC Compressor not working Manual Compressors off OF Fans not working Manual Fans and compressors off OV Compressor or fans not working Manual Fans and compressors off PP Product probe not inserted correctly Automatic The cyde ends by time OP Overload excess product Automatic cht High condenser temperature warning clean the condenser Automatic CHT High condenser temperature alarm Manual Compressors off PD Warning pump down ended after exceeding maximum duration Automatic Auto start procedure disabled Ed Warning defrost ended after exceeding maximum duration Automatic MCI Compressor maintenance required Manual MC2 Compressor 2 maintenance required Manual MEF Evaporator fan maintenance required Manual MCF Condenser fan maintenance required Manual MU Unit maintenance required Manual ML UV light maintenance require
55. check they are sufficiently tight separate as much as possible the sensor signal digital input and serial line cables from the cables carrying inductive loads and power cables to avoid possible electromagnetic disturbance Never insert power cables including the electrical cables and probe signal cables in the same conduits Do not install the sensor cables in the immediate vicinity of power devices contactors circuit breakers or similar reduce the path of the sensor cables as much as possible and avoid spiral paths that enclose power devices power supplies other than those specified seriously damage the system a Class 2 safety transformer rating 50 VA must be used in the installation to supply just one pCO controller the power supply to the pCO controller and terminal or pCO controllers and terminals should be separated from the power supply to the other electrical devices contactors and other electromechanical components inside the electrical panel if the power transformer secondary is earthed check that the earth wire corresponds to the wire that runs to the controller and enters terminal GO This applies to all the devices connected to the pCO a yellow LED indicates that power is connected to the pCO 030220851 rel 1 5 09 12 2008 14 e avoid touching or nearly touching the electronic components fitted on the boards to avoid electrostatic discharges extremely damaging from the operator to the compon
56. control Maximum output Minimum output Condenser temperature Differential Fig 4 11 Modulating condenser fan control The behaviour is however different when the compressor is first started as the activation threshold has as fixed differential of 0 2 C 24 CAREL In the event of probe errors the fans are always on If compressor stop due to external alarm has been configured in such a way that the compressor remains on when an alarm occurs and in addition the condenser fan temperature probe and the output have been configured the fans will always be on based on control If the condenser temperature probe has not been configured yet the output has been configured the fans are always off Note if the version fitted on the pCO board is being used a PWM analogue output can be managed If output Y3 is configured for the condenser fans these must also be managed by the parameters relating to maximum and minimum phase shift triac pulse width and mains frequency In this mode the following hardware modules can be connected FCS CONVONOFF CONVO 10A0 or MCHRT series 4 5 Defrost Input enable defrost activate defrost evaporator temperature probe Parameters type of defrost time between defrosts start defrost temperature threshold end defrost temperature threshold maximum defrost duration defrost activation delay dripping time compressor protection in relation to defrost priority defrost day and time
57. d Automatic Sterilisation not available Etc Clock not working Manual Cannot schedule the actions defrost lights auxiliary outputs AFr Antifreeze alarm Manual Compressors off EE Controller not working Automatic Controller not working HI High temperature alarm Automatic Disabled if the door remains open for a preset time and after defrost LO Low temperature alarm Automatic Compressors off and disabled during continuous operating mode Ptr Printer not working Manual Printer disabled 7 1 High and low temperature alarm Low temperature alarm High temperature alarm Blast chiller temperature Differential Differential Low temp thresh High temp thresh Fig 7 1 High and low temperature alarm CAREL Blast Chiller can be connected to various supervisory systems using the following BMS communication protocols Carel Modbus and Lon A BMS or FieldBus serial port is used for the connection The various connection protocols are managed using the following optional cards e Carel RS485 code PCOS004850 Carel RS232 code PCO100MDMO code PCOSOOFD20 Modbus RS485 code PCOS004850 Lon Works FTT10 code PCO10000FO BACnet RS485 code PCO1000BA0 BACnet Ethernet code PCO1000WBO Trend code PCO100CLPO Note these communication protocols are currently not implemented however the Blast Chiller software can manage them Blast Chiller uses the CAREL PlantVisor PRO software as the supervisor application The t
58. ddress of the screen with reference to the map of the functions tree described above Fig 5 5 Note Fig 5 5 shows an example of the reference to the Blast Chiller screen map ba01 in fact indicates that inside the menu after having chosen branch b and sub branch a the user has accessed the screen for configuring the serial port 5 7 a Information This menu shows information on the hardware and the firmware and software versions Fig 5 6 5 7 b Maintenance settings This branch includes the following functions e _ 7 b a Config serial ports used to set all the parameters required for connection to the supervisory system which depend on the type of optional board and connection protocol selected e _ 7 b b Set op hours used to select the various time thresholds for the planned maintenance of the various devices CAREL e 7 b c Calibrate probes used to set the offset to be added to subtracted from the value read by the probe so as to give a more accurate indication of the temperature acquired e _ 7 b d Temperature control features the parameters relating to temperature control these can be modified when starting or during the maintenance of Blast Chiller except those covered by the manufacturer access level password PW3 5 7 C Manual management Used to switch from automatic to manual operating mode for each device connected to the Blast Chiller The digital outputs can be ON or OFF while for t
59. e first row containing the string REPEAT in the middle is er LEU see the table below an icon that shows the type of cycle selected and the main variables measured while 4 Tools for navigating the Blast Chiller software amp the last two rows show the name of the cycle pressing for 3 seconds starts the Specifically the bar at the bottom 3 features the following icons cycle and Blast Chiller returns to display the screen shown in Fig 5 2 Conservation phase set 52b Standard l m P This submenu displays the standard cycles available loaded as default on Blast Chiller ES Defrost in progress or pending if flashi l l d r n prog U DS Use M and d to scroll the list of standard cydes while pressing for 3 seconds e Compressors on starts the cycle displayed at that moment once the cycle has been started Blast Chiller e Fans on returns to the screen shown in Fig 5 2 Ls hasst HACCP alarms active i HN Product probe error 5 2 C Custom This submenu describes the various custom cycles defined by the user up to a Alarms active Note the conservation phase is selected by default for the standard cycle while the set point is 2 C The right of the bottom bar 4 on the other hand contains the following information nme id v ee stom onle wike pressing for 3 seconds starts the cycle displayed at that moment once the cycle Start custom cycle pid has been started Blast Chiller returns to the screen shown in Fig 5 2
60. e function this function of the Blast Chiller is used to record possible anomalies when running cycles or during the conservation phase The following anomalies are recorded e cycle ended when exceeding the maximum time due to problems with the probe e cyde ended after the maximum time e blackout when running the cycle e blackout during the conservation phase e HACCP high temperature alarm threshold exceeded If the cycle by temperature mode has been selected and a probe error occurs the cyde ends when the maximum time set is reached and the following are saved e date and time e final product temperature e the type of HACCP alarm that is in this case cycle ended by exceeding maximum time If on the other hand when the cycle by temperature is selected the cycle ends when exceeding the maximum time set the following are saved e date and time e the extra time required for the product to reach the final temperature e the type of HACCP alarm in this case cycle ended by exceeding maximum time in the event of blackout when running a cycle the following data are saved e date and time e duration of the blackout e the type of HACCP alarm blackout when running a cycle Note if the duration of the blackout is greater than the maximum blackout duration set the cycle is stopped If the blackout occurs during the conservation phase and the duration is greater than the value set for the corresponding paramet
61. ent compressors 4 3 2 Continuous operating mode Parameters continuous operating mode duration low temperature alarm delay after continuous operating mode Output compressor second phase compressor Description of the function during continuous operating mode the compressor continues operating normally ignoring temperature control for the entire duration of the operating mode The temperature of the blast chiller freezer may fall below the set point however cannot fall below the low temperature alarm threshold Consequently continuous operating mode can end for two reasons e the set duration elapses e the low temperature alarm threshold has been reached The mode can be activated if e the duration has been set to 0 e the temperature is below the low temperature alarm threshold Finally continuous operation remains pending when e _ the compressors timers are in progress e a compressor alarm is active e X the defrost dripping and post dripping functions are in progress e the door is open If one of the digital inputs has been configured as the door switch when the door is opened continuous operating mode is stopped once the door is dosed again the mode resumes from the point time where it was stopped If the second phase compressor has also been configured continuous operating mode acts on both phases and rotation and the compressors timers are observed 4 3 3 Pump down Input low pressure switch Parameter
62. ential Defrosts with temperature control can only end by time The operating principle of the defrost by temperature is shown in Fig 4 12 When the defrost is called the system checks whether the value measured by the temperature probe is lower than the start temperature threshold point A if the check is positive after having waited the defrost activation delay time the defrost starts point b Evaporator temperature probe A B C Time Defrost start delay Fig 4 12 Defrost by temperature 030220851 rel 1 3 09 12 2008 Te defrost cannot start in the following cases not even if the conditions are right e ifthe defrost digital input has not been enabled e if the compressor timer is in progress e ifthe low pressure alarm is active only for the defrost with reverse cycle e ifthe pump down procedure is active e in continuous operating mode e ifthe door of the blast chiller freezer is opened only for the defrost with reverse cycle and if the compressor is off e ifthe high condenser temperature alarm is active only for the defrost with reverse cycle e ifa external alarm is active When the system calls the defrost before starting a cycle and the defrost is pending the display shows the cycle running screen with the defrost icon flashing telling the user that the cycle cannot start If on the other hand the defrost is set before the conservation phase the icon flashes but the program also starts
63. ents e ifthe power transformer secondary is earthed check that the earth wire corresponds to the wire that runs to the controller and enters terminal GO this applies to all the devices connected to the pCO e do not secure the cables to the terminals by pressing the screwdriver with excessive force to avoid damaging the pCO e _ for applications subject to considerable vibrations 1 5 mm pk pk 10 55 Hz secure the cables connected to the pCO around 3 cm from the connectors using clamps e ifthe product is installed in industrial environments application of the EN 61000 6 2 standard the length of the connections must be less than 30 m e all the very low voltage connections analogue and 24 Vac Vdc digital inputs analogue outputs serial bus connections power supplies must have reinforced or double insulation from the mains network e in residential environments the connection cable between the pCO and the terminal must be shielded e there is no limit to the number of cables that can be connected to an individual terminal The only limitation concerns the maximum current crossing each terminal this must not exceed 8 A e the maximum cross section of the cable that connected to a terminal is 2 5 sq m 12 AWG the maximum value of the twisting torque to tighten the screw on the terminal torque tightening is 0 6 Nm A Important Installation must be performed according to the standards and legislation in force in the country wh
64. er and at the end of the blackout the blast chiller freezer temperature is higher than the high temperature alarm threshold the following are saved e date and time e blackout duration e blast chiller freezer temperature after the blackout e the type of HACCP alarm blackout during the conservation phase If during the conservation phase the blast chiller freezer temperature exceeds the high temperature alarm threshold for a time greater than or equal to the high temperature alarm delay time plus the HACCP alarm delay time as illustrated in Fig 4 15 the following data are saved e date and time e duration of the alarm e maximum temperature value reached by the blast chiller freezer e type of HACCP alarm that is blast chiller freezer high temperature CAREL Maximum temperature Alarm threshold High temperature alarm HACCP alarm delay Q Alarm duration Fig 4 15 HACCP high temperature alarm 4 6 1 X Using the printer Blast Chiller can be connected to a printer RS232 serial port for printing the data on the last cycles performed and the most recent HACCP alarms If the device has been correctly configured a report is printed at the end of each cyde and whenever an HACCP alarm is activated or more simply whenever the user requires The hardware requirements for using the serial printer are e The printer used must be able to manage a number of columns at least equal to the number on the pCO terminal e
65. ere the device is used e for safety reasons the equipment must be housed inside an electrical panel so that the only accessible part is the display and the keypad e inthe event of malfunctions do not attempt to repair the device but rather contact the CAREL service centre e the connector kit also contains the stick on labels 2 1 5 Anchoring the pCO The pCO is installed on a DIN rail To fasten the unit to the DIN rail press it lightly against the rail The rear tabs will click into place locking the unit to the rail Removing the unit is just as simple using a screwdriver through the release slot to lever and lift the tabs The tabs are kept in the locked position by springs 2 2 Power supply Power supply to the pCO controller with terminal connected 28 to 36 Vdc 10 20 or 24 Vac 10 15 50 to 60 Hz Maximum current P 15 W Vdc power supply P 40 VA Vac Power supply to the pCO 20 60 Vdc or 24 Vac 15 50 to 60 Hz Maximum current P 6 1 W Vdc P 8VA Vac 2 3 Connecting the analogue inputs The analogue inputs on the pCO can be configured for the more common sensors on the market 0 to 1 V 0 to 10 V 0 to 20 mA 4 to 20 mA The different types of sensors can be selected by setting a parameter on the user terminal 2 3 1 Connecting the universal NTC temperature sensors The analogue inputs are compatible with 2 wire NTC sensors The inputs must be pre configured for NTC signals by the application
66. erilisation NO 6 condenser fans pump down second phase compressor probe heater Compressor defrost generic alarm evaporator fans lights aux output sterilisation NO 7 condenser fans pump down second phase compressor probe heater Compressor defrost generic alarm evaporator fans lights aux output sterilisation NO 8 condenser fans pump down second phase compressor probe heater 050220851 rel 1 5 09 12 2008 45 CAREL Analogue outputs No pCO Small pCO YI Evaporator fans condenser fans sterilisation Evaporator fans condenser fans sterilisation Y2 Evaporator fans condenser fans sterilisation Evaporator fans condenser fans sterilisation Y3 Evaporator fans condenser fans sterilisation Evaporator fans PWM condenser fans PWM Y4 The following tables on the other hand show the standard configurations used by default Analogue inputs No pCO Small pCO B1 Product temperature 1 Product temperature 1 B2 Product temperature 1 Product temperature 1 B3 Evaporator temperature Evaporator temperature B4 Condenser temperature Condenser temperature B5 Antifreeze Digital inputs No pCO Small pco ID 1 On Off ID 2 External alarm ID3 Low pressure ID 4 Door switch ID 5 Activate defrost ID 6 Overload D7 ID 8 High pressure Digital outputs No pCO Small pCO NOI Compressor NO2 Generic alarm NO3 Light Light NO4 Aux output NOS Defrost NO 6 NO 7 NO8 Analogue outputs No pC
67. es are disabled by the manufacturer the set of cycles that can be selected by the user is limited to the following e Standard 3 C by temperature soft e Standard 5 C by temperature hard e Standard 3 C by time soft e Standard 3 C by time hard Enable negative temperature cycles CAREL In addition when saving a custom cycle a custom cycle can only be created starting from positive temperature cycles with one or two phases Note to prevent the user from setting a negative temperature set point the values of the minimum product temperature set point and minimum cold room temperature set point parameters must be set suitably 4 2 Temperature control Input blast chiller freezer temperature probes day night switch Parameters blast chiller freezer temperature set point control differential type of blast chiller freezer temperature value calculation set point deviation with day night switch differential deviation with day night switch parallel operating mode of the compressors Description of the function temperature control is performed by evaluating the temperature of the blast chiller freezer and generating the temperature control request as shown in the following figure Blast chiller temperature Set point Control differential Fig 4 5 Temperature control If a compressor has been configured for the second phase there are two possible situations if parallel operating mode is selected
68. ess for the supervisory system 1 to 200 1 BMS speed 7 b a Communication speed of the BMS serial port bps 11200 2400 4800 9600 19200 19200 Carel ModBus Carel RS232 Field Bus protocol 7 b a Protocol used for the Field Bus serial port printer Carel Field Bus speed 7 b a Select the communication speed of the Field Bus serial port bps 11200 2400 4800 9600 19200 19200 Compressor op hour threshold 7 b b bb01 Compressor op hour threshold h 0 to 30000 350000 Reset compressor op hours 7 b b bb01 Reset compressor op hours NO YES NO Compressor 2 op hour threshold 7 b b bb02 Second compressor op hour threshold h 0 to 30000 30000 Reset compressor 20p hours 7 b b bb02 Reset second compressor op hours NO YES NO Evap fan op hour threshold 7 b b bb03 Evaporator fan op hour threshold h 0 to 30000 30000 Reset evap fan op hours 2 7 b b bb03 Reset evaporator fan op hours NO YES NO Cond fan op hour threshold 7 b b bb04 Condenser fan op hour threshold h 0 to 30000 30000 Cond evap fan op hours 7 b b bb04 Reset condenser fan op hours NO YES NO UV light op hour threshold 7 b b bb05 UV light op hour threshold h 0 to 50000 30000 Reset UV light op hours 7 b b bb05 Reset UV light op hours NO YES NO Unit op hour threshold 7 b b bb06 Unit op hour threshold h 0 to 30000 30000 Reset unit op hours 7 b b bb06 Reset unit op hours NO YES NO Probe B1 offset 7 b c bc01 Offset in the reading of probe B1 9 9 to 9 9
69. eypad LEDs 3 programmed by application software red Alarm and green ON OFF and repeat cycle buttons Power supply Voltage power supply from pCO via telephone connector or from 18 30 Vdc external source protected by external 250 mAT fuse Maximum power input 1 2 W 3 1 1 Connecting the user terminal to the pCO board The typical connection between the pGD terminal and the pCO is made using a 6 wire telephone cable supplied by CAREL code S90CONNOO see the table To make the connection simply plug the cable into the 6 pin connector on the pCO board J10 for the pCO and J5 for the pCO until it clicks into place To remove the connector lightly press the plastic catch and remove the cable The telephone connector provides both the data link and the power supply to the terminal User terminal interface connection cables length m code 0 8 SOOCONNOO2 15 590CONN002 3 S90CONNOOI 6 590CONN003 N Important The membrane terminal is on the other hand already connected via the ribbon cable to the display interface 3 1 2 Installing the terminal To make the connection simply plug the telephone cable into the RJ12 telephone connector on the rear of the terminal and into connector e J5onthe pCO E J10 on the pCO The address of the terminal can be set in the range between 0 and 32 addresses between 1 and 32 are used by the pLAN protocol while address 0 identifies the Local terminal protocol used for point
70. ezer Blast chiller set point 6 a a Blast chiller temperature set point C temperature set point 0 0 9 minimum product set point Product set point temperature if the cycle finishes by time this value is temperature to maximum Product set point 6 aa Ignored C product set point temperature 3 0 Duration of the cycle if the cycle finishes by temperature this is the Phase duration 6 a a maximum duration of the cycle min Oto maximum cycle duration 90 Conservation 6 a a Conservation phase set after the cycle ends NO YES YES minimum blast chiller freezer temperature set point to maximum blast chiller freezer Cons set point 6 a a Blast chiller freezer temperature set point during the conservation phase C temperatureset point 2 0 Defrost before cycle 6 a a Defrost set before running the cycle NO YES YES Defrost before cons 6 a a Defrost set before the conservation phase NO YES YES 030220851 rel 1 3 09 12 2008 54 CAREL Custom cycle number 6aa Number of the custom cycle to be saved 1 to 10 1 Custom cycle name 6 a a Name of the custom cycle 15 fields AtoZ ato z 0 to 9 Note Blast Chiller features the same mode for setting the custom cycle parameters for all three phases shown above
71. f more Blast chiller freezer than one probe is used depending on the value set for the blast chiller temperature temp probe management parameter blast chiller C 50 0 to 90 0 minimum blast chiller freezer temperature set point to maximum blast chiller freezer Set point Blast chiller freezer temperature set point C temperature set point Alarms HACCP alarms product probe error conservation phase setting Signals defrost fans compressors to Light activation Activation of the light Off On Off Evaporator temperature Evaporator temperature Ee 50 0 to 90 0 End defrost threshold End defrost threshold C 50 0t0 900 4 0 Defrost timer Time remaining until the conclusion of the defrost min maximum defrost duration to 0 Continuous operating mode duration Continuous operating mode duration set point min Oto 9999 480 Continuous operating mode timer Time remaining until the conclusion of the continuous operating mode min J0 to 9999 480 Set point Fvaporator set point temperature C 500to 90 0 2 0 On Off RE main menu Unit status Unit status ON OFF from supervisor OFF from keypad OFF from digital input OFF from alarm Off Cycle ISS main menu Current cycle 2 2 Last cycle completed 030220851 rel 1 3 09 12 2008 55 CAREL Blast chiller freezer temperature the highest or the average value If more than one probe is used depending on
72. ght is switched off off time with light sensor light controlled by the user light activation during OFF status Output light 030220851 rel 1 5 09 12 2008 21 Description of the function the light can be controlled by e the door open closed switch e the curtain switch e the keypad Note the possibility to control the light from the keypad must be set by the manufacturer otherwise these settings are not visible to the user e the supervisor e the light sensor e the daily time bands Control of the lights by the daily time bands can be activated even if Blast Chiller is off by setting the light activation parameters accordingly As concerns the brightness sensors these can be located inside the blast chiller or on the door frame in the latter case they signal when the door is opened by sensing the light The inside light is therefore switched on when light is detected and off when not When the brightness sensor is on the other hand located inside the blast chiller light is also detected when the inside light is on to overcome this problem after a time set for the off time with light sensor parameter the inside light is switched off for 5 seconds so that if no other light is detected it means that the door is closed and therefore the inside light is kept off while it remains on if the door is found to be open If the off time with light sensor parameter is set to 0 it means that the sensor is located on
73. he analogue outputs the percentage can be selected The default values are Auto Manual operating manual ignores temperature control but not the thresholds for the various alarms so as to guarantee the safety of the system This mode is usually used to test the operation of the individual devices or to set a preset value for a certain output 5 7 d Default PW2 Alarms Used to set the default values for the manufacturer parameters therefore cancelling all the custom settings and rebooting Blast Chiller with the default settings This screen can also be used to change password PW2 and delete the data relating to the alarms that have been saved 5 7 e Configuration To select all the main functions of the Blast Chiller such as the operation of each device or whether or not the various components and accessories are fitted 5 74 I O configuration In this menu the functions can be set for each individual I O channel for each input or output a connected probe or device can be selected Once a probe or a device has been selected and assigned to the respective input or output it can no longer be selected For the digital I Os the type of device can also be set NO or NC for the analogue outputs the maximum and minimum values can be set while for the digital inputs the type of probe and the operating range can be configured 5 7 Manufacturer settings Used to select and set the parameters that can be configured by the manufacturer 5 7 h I
74. ic disturbance A Important if the control voltage is drawn in parallel with a coil fit a dedicated RC filter in parallel with the coil the typical ratings are 100 O 0 5 uF 630 V If connecting the digital inputs to safety systems alarms remember that the presence of voltage across the contact must be the normal operating condition while no voltage must represent an alarm situation This will ensure that any interruption or disconnection of the input will also be signalled Do not connect the neutral in place of an open digital input Always interrupt the phase The 24 Vac Vdc digital inputs have resistance of around 5 kQ 2 4 1 Digital input connections for the pCO The following figure represents one of the most common diagrams for connecting the 24 Vac and 24 Vdc digital inputs on a pCO To maintain the optical isolation of the digital inputs a separate power supply must be used just for the digital inputs The connection diagrams shown in these figures which while being the more common and the more convenient do not exclude the possibility of powering the digital inputs independently from the power supply to the pCO In any case the inputs only have functional insulation from the rest of the controller 2 42 Connecting the digital inputs for the pCO The following figure shows the diagram for connecting the digital inputs 030220851 rel 1 5 09 12 2008 16 2 4 3 Remote connection
75. ight ID 4 switch activate aux output sensor night day switch activate aux output On Off external alarm door switch low pressure high pressure enable defrost On Off external alarm door switch low pressure high pressure enable activate defrost overload compressor overload fan overload light sensor night day defrost activate defrost overload compressor overload fan overload light ID 5 switch activate aux output sensor night day switch activate aux output On Off external alarm door switch low pressure high pressure enable defrost On Off external alarm door switch low pressure high pressure enable activate defrost overload compressor overload fan overload light sensor night day defrost activate defrost overload compressor overload fan overload light ID 6 switch activate aux output sensor night day switch activate aux output On Off external alarm door switch low pressure high pressure enable defrost activate defrost overload compressor overload fan overload light sensor night day ID 7 switch activate aux output On Off external alarm door switch low pressure high pressure enable defrost activate defrost overload compressor overload fan overload light sensor night day ID 8 switch activate aux output Digital outputs No pCO Small pco Compressor defrost generic alarm evaporator fans lights aux output Compressor defrost generic alarm evaporator fans lights aux
76. l 68 RW Digital 69 R W Digital Digital Digital Digital Digital Digital 75 R W Digital Digital Digital Digital 79 R Digital 180 FRU Digital Digital 82 TRO Digital 185 FRO Digital 84 TRO Aug 1 JR 9 Analog 12 R Analog 13 RO Analog 4 R Analog Analog 6 TRO Analog 17 RO Analog 8 RO Analog 19 JR Analog 10 RO Analog R 9 O Mag J RO Analog 15 TRO Analog 14 RRO Analog 1 RO Analog 16 R O Analog 17 JR i O Analog 18 RO Analog R__________ Analog 20 RO Analog 2 RRO Analog 2200 RO Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Analog Lo Integer Integer 2 RO Integer Integer 4 R_________ Integer 5 RG Integer 6___ R_________ negr 7 R_________ Integer 8____ R_________ Integer 9 R_________ 030220851 rel 1 5 09 12 2008 Probe heater Dripping phase Post dripping Defrost type Unit On Off status Buzzer enable High temperature alarm enable Low temperature alarm enable Fan status during defrost Compressors control mode Enable pumpdown Alarms reset Buzzer reset Manufacturer parameters restore On off by supervisor system Manual defrost by supervisor system Light on off by supervisor system Auxiliary on off by supervisor system Conservation phase presence after the cycle Celsius
77. lar to the following 7 Press again the configuration screen will be shown similar to the following 8 Change the terminal configuration as required The button is used to move the cursor from one field to another while and V change the value of the current field The P xx field displays the address of the pCO board selected in the example shown in the figure this is board 1 9 Toexit the configuration procedure and save the data select the Ok field set Yes and confirm by pressing During the configuration procedure if the terminal remains inactive no button pressed for more than 30 seconds the pCO board automatically interrupts the procedure without saving any changes Important if during the operation the terminal detects the inactivity of the pCO board being displayed the display is cancelled completely and a message similar to the following is shown If the terminal detects the inactivity of the entire pLAN network that is no message is received from the network for 10 consecutive seconds the display is cancelled completely and the following message is shown 050220851 rel 1 5 09 12 2008 19 To complete the Blast Chiller installation procedure set the pLAN address on the pCO the pCO and pCO controllers do not have dipswitches for setting the pLAN network address the pLAN address can be set from any pGD1 terminal on the models where fitted 1 Set address 0 on the te
78. low pressure high pressure enable defrost On Off external alarm door switch low pressure high pressure enable activate defrost overload compressor overload fan overload light sensor night day defrost activate defrost overload compressor overload fan overload light ID 1 switch activate aux output sensor night day switch activate aux output On Off external alarm door switch low pressure high pressure enable defrost On Off external alarm door switch low pressure high pressure enable activate defrost overload compressor overload fan overload light sensor night day defrost activate defrost overload compressor overload fan overload light ID 2 switch activate aux output sensor night day switch activate aux output On Off external alarm door switch low pressure high pressure enable defrost On Off external alarm door switch low pressure high pressure enable activate defrost overload compressor overload fan overload light sensor night day defrost activate defrost overload compressor overload fan overload light ID 3 switch activate aux output sensor night day switch activate aux output On Off external alarm door switch low pressure high pressure enable defrost On Off external alarm door switch low pressure high pressure enable activate defrost overload compressor overload fan overload light sensor night day defrost activate defrost overload compressor overload fan overload l
79. mation of corrosive patina with possible oxidation and reduction of insulation Positioning the instrument inside the panel 2 12 The position of the instrument in the electrical cabinet must be chosen so as to guarantee correct physical separation of the instrument from the power components solenoids contactors actuators inverters and the connected cables Proximity to such devices cables may create random malfunctions that are not immediately evident The structure of the panel must allow the correct flow of cooling air Wiring procedure When laying the wiring physically separate the power part from the control part The proximity of these two sets of wires will in most cases cause problems of induced disturbance or over time malfunctions or damage to the components The ideal solution is to house these two circuits in two separate cabinets Sometimes this is not possible and therefore the power part and the control part must be installed inside the same panel For the control signals it is recommended to use shielded cables with twisted wires If the control cables have to cross over the power cables the intersections must be as near as possible to 90 degrees always avoiding running the control cables parallel to the power cables Use cable ends suitable for the corresponding terminals Loosen each screw and insert the cable ends then tighten the screws When the operation is completed slightly tug the cables to
80. nimum HACCP high E temperature alarm threshold to High temp alarm Maximum HACCP high threshold 6 b d HACCP high temperature alarm threshold C temperature alarm threshold 5 0 HACCP temp alarm delay 6 b d HACCP high temperature alarm delay S 0 to 9999 120 Monday to Sunday Mon to Sat Monday 0 to 25 0 Day 6 b e Day light first switched 0 to 59 0 Monday 0 to 23 0 First start time i 6 b e Day hours and minutes light switched on 0 to 59 0 Monday 0 to 25 0 First end time 6 be Day hours and minutes light switched off 0 to 59 0 to to Monday 0 to 23 0 First start time 6 be Day hours and minutes light switched on 0 to 59 0 Monday 0 to 25 0 Fourth end time 6 b e Day hours and minutes light switched off 0 to 59 0 Monday 0 to 23 0 First start time 6 b e Day hours and minutes auxiliary output activated 0 to 59 0 Monday 0 to 25 0 First end time 6 b e Day hours and minutes auxiliary output deactivated 0 to 59 0 Compressor m 6 c Compressor op hours h 0 to 30000 Control in 6c Time remaining before next compressor control h 0 to 30000 30000 Compressor 2 6 C Second compressor op hours h 0 to 30000 Control in 6c Time remaining before next second compressor control h 0 to 30000 30000 Evap fan 6 c Evaporator fan op hours h 0 to 30000 Control in 6c Time remaining before next evaporator fan controls h 0 to 30000 30000 Cond fan 6 c _ Condenser fan op hours h 0 to 30000 Control in 6c Time remaining before nex
81. nputs to be configured as voltage free digital inputs The inputs must be pre configured as voltage free digital inputs by the application program resident in the flash memory input 24 Ve V 50 to 60 Hz max power 40 VA 15 W field card Controller pco digit digt2 digt3 digita BCIO BC4 BC5 BC9 CAREL pco Not avallable Warning the maximum current available at the digital input is 5 mA thus the rating of the external contact must be at least 5 mA These inputs are not optically isolated 2 3 5 Remote connection of the analogue inputs The sizes of the cables for the remote connection of the analogue inputs are shown in the following table size mm for length up to 100 m size mm for length up to 50 m type of input NTC PT1000 current V voltage If the product is installed in industrial environments application of the EN 61000 6 2 standard the length of the connections must be less than 50 m This length shouldn t be exceeded in any case to avoid measurement errors 2 4 Connecting the digital inputs The pCO features digital inputs for connecting safety devices alarms device status remote switches These inputs are all optically isolated from the other terminals They can work at 24 Vac 24 Vdc and some at 230 Vac Q Note separate the sensor signal and digital input cables as much as possible from the inductive load and power cables to avoid possible electromagnet
82. obe errors If on the other hand the duty setting off time is set to 0 the compressor operates continuously in the event of probe errors If the probe error occurs while the compressor is off this remains off for the duty setting off time and then is started and remains on for the duty setting on time then stopped and started again as illustrated in Fig 4 5 Compressor Duty cyde OFF e 2 Duty cycle ON Pa Probe error z Min OFF time Min ON time gt Second phase comp Duty cycle OFF Duty cycle ON Min OFF time Min ON time N Second phase delay Fig 4 5 Duty setting a If on the other hand the probe error occurs while the compressor is operating it remains on for the duty setting on time and is then stopped and remains off the duty setting off time then starting again as described in Fig 4 6 Probe error amp Mn ONtme i Min OFF time gt CAREL Compressor Duty cyde ON Duty cyde OFF Time Second phase comp Duty cyde ON Duty cyde OFF Min OFF time gt gt Min ON time NS l l Second phase delay Fig 4 6 Duty setting b As soon as the probe errors are resolved normal control resumes Note if the second phase compressor has also been configured the two duty setting parameters act on both phases Rotation continues to be applied as does the minimum time between the starts of differ
83. of 3 3V The relay is SPDT with max current of 10 A and max inductive load of 1 5 HP The mechanical dimensions of the module are 87x56x60 mm 2 DIN modules with IP20 index of protection 2 6 Connecting the digital outputs The pCO features digital outputs with electromechanical relays For ease of installation the common terminals of some of the relays have been grouped together If the following diagram is used the current at the common terminals must not exceed the rating nominal current of a single terminal 8 A 2 6 1 Electromechanical relay digital outputs ee a a RS mom o S ey SS ey S v gv 970g J14 J15 EA xm Dis ger fey m e n BERO The relays are divided into groups according to the degree of insulation Inside each group the relays have Just basic insulation and thus must have the same voltage generally 24V ac or 110 to 230 Vac Between the groups there is double insulation and thus the groups can have different voltages There is also double insulation from the rest of the controller 2 6 2 Changeover outputs Some relays feature changeover outputs Changeover relay reference pCO terminals pCO terminals 2 65 Solid state relay SSR digital outputs The pCO also features a version with solid state relays SSR for controlling devices that require an unlimited number of switching cydes and thus would not be supported by electromechanical relays They are dedicated to loads
84. of action Type of disconnection or microswitching Category of resistance to heat and fire Immunity against voltage surges Ageing characteristics operating hours 030220851 rel 1 5 09 12 2008 13 DIN modules 110x 227 5 x 60mm Fitted on DIN rail as per DIN 45880 and IEC EN 50022 Technopolymer VO UL94 and 960 C IEC 695 125 C gt 250 V Grey RAL7035 25T70 C 90 rH non condensing 40T70 C 90 rH non condensing IP20 IP40 on the front panel only 2 to be integrated into Class 1 and or 2 appliances 250 V long IC microswitching for all relay outputs Category D Category 1 80 000 CAREL No of automatic operating cycles Software class and structure Category of immunity to voltage surges IEC EN 61000 4 5 1 4 5 Electrical specifications of the pCO Small board Power supply Maximum current with terminal connected Type of insulation of the power supply from the rest of the cont Terminal block Cable cross section CPU Program memory FLASH MEMORY Data memory RAM T buffer memory EEPROM MEMORY P parameter memory EEPROM MEMORY Working cycle duration application of average complexity Clock with battery 1 4 6 Dimensions of the pCO Small ro r 1 yl Uii Oz EA INT vow CCAREL j a gt Lx Y A I LI s Lu L ZLIV IC 7S3 SC SESSIONI TUI n Serial Card 1 5 1 Meaning of the inputs outputs on the pCO board connector signal description
85. oltages There is also double insulation between each terminal of the digital outputs and the rest of the controller The relays belonging to the same group individual cell in the table have basic insulation and therefore must have the same power supply 24 Vac or 230 Vac Reference for the relays with the same insulation Group 2 Insulation distance a Type of relay Type A Type A Number of changeover contacts 1 output 8 Switchable power NER Relay ratings SPDT 2000VA 250Vac 8 A resistive 2 5 A resistive 2 A FLA 12 A LRA 250Vac C300 pilot duty 30 000 cycles relay PCO approval EN 60730 1 2 A resistive 2 A inductive cosp 0 6 2 2 A 100 000 cycles Max number of SSR outputs 1 output 7 N Important the groups that the digital outputs are divided into have two common pole terminals to simplify wiring make sure that the current running through the common terminals does not exceed the rated current of an individual terminal that is 8 A 1 43 Mechanical specifications of the pCO Small board Mechanical dimensions Plastic case Assembly Material Flame retardance Ball pressure test Resistance to creeping current Colour 1 44 Other specifications of the pCO Small board Operating conditions Storage conditions Index of protection Environmental pollution Class according to protection against electric shock PTI of the insulating materials Period of stress across the insulating parts Type
86. on 10 Relay SSR digital output 11 Digital output for alarm relay with changeover contact SSR 12 Yellow power LED and 3 status LEDs 13 Cover for inserting the supervisor and telemaintenance option 14 Cover for inserting the clock board J1 1 24 Vac or 20 60 Vdc power supply J1 2 power supply reference 12 1 synchronicity input for phase control GO is the reference 2 2 universal analogue input 1 NTC 0 1V 0 5 V 0 20 mA 4 20 mA 12 3 universal analogue input 2 NTC 0 1V 0 5 V 0 20 mA 4 20 mA 2 4 universal analogue input 3 NTC 0 5 V 12 5 universal analogue input 4 NTC 0 5 V 12 6 reference for analogue inputs J2 7 power supply for 0 5 V ratiometric probes J2 8 power supply for 24 Vdc active probes J3 1 analogue output no 1 0 10 V 3 2 analogue output no 2 0 10 V J3 3 analogue output no 3 PWM for phase cutting speed controllers J2 4 reference for analogue output 050220851 rel 1 5 09 12 2008 10 CAREL J4 ID1 digital input no 1 42 digital input no 2 J4 3 digital input no 3 4 4 digital input no 4 J4 5 ID5 digital input no 5 J4 6 IDD6 digital input no 6 J4 7 IDCI common for digital inputs from 1 to 6 J5 pin telephone connector for connection to the standard user terminal J6 1 RX TX connector for connection over RS485 to the pLAN network J6 2 RX TX connector for connection over RS485 to the pLAN network J6 3 GND reference for connection over RS485 to the pLAN netw
87. on cannot be performed when running a cyde or if the blast chiller door is open however the operation can be run during the conservation phase Note the value of the sterilisation duration parameter must be less than or equal to the value of the maximum sterilisation duration parameter set by the manufacturer 4 12 Heat probe Input product temperature Parameters probe heater time probe heater threshold Output probe heater Description of the function the heat probe function piercing probe cannot be activated if it has not been correctly enabled and the probe is not fitted This function in addition can only be activated if the temperature measured by the probe in the heart of the product is less than 4 C The corresponding digital output remains active until the temperature measured exceeds the set threshold or the maximum duration has been reached 030220851 rel 1 5 09 12 2008 28 CAREL Main menu functions tree 1 Mi oort Cucle Pi Repeat EX Standard Ca IM custom Conservation EE sterilisation Heat Probe om jon je ca 1 ay Settings a RM custom cocle O OO From std 3 C soft f From std 3 C hard From std 15 C soft From std 18 C hard 5 Se _ Ei Complete 135 b LJ Conservation E a Temperature control Eg b Defrost dis c Fans d ad Alarms e ther settings A Oreratina hours ri Change larnguage Plll
88. ong Type of action 1 Type of disconnection or microswitching microswitching for all relay outputs Category of resistance to heat and fire Category D Immunity against voltage surges Category 1 Ageing characteristics operating hours 80 000 No of automatic operating cycles 100 000 EN 60730 1 30 000 UL 873 Software class and structure Class A Category of immunity to voltage surges IEC EN 61000 4 5 Category 2 1 5 55 Electrical specifications of the pCO board Power supply 24 Vac 10 15 50 60 Hz and 24 48Vdc 10 20 Maximum current with terminal connected P 8W Type of insulation of the power supply by the rest of the contr functional Terminal block with male female plug in connectors 250Vac max 8 A max Cable cross section min 0 5 mm max 2 5 mm CPU H8S2320 16 bit 24 MHz Program memory FLASH MEMORY 1 MB x 16 bit expandable up to 1 1MB Dual Bank Data memory RAM 128 KB x 8 bit expandable up to 512 KB T buffer memory FLASH MEMORY 4 KB x 16 bit P parameters memory EEPROM MEMORY 32 KB not visible from the pLAN network Working cyde duration application of average complexity 0 35 Clock with battery Optional 1 5 6 Dimensions of the pCO Product certification IEC EN 50155 standard Railway applications Electronic equipment used on rolling stock UL 873 and C222 No 24 93 Temperature Indicating and Regulating Equipment EC regulations 57 2005 of 12 January 2005 in particular
89. ork J7 amp AN terminal connector J8 1 tLAN network connector J8 2 reference for connection to the tLAN network J9 1 common relay 1 2 3 J9 2 normally open contact relay no 1 J9 3 NO2 normally open contact relay no 2 J9 4 normally open contact relay no 3 J10 1 common relay 4 J102 normally open contact relay no 4 J11 1 NO5 normally open contact relay no 5 J112 common relay 5 J11 3 normally closed contact relay no 5 1 5 2 Technical specifications of the pCO board Analogue inputs Analogue conversion 10 bit A D converter embedded in CPU Maximum number 4 Universal 2 inputs B1 B2 CAREL NTC 50T90 C R T 10kQ 1 at 25 C Voltage 0 to 1 Vdc 0 to 5 Vdc ratiometric Current 0 to 20 mA or 4 to 20 mA Input resistance 100Q Can be selected via software Universal 2 inputs B3 B4 CAREL NTC 50T90 C R T 10kQ 1 at 25 C Voltage 0 to 5 Vdc ratiometric Type Can be selected via software Time constant for each input Is NTC input precision 0 5 C 0 1V input precision 3mV 0 5V input precision 15mV 0 20 mA Input precision 0 06 mA Important the 24Vdc available at the 24Vdc terminal 12 can be used to power any active probes The maximum current is 80 mA thermally protected against short circuits To supply the 0 to 5 V ratiometric probes use the 5V available at terminal 5Vref J2 The maximum current is 60 mA Digital inputs Type Voltage free contact not optically isolated
90. orking hours of the compressor 2 low part Remaining time of the cycle phase Black out time Cyde phase Cyde phase 5 duration Cyde phase 2 duration 45 CAREL Integer Cycle phase 1 duration Integer ie Year Integer 12 RR Integer IS PRO 14 R Integer Integer _ _ _9 Integer 16 Month Day Hour Minute Day of the week Integer Type of defrost Integer Integer Integer 20 R W Integer Integer Integer Integer Integer Integer 28 Integer RS 030220851 rel 1 3 09 12 2008 Evaporator fan management Room high temperature alarm delay Room low temperature alarm delay Room temperature alarm delay HACCP Low pressure start delay Low pressure delay Maximum duration defrost time Interval defrost time Number of compressors Unit status 44 CAREL Below are the possible Blast Chiller configurations depending on the type of pCO board used Analogue inputs No pCO Small pco Blast chiller temperature 1 product temperature1 evaporator temperature Blast chiller temperature 1 product temperature1 evaporator temperature condenser temperature product temperature 2 product temperature 3 blast chiller condenser temperature product temperature 2 product temperature 3 blast BI temperature 2 blast chiller temperature 3 antifreeze chiller temperature 2 blast chiller temperature 3 antifreeze Blast chiller temperature 1 product temperature1 evaporator temperature Blast chiller temper
91. output sterilisation sterilisation condenser fans pump down second phase compressor probe NOI condenser fans pump down second phase compressor probe heater heater Compressor defrost generic alarm evaporator fans lights aux output sterilisation Compressor defrost generic alarm evaporator fans lights aux output condenser fans pump down second phase compressor probe heater sterilisation condenser fans pump down second phase compressor probe NO2 heater Compressor defrost generic alarm evaporator fans lights aux output sterilisation Compressor defrost generic alarm evaporator fans lights aux output condenser fans pump down second phase compressor probe heater sterilisation condenser fans pump down second phase compressor probe NO3 heater Compressor defrost generic alarm evaporator fans lights aux output sterilisation Compressor defrost generic alarm evaporator fans lights aux output condenser fans pump down second phase compressor probe heater sterilisation condenser fans pump down second phase compressor probe NO4 heater Compressor defrost generic alarm evaporator fans lights aux output sterilisation Compressor defrost generic alarm evaporator fans lights aux output condenser fans pump down second phase compressor probe heater sterilisation condenser fans pump down second phase compressor probe NO5 heater Compressor defrost generic alarm evaporator fans lights aux output st
92. pressors delay when starting the compressors minimum time between starts of the same compressor minimum on time minimum off time second phase delay enable rotation compressor stop when opening the door door open delay parallel operating mode Output compressor second phase compressor Description of the function 050220851 rel 1 5 09 12 2008 22 the compressor and second phase compressor parameters can control two different compressors that operate together this means that all the functions that require the activation of the compressor act on both outputs If the number of compressors parameter is equal to 1 or the second phase compressor is not configured then Blast Chiller manages just one compressor If there are two compressors and rotation has been enabled these will be managed based on FIFO logic first in first out the first compressor to start is the first to stop The activation of the compressors must also observe the settings relating to the time delays e delay when starting the compressor this time must elapse before starting it to prevent the compressor from continuously restarting in the event of frequent blackouts e Minimum time between different starts of the same compressor this time must elapse before the compressor starts again even if the compressor has been called to start This parameter is used to limit the number of restarts per hour for each compressor e Minimum time between starts of differen
93. ressor off parameter can be used to set the fans as always on or only on when the compressor is running CAREL Fans off when Type of fan control Fan behaviour compressor off Fans always on no control Always on based on the difference between blast chiller freezer Depending on the temperature and evaporator temperature of the temperature evaporator and the temperature only Fans on when the no control On when the compressor Is on compressor is on based on the difference On when the between blast chiller freezer compressor is on temperature and evaporator depending on the temperature temperature of the based on the evaporator evaporator and the temperature only blast chiller Note if two compressors have been configured and the start fans when compressor Is started option Is set the fans are on when at least one of the two compressors is on and off only when both compressors are off In the event of probe errors the fans are always on If the blast chiller door is opened the fans remain in their current status or are stopped depending on the configuration of the corresponding parameters In addition control can be managed in modulating mode Fig 4 9 or in on off mode Fig 4 8 Control based on the diff between blast chiller temp and evaporator temp Blast chiller freezer temp Evaporator temp Set point g Differential Control based on the evaporator temperature Evaporator temp
94. ressure or by temperature During pump down once the compressor has been stopped in order to reach the low pressure value if the pressure still falls for example due to leaks from the valve the compressor is started again until the low pressure is reached This procedure is called auto start Note the auto start procedure observes the minimum compressor off time and minimum time between different starts of the same compressor but not the minimum on time If this procedure has been disabled pump down is run whenever the temperature control process calls the compressor to stop if on the other hand auto start is enabled the pump down procedure is run even when the low pressure switch signals that the pressure has increased and there is no call to start the compressor Auto start is disabled in the following cases e Blast Chiller is off before startup if the corresponding parameter is set to 0 in the event of pump down alarms if the pump down procedure ends after having exceeded the expected duration 4 3 4 Stop compressor due to external alarm Input External alarm Parameters compressor operating time with external alarm compressor off time with external alarm Output compressor second phase compressor Description of the function if any external alarm has been activated Blast Chiller works in similarly to duty setting mode In fact in the event of external alarms the compressor can be kept on until the problem ha
95. rminal see the previous sections for details on how to select the address 2 Power down the pCO 3 Connect the terminal to the pCO 4 Power up the pCO pressing the UP and ALARM buttons together on the terminal After a few seconds the pCO runs the start up sequence and the display shows a screen similar to the following 5 From the moment when the screen is displayed wait 10 seconds and then release the buttons 6 The pCO interrupts the start up sequence and shows a configuration screen similar to the following Then change the pLAN address using the and Jj buttons on the terminal 8 Confirm the address by pressing the button the pCO completes the start up sequence and uses the address specified MN Important for the Blast Chiller the pLAN address of the controller needs to be set to 1 and the terminal to 32 the latter needs to be set as private for board 1 if the settings have not been made correctly the text and the images on the display will be shown in an incorrect and unorderly manner Important When switching the instrument on the first time wait a few minutes before configuring the terminal and the pLAN address otherwise the installation of the default values will be interfered with If the default values are not installed successfully simply switch the instrument off an on again 5 2 Navigation buttons Alarm displays the list of alarms mien Menu used to enter the main menu tree SC
96. rost time is calculated as follows dE I 1 dn dE X 100 dP 50 where I 4 time between defrosts dn nominal duration of the defrost in normal operating conditions expressed as a percentage of the maximum defrost duration dE current duration of the previous defrost dP maximum defrost duration dH proportional factor used to increase or decrease the influence of the duration of the current defrost If GH 0 this has no influence The time between defrosts is limited between n 2 and 2 2 Skip defrost the completion of the defrost is based on the previous defrost duration dn JP If the defrost duration is less than or equal to 100 the next defrost is skipped When the defrost is next run the check is repeated and if the duration is dh dp still less than or equal to 100 the next two defrosts will be skipped and so on until three consecutive defrosts If three consecutive defrosts are skipped the sequence restarts and the dn next time the duration calculated is less than or equal to 100 only one defrost will be skipped When Blast Chiller is started seven defrosts are completed before checking the duration 3 Combination of the previous two modes with this type of defrost the time between defrosts is increased or decreased based on the previous defrost and the completion of the defrost is also based on the duration of the previous as described for the previous types and in Fig 4 14
97. s enable pump down select type of end pump down maximum pump down time enable compressor auto start in pump down delay time between pump down valve activation and compressor start Output compressor second phase compressor pump down valve Description of the function the pump down procedure starts when the compressor Is stopped both by the temperature controller and when the Blast Chiller is switched off If the compressor or more in general the Blast Chiller is shutdown due to a serious alarm the pump down procedure is not run When the pump down procedure starts the corresponding valve is closed and the compressor runs until the end of the procedure as shown in Fig 4 7 When the temperature control process calls the compressor to start the pump down valve is opened and after a delay time the compressor is started If the compressor is called to stop while the valve is open however the compressor is already off the valve is closed and the pump down procedure starts If on the other hand there is a start call while the valve is closed and the compressor is already on the valve is immediately opened 050220851 rel 1 5 09 12 2008 25 Compressor call Pump down valve Time Compressor He Pump down time Time Fig 4 7 Pump down The pump down procedure ends when the low pressure value is reached or the maximum duration has elapsed depending on the selection made relating to the pump down mode by p
98. s been identified and resolved The compressor Is on for a compressor operating time with external alarm set by parameter and off for a compressor off time with external alarm Setting the corresponding parameters to 0 the functions are ignored compressor on off Note if duty setting mode has been activated at the same time the time values used are those relating to the compressor on and off with external alarm and not the on off times corresponding to duty setting 4 44 Fan management 4 4 1 Evaporator fans Input blast chiller freezer temperature probes evaporator temperature probe Parameters type of fan control evaporator fan control set point fans off when compressor off fan operation during defrost post discharge duration evaporator fan control differential minimum evaporator fan output maximum phase shift minimum phase shift triac pulse width mains frequency fan start delay at power on fans off when opening the door door switch delay fan speed up time Output evaporator fans Description of the function the evaporator fans can be managed in different ways depending on the settings made for the type of control and whether the fans are off when the compressor is off The following types of fan control are available e no control e based on the difference between the blast chiller freezer temperature and the evaporator temperature e based on the evaporator temperature only in addition the fans off when comp
99. soft one phase chill two phases soft two phases freeze hard one phase Cyde one phase hard two phases by temperature soft two phases freeze one phase Product temperature Product temperature Chill cycles Freeze cycles start cycle end cycle start cycle end cycle Fig 4 1 Chill cycles hard and soft and freeze cycles hard and soft Blast Chiller features the following preset standard cycles e Standard 3 C by temperature soft Standard 3 C by temperature hard Standard 5 C by time soft Standard 3 C by time hard Standard 18 C by temperature soft Standard 18 C by temperature hard Standard 18 C by time soft Standard 18 C by time hard These cydes are set according to the following set points and durations Cycle phase 1 phase 2 Conservation blast chiller ETCEN To IR Ee few E SE 2 C 2 C E 2 C Standard 3 Cbytimehard 20 C 60mn OPC 30min 2 C 20 y 8 Standard 18 C by temperature hard__ 35 C 18 240min 0 ED Siandard 1e Cbytimeso oe f gt omo 355 om 20 C Standard 18 C by time hard 35 C 240mn 20 C 050220851 rel 1 5 09 12 2008 20 CAREL Blast Chiller also allows the user to define up to ten custom cycles changing the values of the parameters according to needs The custom cycles can be set st
100. stive 2 A FLA 12 A LRA 250Vac 30 000 cycles Switchable power Type A relay PCO approval 2 A resistive 2 A inductive cosp 0 6 2 2 A 100 000 cycles Maximum number of 2 outputs 4 and 5 SSR outputs Electrical specifications working voltage 24 Vac Vdc maximum switchable power 10 Watts N Important the groups that the digital outputs are divided into have two common pole terminals to simplify wiring Make sure that the current running through the common terminals does not exceed the rated current of an individual terminal that is 8A 1 53 Mechanical specifications of the pCO board Mechanical dimensions 13 DIN modules 110 x 227 5 x 60mm Plastic case Assembly Fitted on DIN rail as per DIN 43880 and IEC EN 50022 Material technopolymer Flame retardance VO UL94 and 960 C IEC 695 Ball pressure test 125 Resistance to creeping current 250 V Colour Grey RAL7035 1 5 4 Other specifications of the pCO board Operating conditions 10T60 C 90 rH non condensing standard vers 25T70 C 90 rH non condensing extended range vers Storage conditions 20T70 C 90 rH non condensing standard vers 40T70 C 90 rH non condensing extended range vers Index of protection IP20 IP40 on the front panel only Environmental pollution 2 Class according to protection against electric shock to be integrated into Class 1 and or 2 appliances PTI of the insulating materials 250 V Period of stress across the insulating parts l
101. sts 7 8 823 Type of advanced defrost 4 variable time skip None Nominal defrost 7 2 23 Nominal defrost duration 0 to 100 65 Prop factor 7 8 g25 Proportional factor in defrost duration Oto 100 50 Min compressor on time 7 8 824 Minimum compressor time on S 0 to 9999 60 Min compressor off time 7 8 824 Minimum compressor off time S 0 to 9999 180 Minimum time between starts of same compressor 7 8 824 Minimum time between compressor starts S 0 to 9999 360 Comp and fan start delay at on 7 8 225 Initial delay in starting compressor and fans S 0 to 9999 60 Phase 2 delay c 7 g g25 Minimum time between starts of different compressors S 0 to 9999 180 Comp off with door 7 8 g25 Compressor behaviour with door open On Off On Door stop delay 7 2 g25 Delay after which compressors and fans start again with door open S 0 to 9999 360 Duty setting on time 7 8 826 Duty setting on time min Oto 9999 5 Duty setting off time 7 8 826 Duty setting off time min Oto 9999 10 Continuous operation time 7 g g27 Continuous operating mode duration min Oto 9999 480 Low temp delay after continuous Op LI 7 8 27 Low temperature delay after continuous operating mode S 0 to 9999 30 Enable pump down 7 2 g28 Enable pump down NO YES NO P down valve and comp delay 7 2 g28 Pump down valve and compressor delay S 0 to 9999 30 End pump down 7 8 g29 Select type of end pump down By time by press By time Compressor auto start during pump down 7 g g29 En
102. t compressors time that must elapse before starting the second phase compressor even if the compressor has been called to start This parameter is used to avoid the simultaneous starting of both compressors e _ Minimum on time once on the compressor cannot be stopped until this time has elapsed In the event of overload this time is ignored e Minimum off time once off the compressor cannot be started again until this time has elapsed e The parameters described here are valid for both compressors compressor and second phase compressor If the door is opened the compressors either remain in their current status or are switched off depending on the settings made in the section corresponding to shutdown with the door open If the door is opened longer than the door open delay the compressor Is reset and starts operating normally If the second phase compressor has been set operation is the same as described in the previous paragraph 4 3 1 Duty setting Input blast chiller freezer temperature probes Parameters duty setting on time duty setting off time Output compressor second phase compressor Description of the function in the event of control probe errors the compressor can be kept on until the problem is resolved The compressor remains on for a duty setting on time and off for a duty setting off time If the duty setting on time is set to 0 the function is ignored and the compressor remains off in the event of pr
103. t condenser fan control h 0 to 30000 30000 UV light 6 c UV light op hours h 0 to 30000 Control in 6c Time remaining before next UV light control h 0 to 30000 30000 Unit 6 c Op hours unit h 0 to 30000 030220851 rel 1 3 09 12 2008 55 CAREL Control in 6c Time remaining before next unit control h 0 to 30000 30000 English French Italian German Change language 6 d Change the language of the user interface Spanish English Show screen when starting 6 d Enable display of the change language screen at start up NO YES YES vij Delay time within which the change of language is accepted without Change language in 6 d modifications S 0 to 9999 60 Unit of measure 6d Change temperature unit of measure EE SC Date setting 6d Change the date settings dd mm yy mm dd yy dd mm yy Enable buzzer 6 d Enable the buzzer N Y Y New PSW 6 d Change the user password 0 to 9999 1234 Maintenance EM main menu 1234 Enter password 1 2 Maintenance or manufacturer password 0 to 9999 1254 Type of board 7a Type of hardware pco pCO Boot 7 a Boot version Bios 7 a Bios version n EN Carel ModBus LON Carel BMS protoc 7 b a ba02 Protocol used on the BMS port RS232 printer printer BMS address 7 b a ba02 Addr
104. t conservation temperature The end of a cyde is signalled by an audible buzzer Note if when running a cyde there is a power failure or the door of the blast chiller freezer is opened the cycle starts again from the point it was interrupted if the duration is less than the set point if on the other hand the duration is greater than set point the cycle is terminated and an alarm signals the event Note when running a cycle custom cydes cannot be created or saved ES How to use one of the standard cycles 1 from the main menu gt Cycle gt Standard cycle 2 scroll the list of the standard cycles using and v 3 choose from the 8 available one of the standard cycles pressing for 5 seconds 030220851 rel 1 5 09 12 2008 2 Note the cycle ends when the end conditions are satisfied or can be stopped by the user LEG Stop I How to create and use a custom cycle 3 phases most complete example 1 fromthe main menu gt Settings 2 enter the password any from PW1 PW2 and PW3 gt Custom cycle 3 scroll the list of the standard cycles using and that can be used as the base fro setting a custom cyde one two or three phases 4 select Complete cycle with three phases gt now choose whether to set the cyde by time or by temperature 5 Blast Chiller now requires the settings for phase 1 the set point of the blast chiller freezer the product set point and the duration of the phase and J
105. t overstock Product temperature out of range If an NTC sensor is selected with a range from 50 C to 90 C at the start of the cycle the product temperature may be greater than 90 C in this case the probe alarm and the value displayed are disabled A flashing message gt 90 C is displayed and stops when the temperature measured returns within the specified range that is less than 90 C If however after a certain delay settable by parameter the value measured and displayed continues to remain outside of the range it means that the probe is faulty and an alarm is signalled Probe not inserted If a cycle is selected by temperature and the product temperature probe is not working or has not been inserted correctly an alarm signals the event and the cycle ends by time Overload When the cycle starts or the door is closed a check is performed to evaluate the risk of overstock If the outcome is negative the check is repeated after a set check period and if still negative an overstock alarm is signalled The check is performed both on the blast chiller freezer temperature and the product temperature 4 1 2 Parameters Enable negative temperature cycles minimum product set point temperature minimum set point cold room temperature Description of the function The selection and execution of negative temperature cycles can be enabled disabled using the enable negative temperature cycles parameter If the negative temperature cyd
106. tal output 8 in manual operating mode On Off Off Device connected to an See Chap 9 out 1 7 h h16 Device connected to analogue output 1 CONFIGURATIONS Steril An out 1 operation 7 h h16 Operating mode of analogue output 1 Auto Manual Auto An out 1 status in manual mode 7 h h16 Status of analogue output 1 in manual operating mode 0 0 to 100 0 S 7h Device connected to an See Chap 9 out 3 7 h h16 Device connected to analogue output 3 CONFIGURATIONS Condenser fan An out 5 operation 7 h h16 Operating mode of analogue output 3 Auto Manual Auto An out 3 status in manual mode 7 h h16 Status of analogue output 5 in manual operating mode 0 0 to 100 0 CAREL default 7i Reset the CAREL default settings NO YES NO Save config EN 7i Save the manufacturer configuration NO YES NO New manufacturer password Ti New manufacturer password 0 to 9999 1234 Clock ME main menu dd 8 Day setting 1 to 51 mm 8 Month setting 1 to 12 yy a 8 Year setting 0 to 99 hh 8 Hour setting 0 to 23 mm 8 Minute setting 0 to 59 Log I main menu Save HACCP alarm data for each alarm the date time code description HACCP _xxx 9 a and help message are saved to Save alarm data for each alarm the date time code description and help AL_XXXX 9 b message are saved to Enable continuous print pico 9 0 Enable continuous printing of the HACCP alarms and the cycle data NO YES NO Print last HACCP 9 c Print last HACCP alarm NO YES NO Print last 5 HACCP 9 C Print last
107. th plastic faceplate and another version with membrane keypad for assembly behind the panel terminal with plastic faceplate dimensions 156 amp Blast Chiller gt 138 30 Display Type FSTN graphic Backlighting white LEDs controlled by application software Graphic resolution 132x64 pixels Text modes 8 rows x 22 columns 5x7 and 11x15 pixel fonts 4 rows x 11 columns 11x15 pixel fonts or mixed modes Character height 3 5 mm 5x7 pixel fonts 75 mm 11x15 pixel fonts 66x52 mm 72x36 mm Size of the active area Size of the display area Keypad LEDs 2 programmed by application software red and orange Menu and Alarm buttons 4 green other buttons used to control the backlighting of the LCD Power supply Voltage power supply from pCO via telephone connector or from 18 30 Vdc external source protected by external 250 mAT fuse Maximum power input 1 2 W terminal with membrane front panel dimensions 180 1 m N a aS ua v Blast Chiller are Display Type FSTN graphic Backlighting white LEDs controlled by application software Graphic resolution 132x64 pixels Text modes 8 rows x 22 columns 5x7 and 11x15 pixel fonts 4 rows x 11 columns 11x15 pixel fonts or mixed modes Character height 3 5 mm 5x7 pixel fonts 75 mm 11x15 pixel fonts Size of the active area 66x32 mm Size ofthe display area 72x36 mm 030220851 rel 1 3 09 12 2008 18 K
108. the conservation phase as the defrost can also be run during this phase The defrost by temperature can end if the value read by the probe exceeds the end temperature threshold or because the maximum duration of the defrost has elapsed in this case an alarm is generated An alarm is also generated if the defrost ends because the temperature probe is broken During the defrost the fans may be on or off in any case at the end of the defrost a dripping phase can be set depending on the settings of the corresponding parameter setting the dripping time to O skips the operation At the end of the defrost phase e ifthe dripping phase has been set the compressors are stopped using the pump down procedure if enabled If on the other hand this phase has not been set the compressors remain in the previous status and normal control resumes e ifthe dripping and the post dripping phase has been set the fans are off If on the other hand these phases have not been set the fans remain in the previous status and normal control resumes e the defrost relay is deactivated e the post defrost alarm delay is deactivated e if there are defrost calls pending these are reset The defrost procedure can also be completed e if the digital input has been disabled e Blast Chiller is stopped from the keypad supervisor or digital input e ifthe phase is terminated from the keypad or controlled by the supervisor Note in these cases the
109. the door frame 4 8 Auxiliary output Input activate auxiliary output Parameters day hours and minutes the auxiliary output is activated day hours and minutes the auxiliary output is deactivated auxiliary output controlled by the user auxiliary output activation in OFF status Output auxiliary output Description of the function the auxiliary output can be controlled by a digital input if configured the keypad a supervisor and daily time bands The possibility to control the output from the keypad must be configured by the manufacturer otherwise the user will not be able to access the settings Control by the daily time bands can be activated even if Blast Chiller is off by setting the auxiliary output activation in OFF status parameter accordingly 4 9 Antifreeze Input antifreeze temperature probe Parameters antifreeze temperature alarm threshold antifreeze alarm delay Description of the function the antifreeze function is only active if the antifreeze input has been configured When the antifreeze temperature is lower than the antifreeze temperature alarm threshold for a time equal to the antifreeze alarm delay an antifreeze alarm is generated this alarm immediately stops the compressor and activates the generic alarm output 4 10 ON OFF Parameters light activation in OFF status auxiliary output activation in OFF status Description of the function the ON OFF status of the Blast Chiller can be m
110. the set threshold or if necessary show a message that indicates the reason why the probe did not start heating The operation of this menu is similar to the previous one Sterilisation 5 6 EH Settings The Settings menu accesses the pages of the functions available only to advanced users in fact to access this menu a password needs to be entered PW1 Remember that some screens are only displayed if the corresponding functions are available The menu shows SETTINGS at the top and four submenus in the middle a Custom cycle b Storage c Operating hours and d Change language which correspond to four icons 5 6 a Custom cycle This submenu is used to define a custom cycle First of all the user can choose the standard cycle to use as the basis for creating the custom cycle e 6a From std 3 C soft e 6a bFrom std 3 C hard e 6a cFrom std 18 C soft e 6a From std 18 C hard e 6a e Complete that is three phases The two basic cycles 6 a a and 6 a d both contain the parameters for the cycle with Just one phase the parameters can be set using and aly to increase or decrease the values and the values must be confirmed by pressing Once the value of the parameter has been set the cursor automatically moves to the next parameter and after having set the last parameter the screen for saving the custom cyde is displayed The same thing occurs when selecting the two cycles 6 a b and 6 a c two phases howe
111. time HACCP Digital 30 R High temperature alarm Digital 31 R Low temperature alarm Digital 32 RL Printer error Digital 33 R Cycle phase Digital Conservation phase Digital 35 R Onoffdigitalinput Digital 36 R External alarm from digital input Digital 37 R Door switch Digital 38 R Low pressure digital input Digital 39 R High pressure digital input Digital 40 R Defrost enable digital input Digital 41 R Defrost activation digital input Digital 42 R Overload Digital 435 R Compressor overload Digital 44 R Fans overload Digtal 45 R Light sensor Digital 46 R Day night digital input Digital 47 RL Auxiliary output activation digital input Digital 48 R Compressor Digital 49 R Defrost phase Digital External alarm Digital 5l R Evaporator fans Digital 52 R Light Digital 55 3 R Aukliary output Digital 54 JR Sterilization Digital 55 R Condenser fans Digital 56 R Pumpdownvalve Digital 57 R Compressor And step 030220851 rel 1 3 09 12 2008 42 Compressor 2 alarm CAREL Digital 58 R Digital oo R Digital 61 ERT Digital KT R o Digital 63 RW Digital Digital 65 RW Digital 66 RW Digital Digita
112. tion over RS485 to the pLAN network GND connector for connection over RS485 to the pLAN network common relay 1 2 3 normally open contact relay no 1 normally open contact relay no 2 normally open contact relay no 3 common relay 1 2 3 common relay 4 5 6 normally open contact relay no 4 normally open contact relay no 5 normally open contact relay no 6 common relay 4 5 6 common relay no 7 normally open contact relay no 7 common relay no 7 normally open contact relay no 8 common relay no 8 normally closed contact relay no 8 power supply to additional Aria terminal power supply common power supply for 0 5 V ratiometric probes 1 42 Technical specifications of the pCO Small board Analogue inputs Analogue conversion Maximum number Type 10 bit A D converter embedded in CPU 5 Universal 6 inputs B1 B2 B3 B6 B7 B8 CAREL NTC 50T90 C R T 10kQ 1 at 25 C or HT NTC 0T150 C Voltage 0 to 1 Vdc 0 to 5 Vdc ratiometric or 0 to 10 Vdc Current 0 to 20 mA or 4 to 20 mA Input resistance 100Q Can be selected via software Passive 4 inputs B4 B5 B9 B10 CAREL NTC 50T90 C R T 10kQ 1 at 25 C PT1000 100T200 C R T 1k 2 to 0 C or digital input from voltage free contact Can be selected via software Normally open open closed open 250ms Minimum normally open voltage free digital input detection time Normally closed closed open closed 250ms
113. ture Duration The cydes can be defined by time or by temperature If the cycle has been defined by time the duration is defined while if the cycle is defined by temperature it ends when the product internally reaches the set temperature in both cases the control probe is the temperature sensor in the blast chiller used to control the compressor A cycle can also be defined as soft or hard the meaning of soft and hard differs according to whether it refers to a chill cycle or a freeze cycle For the chill cydes if soft Blast Chiller works for the entire duration of the cycle considering the final temperature of the blast chiller as the set point usually around 0 C on the other hand if the cycle is hard Blast Chiller works with two different temperature set points for the blast chiller one lower around 20 C used until the internal product temperature reaches the set value or the pre set time expires and a second set point higher around 0 C used until the end of the cycle For the freeze cycles if soft Blast Chiller works with two different set points the first higher around 0 C used until the product internally reaches the set temperature or until the end of a predefined time the second set point lower is then used until the end of the cycle if on the other hand the cycle is hard Blast Chiller always works only considering the final set point of the blast freezer usually around 55 C
114. ver there are more parameters those relating to the second phase Selecting a complete cyde that is with three phases the procedure to configure the custom cyde is the same only longer as there are even more parameters to set In each step the last row of the display shows a string that describes the phase corresponding to the parameter being set at that moment Note the name used to save the custom cydes can have a maximum of 15 characters The characters are selected by scrolling the list in alphabetical order using and Jy and then confirming the character with once the required name has been set press for 5 seconds to save it Confirmation CYCLE SAVED PRESS MENU FOR THE MAIN MENU tells the user that the cycle has been saved Note pressing ESC at any time returns to the previous step Note if the negative temperature cycles are disabled only submenus 6 a a and 6 a b are available 5 6 b Conservation This menu is used to configure all the parameters relating to the conservation phase In the same way as described for menu 6 Settings the top of the display shows the string CONSERVATION while in the middle are four submenus e 6 b a Temperature control e 6G b b Defrost e 6Gb cFans e 6b d Alarms When entering each of these submenus the various parameters can be set in the same way as in the previous menus using and Wy to choose the various values and confirming by pressing while pressing E

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