Aladdin CR3 Parts List
CONVECT-RITE
™
Air Cooled
III
Manual P/N 97394
Rev. K 10/23/2009
Convect-Rite™ III
Docking Stations
24 Meal Capacity (CR3D0XXX1)
30 Meal Capacity (CR3D1XXX1)
Used with
Convect-Rite™III Cart manual 98893
or
Convect-Rite™ Trans-Tray System manual 98871
U.S. Patent Number 7,025,121
INSTALLATION & SERVICE MANUAL
Copyright © 2004 Aladdin Temp-Rite
®
Changes may be made to the information in this document without notication.
MEAL
ENTER
MANUAL
MODE
AUTO
MODE
B
L
D
MANUAL
HOLD
MAN.
RETHERM
PM
PROGRAM
ALARM
SILENCE
CHILLING
RETHERM
EQUALIZE
HOLDING
DEFROST
R
3-18-03
CHILLING
Mode: (Green LED
illuminated) Cart is engaged.
After a 5 second delay, both the
hot side and cold side chambers
will be subjected to refrigeration
cooling to satisfy temperature
set points programmed into
the controller.
RETHERM
Mode: (Green LED illuminated)
The hot side chamber will receive
heating while the cold side chamber
will receive refrigeration cooling. This
cycle is used to rethermalize food on the
hot side of the cart. This mode can be
started using either the MANUAL RETHERM
key or pre-programmed meal times (AUTO
MODE). The timer will display the number of
remaining minutes in the retherm cycle and
Default Time
(Minutes)
Breakfast
Lunch &
Dinner
count down to zero.
24 Meal 30 Meal
38 45
48 55
IDLE
Mode: (Red AUTO MODE
or Red MANUAL MODE LED
illuminated) The Convect-Rite™
III system is powered up. No cart
is engaged. The alphanumeric
display shows the word
“Idle”.
EQUALIZE
Mode: (Green LED illuminated)
After the Convect-Rite III nishes the
RETHERM mode, it will automatically
move into the EQUALIZE mode (default
duration for the 24 meal dock is 10 minute,
for the 30 meal dock is 5 minute). During this
mode, the temperature set point for the hot
side chamber has a lower setting to allow for
temperature saturation throughout the cart.
The fans will continue to run to enhance
the saturation process. The cold side
chamber will continue to receive
refrigeration cooling.
ALARMS
An alarm can arise at any
point during the operation of the
Docking Station. A buzzer will sound
to indicate an alarm has been activated
and both the Red ALARM LED and the red
SILENCE LED will blink on and off. The
alphanumeric display will show which alarm
occurred. Press SILENCE key to silence
the alarm buzzer (the Red ALARM LED will
remain illuminated if the alarm condition
exists). The alarm will terminate once
the alarm condition is satised. See
the Owner’s Manual for all alarm
displays and descriptions.
Mode: (Red LED illuminated) The
HOLDING
HOLDING mode includes a sounding
alarm to indicate the rethermalization
process (RETHERM + EQUALIZE) is
complete. The cart can be removed at any
time. The temperature set point for the hot side
chamber has a lower setting than the EQUALIZE
mode. The fans will continue to run to enhance
the saturation process. The timer will display
the number of minutes held and count up to the
duration setting (default 10 minute duration,
max. hold 60 minute duration). Once the
programmed holding time is reached, all
heating and refrigeration will cease
operation and a second alarm will
sound continuously until the cart
is removed.
DEFROST
Mode: (Green LED illuminated)
If CHILLING mode continues for an
extended amount of time, the DEFROST
mode may be automatically activated.
During this mode, the refrigeration cooling
used during the CHILLING mode will turn off for
the programmed duration (default 10 minutes) of
the DEFROST mode. The fans will still operate.
This mode ensures the coils inside the dock do
not freeze while receiving extended periods of
refrigeration cooling in the CHILLING mode.
Once the DEFROST duration expires ,the
system will return to the CHILLING
mode. This mode will not activate
during the rethermalization
cycle.
CONVECT-RITE™ III Docking Stations
CONTENTS
I. INTRODUCTION 6
Convect-Rite™ III Docking Stations 6
II. RECEIVING INSPECTIONS 8
III. INSTALLATION INSTRUCTIONS 9
INTRODUCTION 10
INSTALLATION POLICIES 11
ELECTRIC POWER REQUIREMENTS 11
SELECTING THE OPERATING LOCATION 11
TEST BOOT 15
Installation & Service
Manual
SETTING AGAINST THE WALL 15
LIFTING THE UNIT OFF THE CASTERS 15
ADJUSTING THE SEAL & LATCHES 16
MOUNTING TO THE FLOOR 16
IV. PARTS LIST & ILLUSTRATION 22
24- Meal (CR3D0XXX1) 22
30- Meal (CR3D1XXX1) 26
V. OPERATION & PROGRAMMING 30
VI. PREVENTIVE MAINTENANCE 31
INTRODUCTION 31
OPERATOR’S TROUBLESHOOTING 33
TROUBLESHOOTING NOTES 33
SERVICING PROCEDURES 39
REPAIRING THE REFRIGERATION SYSTEM 42
PUMP DOWN 42
WIRING DIAGRAMS 44
VII. WARRANTY 52
CONVECT-RITE™ III Docking Stations
I. INTRODUCTION
Convect-Rite™ III Docking Stations
The Convect-Rite™ III Docking Stations are installed and electrically connected in the
ward pantry for a decentralized operation or grouped in one area for a centralized operation. Operation and programming of these units is shown in the Owners Manual. The
Convect-RiteTM III Docking Station is a dual cold and hot air-generator, which may be
used up to three times a day in the Auto mode:
•
To keep the meals at the recommended and safe temperature of
37/41°F (+3°C/+5°C) during stand-by periods prior to rethermalization.
•
To rethermalize starters, soups, hot desserts or main-courses in
approximately 50-60 minutes before service.
•
IMPORTANT NOTE: The food products in the cold section, should be at
maximum homogeneous 50°F (10°C) temperature when loaded inside the
cart, so that the Convect-RiteTM III System can keep them between 37
and 41°F (+3° and +5°C) at the end of the chill-down and rethermalization
cycle.
•
A minimum chill-down cycle of 50 minutes is recommended prior to
rethermalization to assure the lowest possible cold food temperatures.
Installation & Service
Manual
6
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MODELS
This manual covers the standard models for the Convect-Rite™ III Docking Station that
accommodates 24 or 30 meals depending on the unit. Information for the ConvectRiteTM III System is listed in the table below. See below for dimensions.
TABLE 1-1
Tray Capacity, Dimensions, Weight, Electrical Data, & Heat Load Requirements
DIM CONVECT RITETM SYSTEM
A LENGTH/DEPTH
B WIDTH
C HEIGHT
MODELS
ALADDIN SALES CODE FOR
STANDARD MODELS
TRAY CAPACITY
TRAY SPACING
(OFF WALL FOR Docking Station)
WEIGHT
SHIPPING WEIGHT
Cart TURNING RADIUS n/a n/a
MAX HEAT EMISSIONS
@ 70oF AMBIENT
COOLING CAPACITY 6000 BTU/HR 7500 BTU/HR
ELECTRICAL REQUIREMENTS 208V - 3 Phase - 60 HZ / 4 Wire - 30 Amp
24 Meal 30 Meal
CR3D0XXX1 CR3D1XXX1
n/a n/a
32.56”
41.69”
77.63”
530 lb
550 lb
7900 BTU/HR 9900 BTU/HR
Docking Station
(82.7 cm)
(108.89 cm)
(197.18cm)
(240.4 kg)
(249.5kg)
(Hard wire connection required)
32.56”
41.69”
82.08”
573 lb
593 lb
(82.7 cm)
(108.89 cm)
(208.5 cm)
(259.9 kg)
(268.9 kg)
SPECIFICATIONS
CONVECT RITE™ III Docking Station
B
C
A
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7
CONVECT-RITE™ III Docking Stations
#96712
MOCP
SERIAL / PRODUCT INFORMATION PLATES
During manufacture, Convect-Rite™ III Docking Stations are
assigned individual serial numbers. The serial number plate is
located on the top left hand side of the black plastic top cover. The
product information plate lists the model number, serial number,
voltage, power and wiring requirements, amount and kind of
refrigerant, pressure, and ETL listed mark. (See Figure 1-3)
Installation & Service
Manual
Figure 1-3
II. RECEIVING INSPECTIONS
Your Aladdin Convect-RiteTM III Docking Station is factory tested for performance and is free from
defects when shipped. The utmost care has been taken in packaging this product to protect against
damage in transit. All interior ttings have been secured to prevent damage.
You should carefully inspect your Convect RiteTM III components to assure that no damage has occurred in transit. If however, damage is detected, you should save all the packaging materials and
make note on the carriers Bill of Lading describing this shipment. A freight claim should be led
immediately. If damage is subsequently noted during or immediately after installation, contact the
respective carrier and le a freight claim. Under no condition may a damaged unit be returned to
Aladdin Temp-Rite without rst obtaining written permission (return authorization).
PACKAGING:
Your Convect RiteTM III Docking Station is packaged with care and shipped on dedicated carriers to
you from the factory.
IMPORTANT NOTE:
Aladdin Temp-Rite does not recommend laying the unit down on its front, side or back.
However, if you must, please be certain to allow the unit to remain in an upright position for 24 to 48
hours before attempting to place the unit into service, to assure that the compressor oils and refrigerant may settle.
ALADDIN DAMAGED GOODS POLICY
There are two types of damaged merchandise:
A. VISIBLE DAMAGE OR SHORTAGE
B. CONCEALED DAMAGE
8
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A. VISIBLE DAMAGE OR SHORTAGE - (All claims should be reported within 10 business days)
1. Receiver should refuse the damaged portion of the shipment.
2. Receiver should sign the bill of lading indicating (delivery receipt) what merchandise is being
“refused due to damage” and have the driver initial the notation.
3. Receiver should note any shortages on the bill of lading (delivery receipt) in the same manner.
4. Receiver should contact Aladdin Customer Service at 1-800-888-8018 and alert them to the
situation.
B. CONCEALED DAMAGE- (All claims should be reported within 10 business days)
Any receiving operation should inspect for this type of damage.
IF PRODUCT IS DAMAGED
1. Receiver should hold the shipping container and its contents in the same condition as when the
damage was discovered insofar as possible and call the delivering carrier to arrange on site
inspection within 10 days of delivery.
2. Receiver should contact Aladdin Customer Service at 1-800-888-8018 for claims processing
after inspection has been completed.
III. INSTALLATION INSTRUCTIONS
IMPORTANT NOTE:
DO NOT INSTALL a Convect-RiteTM III Docking Station if damage is suspected.
INJURY & EQUIPMENT DAMAGE could result from improper installation of the Con-
vect-RiteTM III Docking Station or from installation of a unit damaged during shipment
or storage. Either of these conditions will void the equipment warranty.
! WARNING !
DO NOT move a Convect-RiteTM III Docking Station up a slope
greater than 10°.
DO NOT EVER tow a Convect-RiteTM III Docking Station
DO NOT push a Convect-RiteTM III Docking Station from the front
or back side
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9
CONVECT-RITE™ III Docking Stations
! CAUTION !
Casters are ONLY intended for use during installation or service.
Unit MUST be positioned securely against a wall during operation!
INTRODUCTION
Install the Convect-RiteTM III Docking Station according to the policies and procedures
outlined in this manual. After selecting and preparing the Convect-Rite™ III Docking
Station operating location, the unit can be positioned and installed. When installation
is complete, perform all start-up checks to verify proper installation and operation.
This section is a guide for installation of the Convect-RiteTM III models identied
in the Introduction section of this manual. This guide is for use by qualied
professionals, and does not include all procedures and precautions in the common
domain of licensed plumbers, pipe tters, and electricians or experienced food
service equipment installers.
Installation & Service
Manual
This guide MUST be used in conjunction with professional experience and thorough
understanding of the local and national utility, construction & sanitation codes.
Before starting installation, the owner and the installer should read through
this chapter and thoroughly understand and agree upon:
• The installation policies of Aladdin Temp-Rite® as stated in Installation Policies
Section.
• An installation plan based on the Installation Instructions and Start-Up Check
List
10
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INSTALLATION POLICIES
The Convect-RiteTM III Docking Station must be installed by qualied electrical, mechanical, or refrigeration personnel, working to all applicable national and local codes. Equipment installation must comply with the local and national codes.
All models of the Convect-RiteTM III Docking Station comply with the applicable standards
•
for manufacturers. Included among those certication agencies are: ETL Safety and ETL
Sanitation.
The Convect-RiteTM III Docking Station is certied for safe operation only when perma-
•
nently installed in accordance with local and/or national codes. Many local codes exist,
and it is the responsibility of the owner and installer to comply with these codes.
In no event shall Aladdin Temp-Rite assume any liability for damage or injury resulting
•
from installations which are not in strict compliance with the Installation, Instructions and
the codes cited above. Specically, Aladdin Temp-Rite will not assume any liability for
damage or injury resulting from improper installation of equipment, including but not limited to temporary or mobile installations.
ELECTRIC POWER REQUIREMENTS
Unit should be hard wired to electrical disconnect requirements specied which can also
be found on the product identication plate. The plate is secured to the top on the left hand
side as you look at the front of the unit as mentioned in serial/product information plate section. 208 volts / 3 phase / 30 amp circuit / 4 wire (3 hots & 1 ground)
SELECTING THE OPERATING LOCATION
For safe and efcient operation, observe the following criteria when selecting an operating
location for the Convect-Rite™ III Docking Station.
IMPORTANT NOTE:
The ooring directly under this unit must be made of non-combustible material and be capable of supporting the weight of this equipment.
1. Do not install these units in areas where combustibles are stored or may accumulate. The surrounding area must be clear of combustibles, including the
space under the unit.
2. A proper air supply for ventilation is critical to safe, efcient operation of the
Docking Station. The area around the Docking Station must have adequate
ventilation and the ambient temperature should never be above 85°F
(35°C).
3. Do not block the louvers or panels. Do not install any heat producing
equipment near the louvers of the unit. Ventilation occurs through open
slots on the dock’s right side and through louvers on the back of the dock.
FOR SERVICE CALL - ALADDIN TEMP-RITE® - Tech Service 1 (800) 888-5426
11
CONVECT-RITE™ III Docking Stations
R
FRONT DOOR SWING
30"
75 cm
R
REAR DOOR SWING
30"
75 cm
4. The dimension drawings in Figure 3-1 specify all dimensions and clearances
required for proper installation operation and service of the Convect-Rite™ III
Docking Station, covered in this manual. Maintain at least a 6” (15.2 cm) oper-
ating clearance between foot pedals of units, at least 10” (25.4 cm) between
foot pedal and sidewall, at least 18” above the unit, and at least a 5 3/4”
(14.6 cm) clearance at the back of the unit. The front and rear door swing
of the cart is 30” (750 cm).
5. The condensing unit and controller can be accessed by removing the black
plastic top cover. Removable side panels provide access for service of
various components; the right side for the cold side blowers and control panel
and the left side for the hot side motors. The back access panel permits
service to the cold side motors and expansion valves. Removing the left
side perforation panels allows access to the hot side heaters and blowers. A
minimum 6” (15.16 cm) clearance should be available on both sides of
the unit. For access to the back and side panels the Docking Station should
be lowered onto the casters and pulled away from the wall where it can be
turned 90°-180° for ease of service.
6. The location selected must be capable of supporting the operational weight
of the Convect-Rite™ III system including the weight of the Convect-Rite™
III cart loaded with trays, crockery, and food-products. See Table 1-1 for
equipment weights.
7. The oor surface under the unit must be level and continuous with the
ooring in front of the unit. The cart must roll smoothly to the Docking
Station for ease of operation and maintenance of the seal between the
Docking Station and the cart.
Installation & Service
Manual
12
Minimum
18” Clearance
(45.7 cm)
Minimum
Minimum
Clearance
10” (25.4 cm)
FOR SERVICE CALL - ALADDIN TEMP-RITE® - Tech Service 1 (800) 888-5426
clearance
between
foot pedals
6” (15.2 cm)
Minimum
5-3/4” Clearance
(14.6 cm)
Figure 3-1
WALL MOUNTING INSTRUCTIONS
IMPORTANT NOTE:
The wall directly behind the Docking Station must be able to support the average cart
Docking force of 550 lbs. Based on the condition of the support wall, a reinforcing
horizontal or vertical brace may be required at the upper and lower wall contact points, for
better stability. See gure below for details.
Support braces should be:
1) 2” x 6” X 3’
SPIB Southern pine wood or equivalent
2) 8” X 3’
10 Gauge 304 Stainless steel or equivalent
3) Use optional Aladdin wall mounting kit PN 98507
50” (127 cm)
13” (33 cm)
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13
CONVECT-RITE™ III Docking Stations
Dedicated electrical
disconnect or J-box
3/4" Liquidtight conduit
Installation & Service
Manual
INSPECTED FOR SHIPPING DAMAGE (see Section
CONNECT ELECTRICAL LINE
Electrical schematic diagrams can be found in Section VI. PREVENTIVE MAINTENANCE.
Connect the electrical cord to the electric connection box as described in Figure below.
Refer to Table 3-1 for amperage distribution
II. RECEIVING INSPECTION)
14
Table 3-1
Convect-Rite™ III Docking Station
208V / 3PH /4 WIRE/
(3 hot, 1 ground)/ 60
HZ
Product Total 9.3 kw MAX* 26 25 25 10 kw MAX* 28 27 27
*Actual duty load during rethermalization cycle is approximately 75% of maximum power
requirements.
24 Meal Unit (CR3D0XXX1) 30 Meal Unit (CR3D1XXX1)
Power
Watts
PH1
Amps
PH2
Amps
PH3
Amps
Power
Watts
PH1
Amps
PH2
Amps
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PH3
Amps
TEST BOOT
With the unit still on all four casters, and after the hard wire connection
is complete, switch the breaker on for the unit and then turn on the
unit (the switch located on the upper right front of the unit). The unit
should boot up and the screen should display the time & “Idle”
(see gure to right) Turn the unit and breaker back off. If the unit
does not boot correctly check electrical connection. For further
information call Aladdin Tech Service 1 (800) 888-5426.
SETTING AGAINST THE WALL
Make adequate space and thoroughly clean the location before you begin the install.The Docking
Station has eight adjustable feet (four on the back & four on the bottom). When starting the
install process all eight feet should be completely seated. Gently push unit within 1/4” of the
wall. Loosen the 7/8” jam nuts on the back four feet. Adjust all four back feet close to the
wall but not touching it. Extend one foot at a time to touch the wall, trying to keep the unit
parallel to the wall as possible (due to wall inconsistency all four feet may be adjusted to
different lengths) NOTE: Recommend adjusting the top feet until the Docking Station sits at
a 5° angle away from the wall as a starting position.
LIFTING THE UNIT OFF THE CASTERS
NOTE: If feet are unevenly set the unit’s frame may be damaged by racking.
The Convect-Rite™ III Docking Station MUST BE LEVEL BOTH FRONT TO BACK AND SIDE TO
SIDE. Depending on oor condition reference gasket alignment between the cart and Docking Station to insure proper gasket seal for correct positioning.
Ensure that both caster locks point away from the wall, and are 90˚ to the wall in the locked
position.
The four feet on the base of the Docking Station are adjustable to achieve this. Be mindful
when setting the feet that:
• A Docking Station set too low can result in interference between the lower cart hinge and
the Docking Station interface channel.
• A Docking Station set out of level right-to-left can result in an insufcient seal between
the unit and the gaskets on the cart.
• A Docking Station set out of level front-to-back can result in an insufcient seal between
the unit and cart and possibly make mating the cart more
difcult.
Loosen the 7/8” jam nuts on the four bottom feet. Then adjust the
four feet close to the oor, but not touching it. Slowly continue to
extend each foot a turn at a time, until the top of the base is 7.1”
(see diagram) off the ground (the caster should be off the ground at
this point). However, due to oor inconsistency, all four feet may be
adjusted to different lengths
FOR SERVICE CALL - ALADDIN TEMP-RITE® - Tech Service 1 (800) 888-5426
7.1”
15
CONVECT-RITE™ III Docking Stations
Mirco Switches
EXTENDING THE REAR FEET AGAINST THE WALL
NOTE: Shims should NOT be used.
Adjust back feet until they are tight against the wall. Check that the
feet are not bowed, skewed, or have less than 3 threads protruding
from rear brackets. If any of these conditions occur, the dock should
be lowered back on its casters and moved closer to the wall.
Installation & Service
Manual
ADJUSTING THE SEAL & LATCHES
Holding Screws
Roll a Convect Rite III Retherm Cart up to the
front of the Docking Station with the door open
on the non-handle end of the cart. NOTE: if
Docking Station is too low the cart will run
into the door support. If the cart does not hit
the door support, dock the cart to the unit.
Adjust any necessary feet until a uniform
compression seal is formed around the cart.
You many need to dock & undock the cart
several time to ensure a proper t.
If the cart does not depress the latches
when engaged to the dock, (see diagram for
location) the latches need to be adjusted. To adjust rst loosen the holding screws, adjust
the latch bolts so the switches are in contact with the cart. To move the switches forward,
turn the bolts clockwise. To move backward, turn counter clockwise. Tighten the holding
screws.
Latch Adjustment Bolts
Latches
MOUNTING TO THE FLOOR
16
The Docking Station should be secured to the oor with oor anchors that are included with
the unit.
Turn the feet out 45°, for better stability . Select a carbide drill bit equal to the
45°
leaving nut ush with end of anchor to protect threads. Drive anchor through the foot until
the washer is ush. Expand anchor by tightening
nut 3 to 5 turns past the hand tight position, or 25 ftlbs. torque.
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anchor diameter, 1/2”. Drill hole to desired depth suitable for the oor type. A
minimum embedment of 1-7/8” is required for concrete. Clean hole or continue
drilling additional depth to accommodate oor nish. Assemble washer and nut,
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