CAPKOLD CKTC-320 Installation Manual

CAPKOLD

TUMBLE CHILLER

MODEL CKTC-320

Instruction & Parts Manual

January 2007

CKTC-320 01-03-07.doc

MODEL # CKTC·320·1101

MACHINE SERIAL # 5846·07·01·102

TABLE OF CONTENTS
Instruction & Parts Manual
CapKold Tumble Chiller
Model CKTC-320

Forward.......................................................................................................................................3

Chapter One...................................................................................................................................4

Introduction................................................................................................................................4

Safety...........................................................................................................................................4

Chapter Two...................................................................................................................................5

Installation..................................................................................................................................5

General....................................................................................................................................................5

Receiving and Setting..............................................................................................................................5

Utility Connections..................................................................................................................................6

Chapter Three................................................................................................................................7

Equipment Description..............................................................................................................7

General....................................................................................................................................................7

General Specifications.............................................................................................................................7

Standard Features and Component Details.............................................................................8

Optional Equipment...................................................................................................................9

Machine Specification Sheet....................................................................................................10

Chapter Four................................................................................................................................13

Operations.................................................................................................................................13

Safety Precautions and Instructions.......................................................................................................13

Preoperational Checks...........................................................................................................................14

Machine Controls..................................................................................................................................15

Chiller Operation...................................................................................................................................17

Manual Operation..................................................................................................................................24

Troubleshooting.....................................................................................................................................27

Chapter Five.................................................................................................................................28

Maintenance and Repair .........................................................................................................28

Scheduled Maintenance.........................................................................................................................28

Sensor Adjustment................................................................................................................................28

Water and Steam Valves.......................................................................................................................29

Door Seal...............................................................................................................................................32

Drive Assembly.....................................................................................................................................33

Chapter Six...................................................................................................................................34

Spare Parts List........................................................................................................................34

Chapter Seven..............................................................................................................................35

Diagrams...................................................................................................................................35

Pneumatic Diagram...............................................................................................................................35

Water Valve Diagram............................................................................................................................36

2

Instruction & Parts Manual

Forward

The purpose of this manual is to provide information that will aid in the installation, operation,
maintenance and repair of a CapKold Tumble Chiller. This manual should be read completely
before installing and/or operating this machine. While every effort is made to provide accurate
and up-to-date information, CapKold reserves the right to change the specifications herein
without notice. CapKold also reserves the right to make changes and improve this product
without obligating itself to install any such changes or improvements in products previously
manufactured. The illustrations and descriptions herein are general in nature and may not include
all standard equipment or may include optional equipment.

The only applicable warranty is our standard written warranty, and there is no other warranty,
written or implied.

3

Chapter One

Introduction

The information in this section will aid in the operation of the CapKold Tumble Chiller and must
be read completely before operating the unit.

The CapKold Model CKTC-320 front loading batch tumble chiller is designed to rapidly chill
food packaged in flexible plastic casings by gently agitating the casings in a water bath that
accelerates product chilling from 180 deg F to 40 deg F in less than 60 minutes. The touch screen
control provides easy operator interface and is also password protected to add or change formulas
to meet the customer’s product requirements. The chilled water source provided by the customer
is pumped through a heat exchanger which includes an automatic back flush to maintain optimal
heat transfer efficiency. A recycle tank is available to reuse chilled water after each cycle saving
water and energy.

Safety

The CapKold Tumble Chiller was designed with the safety of the operator and maintenance
personnel in mind, as well as the safe functioning of the machine. Continuous safety of the
operators and plant personnel can only be maintained through cautious and competent operation
as well as regular and complete maintenance.

Safety precautions and warnings are noted in this manual as their need occurs. Please make note
of them and pay special attention.

This tells the operator that extreme danger exists and explains the necessary and safe actions to

This tells the operator that equipment may be damaged unless certain actions are taken.

Calls attention to an important condition or event.

WARNING

protect himself and others.

CAUTION

NOTE

4

Chapter Two

Installation

General

The following instructions will aid in a quick and correct installation of your new Tumble Chiller.

Receiving and Setting

Receiving: Immediately upon receipt, the unit should be inspected for any damage that may have
occurred during shipping. Any damage should be reported to the driver and the freight company
immediately.

Tools Required: Open end wrenches and flat blade screwdriver.

Lifting and Handling: The approximate weight of the tumble chiller is 2500 lbs. The machine

may be lifted by fork truck from the front of the machine.

Setting Machine: Choose a clean level area protected from weather conditions, moisture, heat,
and any foreign debris above or around the unit. Insure that adequate clearance exists between
machine and other machines and obstructions. A minimum of 3 feet should be maintained.

Final Machine Leveling: Machine must be level from front to back as well as side to side. If
not level, adjust leveling legs maintaining a minimum of 6 inch clearance from floor to bottom of
machine.

Optional Recycle Tank: The approximate weight of the recycle tank is 700 lbs. The tank may
be lifted by fork truck from the front of the machine. Align the 4 pins with the holes on the base
machine and lower in place. Connect hoses to base machine.

Panels: Install all panels using the truss screws provided.

5

Utility Connections

Electrical: Installation and grounding must conform with local codes, or in absence of local
codes, with the National Electrical Code.

Branch Circuit Protection

Machine Voltage Wire Size * Breaker Size

208 VAC 12 15 AMP, 3 Pole
220 VAC 12 15 AMP, 3 Pole
460 VAC 12 15 AMP, 3 Pole

* Wire size based on THW or MTW wire. If run exceeds 300 ft, use next larger size.

Air: The air supply is connected to a 1/4” pipe at the rear left side of the machine. The air supply
must be 90-100 PSIG. A shut off valve should be provided at or near the connection.

Mains Water: The mains water supply is connected to a 1 1/2” pipe located at the rear right side
of the machine (see Figure 2). A shut off valve should be provided at or near the connection.

Chilled Water: The chilled water supply is connected to a 1 1/2” pipe located at the rear right
side of the machine (see Figure 2). The chilled water return is connected to a 1 1/2” pipe located
above the chilled water supply connection. A shut off valve should be provided at or near the
connections.

Steam: The steam supply is connected to a 1-1/4” pipe located at the rear right side of the
machine (see Figure 2). A shut off valve should be provided at or near the connection.

Waste Drain: The waste drain is connected to a 2” pipe located at the rear bottom right side of
the machine (see Figure 2).

6

Chapter Three

Equipment Description

General

The CapKold Model CKTC-320 batch tumble chiller will chill up to 320 gallons of bagged
product. The machine is stainless steel construction throughout with a perforated stainless steel
basket. An inclined loading chute allows continuous loading of product while the basket is in
motion.

The touch screen control provides easy operator interface, with simple custom programming.

The drive system consists of a variable speed 1 HP motor and a selectable reversing function for
improved tumble action while chilling and a manual jog for distribution while unloading. Power
transmission to the cylinder is performed by a direct drive gear box to achieve smooth operation.

The door is locked and sealed pneumatically and may not be opened while the tumble chiller is
operating. This interlock also requires that the door be shut and sealed prior to starting.

General Specifications

Basket Size 58” Diameter x 46” Depth
Basket Volume 70.3 Cubic Ft.
Basket Material 14 Gauge 304 Stainless Steel
Basket Rib Size Four 4 1/4” High Triangular Ribs
Basket Angle 10 Degrees
Door Opening Size 30” Diameter
Door Chute Opening Size 12” Diameter
Drive Motor 1 HP
Centrifugal Pump Motor 1 1/2 HP
Basket RPM 2-8 RPM
Water Inlet Size 1 1/2”
Chilled Water Inlet Size 1-1/2”
Steam Inlet Size 1 1/4”
Drain Size 2”
Overflow/Vent Size 1 1/2”
Electrical Service 208VAC-16 Amps
Air Supply 1/4”, 90-100 PSI
Shipping Weight 2,500 LBS
Shipping Dimensions Tumble
Chiller
Shipping Dimensions Optional
Recycle Tank

64” Wide x 96” Deep x
80” High
64” Wide x 83” Deep x
24” High

7

Standard Features and Component Details

Gear Motor Drive with Inverter: The machine includes a 1 HP single motor drive and AC
variable frequency inverter. This arrangement provides precise speed control of the inner basket
between 2 and 8 rpm’s through a gearbox motor mounted directly to the basket’s main shaft. The
basket rotation options include one way, oscillate and gentle. The energy efficient motor is rated
for continuous duty. The inverter is safely mounted in the electrical cabinet.

Front Door: The front door includes an inclined loading chute to allow continuous loading of
product while the basket is in motion. Pneumatics are used to seal/lock and unlock the door.

Heat Exchanger: The chilled water source is pumped through a high heat transfer coefficient
plate heat exchanger.

Leveling System: A leveling system consisting of four adjustable legs. No special foundation is
required other than a floor with the capacity to hold the static weight load of the machine, water,
and products contained within.

Bearing Design: A shaft mounted flange bearing design and integrated bearing/motor/gear box
supports the cantilevered load of the inner basket. The front and rear bearings are sealed ball
bearings and do not require grease.

Seal Housing: A housing containing a spring loaded ceramic seal keeps water and chemicals
contained in the machines shell from leaking out, while allowing the machine’s main basket shaft
to rotate freely. The ceramic seal is lubricated with water and the basket will not rotate without
the centrifugal pump turned on or without the mains fill open.

Mains Water Inlet Valve: The water inlet valve is pneumatically operated, 1 1/2” butterfly type,
and is closed by spring pressure.

Chilled Water Inlet Valve: The water inlet valve is pneumatically operated, 1 1/2” butterfly
type, and is closed by spring pressure.

Steam Inlet Valve: The steam inlet valve is pneumatically operated, 1-1/4” butterfly type, and is
closed by spring pressure. The standard machine is outfitted with one valve for direct steam
injection into the bottom of the shell through a diffuser nozzle. Steaming does not occur until the
water level has been satisfied. If no steam is available, hot water supply can be used and must be
programmed in the formula.

Drain Valve: A pneumatically operated, 2” butterfly type valve mounted below the outside shell
allows for rapid gravity draining of waste water.

Automatic Back Flush: An automatic back flush of the heat exchanger will back flush build up
of foreign matter which has entered the heat exchanger in order to maintain optimal heat transfer
between chilled water and product.

In-Line Filter: An easily accessible in-line filter provides protection for the pre piped centrifugal
pump in the event a plastic bag breaks open.

8

Touch Screen Controller: A PLC-based, Operator Interface Terminal with a graphical touch
screen provides the formula control for the machine. It provides a storage capacity for up to 99
formulas, up to 99 events (steps) per formula, and 99 product codes. Functions include step time,
rotation intervals and speed, water addition and draining, temperature control, chemical and
steam injection, door operation and safety interlocks for the protection of the operator and
machine. The OIT connects to the machine’s PLC allowing multiple input/output capability,
while providing the operator and maintenance personnel with an easy to program control system.

Optional Equipment

Recycle Tank: An insulated recycle tank with high and low level sensors and 1” water valves to
direct water to the tank. The tank also includes a 1 1/2” drain valve which drains the water into
the shell.

Control Right Side/Left Hinged Door: A control mounted on the right side of the machine with
a left hinged door is available.

Prison Package: The prison package includes tamper proof hardware per the American
Correctional Food Service Association Guidelines.

Automatic Sanitizer Injection: The machine supports liquid supply injection with 1 standard
connection port. Automatic liquid injection can be controlled by the BTC-8 touch screen formula
control with outputs from the PLC terminal strip.

RS232 Port: A 9 pin RS232 port will be available for communication.

9

Machine Specification Sheet

Front Elevation

Figure 1

10

Rear Elevation

Figure 2

11