Foster RBC20-60 User Manual

RBC20-60

Blast Chiller

Contents Page

Introduction 1 to 2
Model Details 2
Controller Technical Detail 2
Parts List 2
Operating Instructions 3 to 6
Electrical Connections 7
Service Information 7 to 19

Diagnostics 8
Function Test 8
Passcode 8
Profiles 9
Parameter Access 9
Parameters 9 to 11
Parameter Definitions 11 to 18
Alarms and Warnings 18

Foot Print Test Operation 19
Probes 19
Technical Data 20 to 22
Wiring Diagrams 23 to

Introduction.

Cook Chill Operation.

Blast chilling is a process to reduce the temperature of cooked food by swiftly arresting the cooking process, locking in its
colour, flavour, texture and nutritional value. Department of health guidelines state that to safely blast chill food the
temperature must be reduced from +70°c to +3°c within 90 minutes.

Pre Chill
Pre chilling ensures the correct cabinet temperature in the unit before chilling commences therefore improving the chilling
performance.

Soft Chilling.

Soft chilling is the process of rapid but gentle chilling of food.
This cycle brings down the food temperature to +3°c in no more than 90 minutes without the air or food temperature going
below 0°c.
This prevents large ice crystals forming therefore maintaining the texture, consistency and appearance of food such as
vegetables, rice, pasta, custard and fruit with no dehydration or cell damage.

Hard Chilling.
Hard chilling is the process of general purpose chilling.
This cycle brings down the food temperature to +3°c in no more than 90 minutes and is ideal for chilling meat pies,
lasagne, pasta and individually portioned meals. The air temperature for this process goes down to -15°c for the first 70%
of the cycle, to extract the maximum amount of heat from the product quickly. The air temperature then increases to +3°c
for the final 30% of the time to reduce surface damage and ensure quality.

Hard Chill Max.
Hard chill max brings down the food temperature to +3°c in no more than 90 minutes and is used for chilling high density
or high fat content food such as meat joints, stews or packaged products.
The air temperature during the cycle is allowed to go down to -20°c.
After either a pre-designated time has elapsed or product temperature has been achieved, the air temperature is allowed
to rise to the ‘hold’ value with the temperature being maintained at this level indefinitely.

Surface Protection.
Removing the heat energy from food product as rapidly as possible by the combination of powerful refrigeration and
evaporator fans moving large volumes of cooled air can cause damage to the food product. The food product could have
a form of ‘Frost Burn’ caused by the fast moving air feeling cooler than the actual air temperature ‘Wind Chill Effect’. This
may lead to product discoloration, dehydration, localised freezing and spoilage of the food product.
Surface protection overcomes this by reducing the evaporation operation, and hence the air speed at pre-determined
stages in the cycle to ensure that this does not happen. This is a discreet function and happens automatically without any
intervention from the operator. To enable the surface protection; and determine at what stage it would be activated values
are set in the service operating parameters.

Longer Term Storage – ‘Hold’ Mode (Conservation)
Upon the completion of the blast chilling cycle the controller will automatically enter the ‘Hold’ mode. This will either be
because the selection set time has elapsed or the product core temperature has been achieved. When the hold period
commences an alarm will sound for a period denoted in the service operating parameters.

1

The controller will determine the temperature to be maintained during the hold phase based on the chilling cycle that has
been completed. If a soft or hard chill has taken place the controller will maintain an air temperature of 2°c.
The hold mode is principally intended as a temporary storage facility offering the operator flexibility until the product can
be unloaded into a longer term storage units at the correct storage temperature. On occasion this hold period may
become extended to operate overnight or to provide emergency refrigeration backup. In such instances defrosting would
automatically occur as necessary.

Model Details.

The RBC 20-60 is capable of blast chilling 60kg of product from +70°c to +3°c in 90 minutes with entry temperature up to
90°c
The cabinet is compatible with the Rational 20 rack GN 1/1 201 trolley.
Refrigerant used is R404A.
The RBC20-60 has two separate refrigeration systems co mprising, two condensing units, a twin circuit condenser and a
twin circuit evaporator. (See pages 20 and 21 for assembly details and page 22 for schematic dual circuit re frigeration
layout).
The RBC20-60R has the same refrigeration systems but the con densing units are remotely sited.
Refrigerant control is by expansion valve to control the correct amount of refrigerant required to meet the demand of the
evaporator. (See page 21 for assembly detail).
The parameter ‘Capacity Enable’ is set to ‘ON’ to allow for both condensing units to be running during the chill cycle
therefore maximising the heat extraction from the product. During the ‘HOLD’ mode with the ‘Capacity Enable’ set to ‘ON’
one compressor will control the temperature throughout unless the temperature exceeds the capacity control limit.
A 1½” BSP drain outlet is fitted in to the base of the cabinet for connection to external drain.
The cabinet is delivered with the legs secured to the base of the cabinet.

Controller Technical Detail

The FCC controller is a three-piece unit made up of the Front Display and Dial Shaft Encoder, Mother Board plus
Evaporator, Food and Air temperature probes. The front display PCB and the CPU/ Switching PCB unit are
interconnected by a ribbon cable. The membrane attached to the front provides an IP rating of IP54 providing a scratch
free wipe clean finish.
The control dial is the method by which the controller is accessed for all requirements. It has three planes of movement,
clockwise, anticlockwise and inwards.
The control dial allows the operator/ engineer to move forward and backwards through various menu selections shown on
the display, and enter a desired programme. The control system will then respond appropriately either commencing the
operating cycle or allowing further configuration.

Part numbers

Item Description Part Number

Controller Mother Board 00-555395
Controller Shaft Encoder 00-555396
Controller LCD Display 00-555394
Air Probe P1 NTC type. 2.5m 00-555397
Evaporator Probe P2 NTC type. 2.5m 00-555397
Food Probe 5M Length 00-555663
Compressor x 2 TAJ4519ZH T 400/50 00-555885
Condenser Coil BC6013/122 01-257300-01
Condenser Fan Assembly S4E300-BP26-30 00-555886
Sight Glass 3/8" 15483015
Drier 00-555388
Solenoid Valve EVR6 32F5219+0 15451215
Liquid Receiver 00-555579
LP Switch 2.5 Bar 0.5 Bar Diff 00-555387
HP Switch 28 Bar – 3 Bar Diff 00-555386
High Pressure Thermostat KP5 Auto Re-set (set at 18 BAR with a 3 BAR diff.) 15452109
Evaporator Coil BC6013/121 01-256400-01
Expansion Valve Valve Body TES2-NL68Z34300/68 15450386
Orifice NO 02 68-2092/68-2072 15451104
Expansion Valve Solder Adaptor 68-2 15450910
Evaporator Fan Motor W4E420-CP02-66788-4-7320 00-555375
hinge Edgemount 00-555880
Door Gasket 1406x546MM 01-256387-01
Door Switch Circular (Reed Type) 00-555829
Door Switch Magnet Circular 00-555828
Door Handle Edgemount Latch Kit 00-555881

2

Standard Operation

When mains electrical power is first applied to the controller it will carry out a self-test function,
for approximately 3 seconds. During this period the display will show.

On completion of the self test, the controller will revert to the last chill program that was run
(Pre-chill, Soft Chill, Hard Chill, Hard Chill Max, Shock Freeze, Professional 1, Professional 2,
or Professional 3). The availability of these is dependent on how the controller has been
configured.
The example shows the controller in Hard Chill mode with the previous and next programs
indicated at the top of the display. To change the program rotate the dial, either clockwise or
anticlockwise to select the type of program you require.(for guidelines refer to page 7)

Blast Chill & Shock Freeze Operating Instructions.

To initiate the program just press and release the dial for the program to start.

The program starts with the screen on the left being displayed for 2 minutes. After which the
intelligent probe determines if the cycle is controlled by time, displayed by the screen in the
middle, or by temperature as displayed by the screen on the right.

On completion of the program the controller will cause the blast chiller to enter the Hold Mode,
as displayed on the left. An alarm will sound, press and release the dial to cancel the alarm, if
the alarm is not cancelled the blast chiller will still enter the Hold Mode with the periodical
sounding of the alarm. To cancel press and release the dial.

To stop the blast chiller during operation, press and hold the dial for 2 seconds, the display returns to the program
selection screen.

At any time when the blast chiller is operational the dial can be rotated to give information on
the status of the particular mode of operation.
The display will remain for 10 seconds and then revert to the normal operating screen
automatically.

3

Pre Chill

This program is used to Pre Chill the cabinet prior to the first cycle.
Blast Chiller empty and is a short time based program of about 20 minutes.
It is generally recognised as the correct method of preparing for a blast chill cycle.
The program is selected by rotating the dial until the display shows, press and release the dial
to start the program.

Defrost.
Defrosting is not normally required but if there is an ice build up on the coil inside the cabinet a manual defrost can be
selected. Rotate the dial until the Defrost screen, below left, is displayed.
Press and release the dial to start the defrost.
During defrost the screens will alternate between the middle and ri ght hand screens.
Defrost will last 20 minutes and when completed the alarm will sound. Press the dial to acknowledged or if not wait until it
comes to the end of the alarm period, the alarm will stop and the display will revert to the previous screen.

Further Operational Features.
Chill time adjustment. (All programs excluding Professional 1, 2 or 3)

Whilst in the pre-programmed selection screen press and hold the dial for 2 seconds, the information screen will be
displayed, below left. Press and release the dial to move to the time set, see below right. Rotate the dial clockwise to
increase the time, anticlockwise to decrease. Once the time has been selected, press and release the dial and ‘CHILL
TEMP’ will be highlighted.
On completion press and hold the dial for 2 seconds to return to the program selection screen, to continue press and
release the dial for the program to start.
On completion of the program the time changes will revert to the default settings.

Chill / Hold temperature adjustments. (Professional 1, 2 or 3 only)

Professional 1, 2 and 3, if configured, are programs that can be used to tailor the chill time and temperature to suit
specific product requirements.
Adjust the ‘CHILL TIME’ as above. With the ‘CHILL TEMP’ highlighted, below second from the left, press and release the
dial to move to the temp set, below second from the right. Rotate the dial clockwise to increase the time, anticlockwise to
decrease. Once the time has been selected, press and release the dial and ‘HOLD TEMP’ will be highlighted. Follow the
procedure for changing chill temp to change the hold temp.

On completion press and hold the dial for 2 seconds to return to the program selection screen, to continue press and
release the dial for the program to start.
The chill time and chill / hold temperature adjusted settings are retained for professional 1, 2 and 3 programs and will not
revert to the default.

This is done with the

4

Information

Whilst in the program selection screen press and hold the dial for 2 seconds, the information
screen will be displayed. Rotate the dial until ‘INFORMATION’ is highlighted. Press and
release the dial to display the screen showing the last run cycle. The information relates to
date, program run, start time, start temperature and end temperature.

HACCP settings.

Whilst in the program selection screen press and hold the dial for 2 seconds, the information screen will be displayed.
Rotate the dial until ‘HACCP SETTINGS’ is highlighted. Press and release the dial to access the HACCP option screen.
Press and release the dial to move to the selection screen for long or short reports, rotate the dial to select which option,
once selected press and release the dial to confirm.
Press and release the dial to move to the selection screen for the print sample, select 3 or 5 minute selection rate.
On completion press and hold the dial for 2 seconds to return to the program selection screen.

Print Data.

Whilst in the program selection screen press and hold the dial for 2 seconds, the information screen will be displayed.
Rotate the dial until ‘PRINT DATA’ is highlighted. If using a hand held printer switch the printer on now. Point the printer at
the infra red download sensor (optional), located in display area, press and release the dial to download the print data.
On completion press and hold the dial for 2 seconds to return to the program selection screen.

Set time and date.

Whilst in the program selection screen press and hold the dial for 2 seconds, the information screen will be displayed,
below left. Rotate the dial until ‘SET TIME/DATE’ is highlighted. Press and release the dial to access the service screen,
below right. Press and release the dial to move to the displayed time in hours and minutes, rotate the dial to alter the time,
once the correct time has been achieved press and release the dial to move to ‘DAY’. If it is necessary to change the day,
month and year change the settings using the same procedure for setting the time.
On completion press and hold the dial for 2 seconds to return to the program selection screen.

Changing Text Language.

Whilst in the program selection screen press and hold the dial for 2 seconds, the
information screen will be displayed continue pressing the dial for a further 2 seconds to
display the ‘SERVICE MENU’. LANGUAGE will be highlighted, press and release the dial,
‘ENG’ (English) will be highlighted. Rotate the dial to change the language. Select the
preferred language, press and release the dial to confirm.

Screen Saver

The screen saver screen is displayed if the machine is not used for 20 minutes, providing power is connected to it. It
shows a series of ‘Z’ indicating sleep mode. Pressing and releasing the dial or opening the door will awaken the unit, the
program selection screen will be displayed.

Alarms and Warnings
Air Probe: If this alarm occurs it will remain in the program selected until it is completed, however no further

operation will be possible. Call your Foster Authorised Service Company.

Evap Probe: If this alarm occurs it will remain in the program selected until it is completed, however no further

operation will be possible. Call your Foster Authorised Service Company.

Food Probe: If this alarm occurs it will automatically change to a timed program until it is completed, however no

further operation will be possible. Call your Foster Authorised Service Company.

Door Open: The display will continue to show the alarm message until the door is closed. If this does not cancel the

alarm call your Foster Authorised Service Company.

5

High Temperature: This alarm will only occur in the hold mode only. Probe the product to determine it is at the correct

HP Switch: Causes for this alarm could be:

Power Fail: If the power fails for up to five minutes the unit will re-start on the resumption of the power supply without

There are Three main programmes RBC 20-60 Blast Chiller.

Soft Chill- for the safe chilling of delicate products such as gateaux and patisserie items, and high water content items
such as vegetables, rice and pasta.

Hard Chill- For general purpose chilling. The Hard Chill cycle is ideal for chilling ‘standard products’ such as meat pies,
lasagne, individually portioned meals etc. Providing surface protection for the later part of the program.

Hard Chill Max- For high density and high fat content products such as meat joints, stews and sous vide.

Guide for Blast Chilling.

Food Type Includes

temperature. If it is at the correct temperature place in a storage refrigerator or freezer and call your
Foster Authorised Service Company. If the product temperature is above the guidelines check the chill
time selected or the weight of product being chilled does not exceed the specification for the Cabinet.

Does the product temperature exceed 90°c. Has too much product been placed in the cabinet. Is the
airflow restricted. Does the condenser filter require cleaning. If the problem persists call your Foster
Authorised Service Company.

affecting the selected cycle. Longer than five minutes and the controller will enter the hold mode. To
check the cycle operation look in the information screen to check the cycle time.

To re-start press and release the dial, the screen will return to the hold screen. Press and hold the

dial for two seconds the display returns to the program selection.

Blast Chill

Programme

required

Time required

to Blast Chill

(Minutes)

Meat Beef, pork, lamb, poultry & mince Hard 40 - 90

Fish
Prepared

dishes
Vegetables &

Pulses
Fruit Stewed and cooked fruits. Soft 60 – 90

Bakery Cakes Hard 30 – 90
Bakery Pastries Hard 60 – 90
Desserts Fruit Based desserts & egg based flans. Soft 30 – 90

Desserts Sponge puddings and dense desserts such as cheesecake. Hard 30 – 90

Fried, poached or baked – haddock, plaice, salmon, cod
fillets etc

Stews & casseroles, lasagne, risotto, shepherds pie Hard 50 - 90

Steamed or roasted veg, rice and potatoes etc. Soft 30 - 90

Soft 30 - 90

NOTE: All times listed should be used as a guide only, and will depend on type, size and quantity.

6

Electrical Connections.
Inputs.

L - Mains ‘Live’ supply (115V 230V, 50Hz / 60Hz). 4 terminals.
N - Mains ‘ Neutral’ supply – 16 terminals.
E - Protective Earth – 16 terminals.

DOOR - Door Switching connection (not voltage carrying).
DOOR2 - Safety door switch connection (not voltage carrying).
HP - High Pressure switch connection (not voltage carrying).

TA - Air probe connection.
TE - Evaporator probe connection.
FP1 - Food/ product temperature connection.
FP2 - Additional second food / product temperature probe connection.
FP3 - Additional third food / product temperature probe connection.

Outputs.
C1 - Condensing system switched relay (30A/ 8A) – normally open (NO) output – 3 terminals.
F1 - Evaporator fan 1 switch relay (8A/ 4A) – normally open (NO) output – 3 terminals.
F2 - Evaporator fan 2 switch relay (8A/ 4A) – normally open (NO) output – 3 terminals.
D1 - Defrost system switched relay (8A/ 4A) – normally open (NO) output – 3 terminals.
S1 - UV light system switched relay (8A/ 4A) – normally open (NO) output 2 terminals.
A1 - Alarm relay (8A/ 4A) normally closed (NC) – 1 terminal, normally open (NO) 2 terminals.
P1 - Capacity relay (8A/ 4A) normally closed (NC) – 1 terminal, normally open (NO) 2 terminals.

Display Power - Man Machine socket 2 – way connection.
Display Data - Man Machine RJ54 Type 4 – way connection.
Logger - 4 – way RS 485 connections.

Service Information

Refer to the operating instructions on page 4 for operating instructions.
When mains electrical power is first applied to the controller it will carry out a self test function, for approximately 3
seconds, to ensure that there are good connections between the component parts. During this period the display will
show.

The information displayed in the centre of the screen refers to which of the profiles the controller is set for.
The software version relates to the software release. The number relates to the major operating changes or model
variants. The letter relates to the minor operating changes that may have been made from the original, such as parameter
settings.

On completion of the self test the controller will revert to the last chill program that was run (Pre-chill, Soft Chill, Hard Chill,
Hard Chill Max, Shock Freeze, Professional 1, Professional 2, or Professional 3). The availability of these is dependent on
how the controller has been configured. The example below shows the controller in Hard Chill.

Press and hold the dial for 5 seconds.
Firstly the display will display the information page, below left, continue pressing until the ‘SERVICE’ screen is displayed,
below right. For changes to language see page 5.

7

Diagnostics

Rotate the dial until you reach ‘Diagnostics’, below left, press and release the dial to highlight the component. In this
program you can test each of the major components on the machine in sequence, 1- COMPRESSOR, 2-FAN1, 3-FAN2,
4- DEFROST, 5- ALARM, 6- CCAP (Capacity Control), 7- UV-L (UV light if fitted), ESC (escape). Rotate the dial until the
relay output is highlighted, once selected press and the dial to test the relay, the relay will remain energised for as long as
it is pressed. On completion of the test you must rotate the dial until you highlight ‘ESC’ press and release the dial to
move to the next program.

Function Test

Rotate the dial until you reach ‘FOOTPRINT’, see below, press and release the dial to initiate the controller function self
test.

This allows for the engineer to test the operation of the machine without having to wait for a full program to run. The test
lasts for ten minutes and should be carried out with the cabinet / room empty. Each of the relays will be energised to
simulate the chill process. Relay 1-COMPRESSOR, Relay 2-FAN1, Relay 3-FAN2, Relay 4-DEFROST, Relay 5-ALARM,
Relay 6-CCAP (Capacity Control), and Relay 7- UV-L will all be switched on and of automatically in a pre determined
manner to simulate program operation (whether they are connected or not).
The test is based around an algorithm built into the software. Prior to starting the program it is advisable to place a probe,
in the centre of the cabinet/room, attached to an independent measuring device to check the air temperature as the air,
coil and food probes are not active during this program. The temperature achieved will depend on the model. The air
temperature should be checked 5 to 6 minutes into the program. The temperature achieved should be the minimum
temperature and can be checked against the model type found in the parameter table on page 9. (For further information
go to page 19).
Once the test is completed the display reverts to the last chill program and not to the service parameters.

Passcode.

Rotate the dial until you reach ‘PASSCODE’, below left, press and release the dial to highlight the code, below right.
Rotate the dial until you reach the code ‘131’. Once achieved press and release the dial to acknowledge.

8

Profiles.
You are now in the program profiles. The controller has 9 operating programs – Pre Chill, Soft Chill, Hard Chill, Hard Chill
Max, Shock Freeze, Professional 1, Professional 2, Professional 3, Defrost and 2 optional programs – UV Sanitisation
and Information. These programs are all available depending upon which of the profiles are selected, see below.

To change the profile rotate the dial to select program, press and release the dial to accept the change. The 3 chevrons in
the box opposite the selected program confirm the change.
The default operating profile for the RBC20-60 and RBC20-60R is ‘LE CHEF’.
The table identifies which programs are available from the profile with ‘LE CHEF’ highlighted.

PROGRAMS

PRE CHILL
SOFT CHILL
HARD CHILL
HARD CHILL MAX
SHOCK FREEZE
PROFESSIONAL 1
PROFESSIONAL 2
PROFESSIONAL 3
DEFROST

UV SANITISATION OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL
INFORMATION OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL

SIMPLE SIMPLE + CHEF CHEF+ LE CHEF EXPERT EXPERT+

U U U U
U U

9 9 9 9 9

9 9 9 9 9 9 9

U U
U

9

U U U U U
U U U U U
U U U U U

9 9 9 9 9

U

9 9 9 9 9 9 9

PROFILES

9

9 9 9

U U

9
9 9
9 9
9 9

Parameter Access.
From the profile screen once the selection has been made press and release the dial to access the parameter list. The
screen will display the parameters as shown in the screen below left. To access the system parameters rotate the dial
anticlockwise see below right.

Selection is made by pressing and releasing the dial.
The table below contains the complete parameter list and includes the selectable range and default values.

Parameters

PARAMETER

PO1 AIR TEMP °C -15 15 -10
PO2 CHILL TIME MINUTES 5 60 15
PO3 HOLD TEMP °C -10 15 3

PO4 AIR TEMP °C -10 15 1
PO5 CHILL TIME MINUTES 5 480 90
PO6 CHILL TEMP °C -5 15 3
PO7 HOLD TEMP °C -5 15 3

PO8 AIR TEMP °C -20 15 -15
PO9 CHILL TIME MINUTES 5 480 90
P10 CHILL TEMP °C -15 15 3
P11 HOLD TEMP °C -15 15 3
P12 CHANGE TIME % 5 95 80
P13 CHANGE TEMP % 5 95 80

DESCRIPTION VALUE MINIMUM MAXIMUM DEFAULT

PRE-CHILL

SOFT-CHILL

HARD CHILL

9