LBC Bakery Equipment LRP-1 Installation Manual

THE INFORMATION IN THIS MANUAL IS CRUCIAL AND MUST BE RETAINED FOR FUTURE REFERENCE. READ, UNDERSTAND, AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MANUAL.

DANGER

WARNING

CAUTION

NOTICE

POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH.

POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY.

Helpful operation and installation instructions and tips are present.

FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.

Model #: Purchased From:

Serial #:

Location:

Date Purchased:

Purchase Order #:

Date Installed:

For Service, Call:

TABLE OF CONTENTS

CHAPTER PAGE

TABLE OF CONTENTS ...................................................................................... 3

READ FIRST ........................................................................................................ 4

SAFETY PROCEDURES ..................................................................................... 6

EQUIPMENT DESCRIPTION ............................................................................. 7

GENERAL DESCRIPTION.................................................................................. 8

GENERAL OPERATION..................................................................................... 9

GENERAL MAINTENANCE .............................................................................. 10

ASSEMBLY.......................................................................................................... 11

WIRING DIAGRAMS.......................................................................................... 33

PARTS LIST ......................................................................................................... 35

LRPR RETARDER MANUAL............................................................................. 40

LRPR RETARDER MANUAL TABLE OF CONTENTS................................... 42

LRPR RETARDER INSTALLATION ................................................................. 50

LRPR RETARDER PARTS LIST ........................................................................ 62

LRPR RETARDER WIRING DIAGRAM ........................................................... 64

WARRANTY........................................................................................................ 65

IMPORTANT READ FIRST IMPORTANT

WARNING

MOVING PARTS HAZARD. FOLLOW LOCKOUT PROCEDURES BEFORE REMOVING AIR DUCT OR EVAPORATOR FAN GUARDS

ELECTRICAL HAZARD BEHIND UPPER FRONT TRIM. FOLLOW LOCKOUT PROCEDURES BEFORE SERVICING.

THE LBC BAKERY LRP SERIES PROOFER PRODUCES HUMIDITY WHICH WILL NATURALLY CONDENSE AND ACCUMULATE WATER ON THE INTERIOR FLOOR CAUSING IT TO BECOME SLIPPERY. ADJACENT EXTERIOR FLOOR MAY ALSO BECOME SLIPPERY. USE EXTREME CAUTION WHEN WALKING IN OR AROUND THIS APPLIANCE.

NOTICE

DANGER

NOTICE

CAUTION

This picture shows an LRP1, LRP2, and LRP3. The LRP1 and some LRP2 models have only one climitizer. Larger models have two climitizers.

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

For best results, always allow your proofer to reach set temperature and humidity before putting product in.

For best results, proof at lower temperatures rather than higher.

To dry proof: Set humidity to the lowest setting (either 45% or less). At this setting the humidity generator is turned off and will not produce humidity.

When the actual humidity is less than 46% display will show 45. When the actual humidity is higher than 45%, display will show the actual humidity.

Service on this or any other LBC BAKERY equipment must be performed by qualified personnel only. Consult your authorized service agency directory or call the factory at 1-888-722-5686 or go to

WWW.LBCBAKERY.COM for the service agent nearest you.

The LRP1 has hinges mounted on the right jamb only.

THIS APPLIANCE, WHEN INSTALLED, MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES, OR IN THE ABSENCE OF LOCAL CODES, WITH THE NATIONAL ELECTRICAL CODE, ANSI/NFPA 70-1996.

ETL File E8138 Rev. B2006

IMPORTANT READ FIRST IMPORTANT

CAUTION

WARNING

FOR INSTALLATION IN CANADA THE INSTALLATION MUST BE IN ACCORDANCE WITH CAN/CGA-B149.1&2 OF THE INSTALLATION CODE, AND LOCAL CODES WHERE APPLICABLE. ALL ELECTRIC WIRING MUST BE IN ACCORDANCE WITH THE CURRENT CANADIAN ELECTRICAL CODE, C22.1 PART 1. GROUNDING THIS APPLIANCE MUST CONFORM TO CANADIAN ELECTRICAL CODE, CSA C22.2.

INSTALLATION OF THE UNIT MUST BE DONE BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY AND PLUMBING. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND /OR DAMAGE TO EQUIMENT. UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICAL CODES

ETL File E8138 Rev. B2006

SAFETY PROCEDURES

WARNING

MOVING PARTS HAZARD. FOLLOW LOCKOUT PROCEDURES BEFORE REMOVING AIR DUCT OR EVAPORATOR FAN GUARDS

ELECTRICAL HAZARD BEHIND UPPER FRONT TRIM. FOLLOW LOCKOUT PROCEDURES BEFORE SERVICING.

Lockout Procedure

1. Announce lockout to other personnel.

2. Turn both heat and control power off at main panel.

3. Clear unit of all personnel.

4. Test lockout by turning power switch on and observing if control panel displays or fan(s) come on.

Check heater circuit with voltmeter.

5. Perform necessary repairs or tests.

6. Clear unit of personnel before restarting.

7. Turn power on at main panel.

8. Announce unit is “on” to other personnel.

Safety Precautions

LBC Bakery Equipment hereby disclaims any and all responsibility for injury, damage, loss or other claim that may occur to person or property from improper alteration, modification, addition, operation, maintenance or service, whether it be mechanical, electrical, fuel, operator, motor or otherwise, which may occur from such improper alteration, modification, addition, operation, maintenance or service to this piece of equipment.

Safety Considerations

Your LBC Bakery LRP Proofer is manufactured to rigid standards. This equipment is E.T.L. listed and meets safety and sanitation standards.

The presence of safety equipment control and interlocks on an appliance and attendant components of installation cannot, in and of themselves, assure absolute safety of operation. Diligent, capable, well trained operators and maintenance personnel, as well as proper programs of operation and maintenance, are essential to the safe and reliable operation of this appliance.

A. The responsibility of the manufacturer

recommendations for the operation and maintenance of the appliance.

B. Trained, qualified and factory-authorized personnel must perform all operation, maintenance and

repair of these appliances. It is the responsibility of the owner / operator happens.

C. A regular periodic program of cleaning, inspection and maintenance must be established and

comprehensive maintenance records maintained. It is the sole responsibility of the user schedule and enforce the frequency and scope of these programs in keeping with recommended practice and with due consideration given to actual operating conditions.

D. The appliance must be operated within limits which will not exceed the working limits of any

component within the appliance as a whole.

is to supply suitable, comprehensive instructions and

to ensure that this

to establish,

ETL File E8138 Rev. B2006

EQUIPMENT DESCRIPTION

Exterior

LRP1

• The Proofer exterior dimensions are 38.4” (97.5 cm) wide x 91.5” (232.5 cm) high x a depth dependent

upon model number [39.3”(100 cm) to 129.3” (328.5cm)]. The Top, Front, Back, and Sides are constructed of stainless steel.

LRP2

• The Proofer exterior dimensions are 78.8” (200 cm) wide x 91.5” (232.5 cm) high x a depth dependent

upon model number [39.3”(100 cm) to 129.3” (328.5cm)]. The Top, Front, Back, and Sides are constructed of stainless steel.

LRP3

• The Proofer exterior dimensions are 102.5” (260 cm) wide x 91.5” (232.5 cm) high x a depth dependent

upon model number [39.3”(100 cm) to 129.3” (328.5cm)]. The Top, Front, Back, and Sides are constructed of stainless steel.

All Units

• Modular design allows for a wide variety of sizes.

• The proofer door is constructed of stainless steel and comes with both single and double doors.

Interior

LRP1

• The Proofer interior dimensions are 33.1” (84 cm) wide x 74.1” (188.1 cm) high x a depth dependent upon

model number [22.1”(56 cm) to 112.1” (284.7 cm)]. The Top, Front, Back, and Sides are constructed of stainless steel.

LRP2

• The Proofer interior dimensions are 68.1” (173 cm) wide x 74.1” (188.25 cm) high x a depth dependent

upon model number [27.1”(68.8 cm) to 117.1” (297.4 cm)]. The Top, Front, Back, and Sides are constructed of stainless steel.

LRP3

• The Proofer interior dimensions are 91.8” (233cm) wide x 74.1” (188.25 cm) high x a depth dependent

upon model number [27.1”(68.8 cm) to 117.1” (297.4 cm)]. The Top, Front, Back, and Sides are constructed of stainless steel.

All Units

• Floor level loading.

Cabinet

Rigid, formed stainless steel panels filled with polyurethane foam insulation re-joined with cam-locks and sealed with gaskets to form a strong, energy-efficient, tight and sanitary enclosure.

Doors

The welded stainless steel door is polyurethane foam-filled. Door bumpers on the inside protect the finish.

Controls

• The microprocessor-based digital controls are mounted for ease in the door. In some models power and

light switches are located above the door.

• Digital read-out with solid-state temperature sensing and controls.

Air-Duct(s)

Each proofer comes with one or two air ducts. These air ducts perform the tasks of heating, humidifying, and circulating the air within the unit. Each duct contains a heater plate, spray nozzle, drain pan, and fan.

ETL File E8138 Rev. B2006

GENERAL DESCRIPTION

Theory of Operation

The LBC Bakery Proofer is a controlled atmosphere chamber. Temperature and humidity can be set independently to meet your particular proofing needs. In Proof mode air temperature is increased as the air duct heater is energized. Humidity is increased as water is sprayed in the air duct. Air is circulated continuously to provide positive movement from bottom to top, creating a uniform distribution of warm, humid air.

Proofer Theory

NOTICE

ETL File E8138 Rev. B2006

This picture shows an LRP2. The LRP1 has only one door and the air duct heater is mounted on the back wall.

GENERAL OPERATION

DANGER

NOTICE

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

For best results, always allow your proofer to reach set temperature and humidity before putting product in.

For best results, proof at lower temperatures rather than higher.

To dry proof: Set humidity to the lowest setting (either 45% or less). At this setting the humidity generator is turned off and will not produce humidity.

When the actual humidity is less than 46% display will show 45. When the actual humidity is higher than 45%, display will show the actual humidity.

See Programming Manual for Operation Instructions!

ETL File E8138 Rev. B2006

WARNING

GENERAL MAINTENANCE

NOTICE

Service on this or any other LBC BAKERY equipment must be performed by qualified personnel only. Consult your authorized service agency directory or call the factory at 1-888-722-5686 or go to WWW.LBCBAKERY.COM for the service agency nearest you.

Every Day

Clean interior and exterior of proofer. See Equipment Cleaning instructions @ WWW.LBCBAKERY.COM under

manuals tab.

Every Six Months

Have factory authorized service personnel check proofer for proper temperature readings. Also inspect air duct drain, heater plate, spray nozzle for proper operation and mineral deposits; de-scale as needed.

As Needed

Clean interior and exterior walls and replace light bulb or any other components as needed.

Specifications

Temperature, humidity, and timer setting ranges:

Thaw:

70-120°F (18-66°C)

50-95% Relative Humidity

Proof:

Timers:

Power:

Water Consumption:

70-120°F (18-46°C)

50-95% Relative Humidity

0-99 Hours and 0-99 Minutes

Varies depending on model and size (See data plate located on the underside of the valence for the specific ratings or contact the factory for the information needed if the data plate is not legible).

.73 gallons per hour average per air duct (2 ducts maximum) @ 30 PSI.

1.70 gallons per hour average per air duct (2 ducts maximum) @ 80 PSI.

Unit will use about 4 gallons per hour when powered on until humidity levels reach set point.

Technical Data Part # Ohms

Elements 11162-09 26Ω Solenoid Valve 70403-01 8 Ω Contactor 30700-06 6 Ω Relay 30701-05 35 Ω Transformer 31400-26 240V primary 75 Ω, 208V primary 64 Ω, 24V secondary 1 Ω Blue to Black Red to Black Yellow to Yellow (no red stripe)

ETL File E8138 Rev. B2006

NOTE: ON UNITS WITH FLOOR ONLY!

Countersunk sides of holes go up.

ASSEMBLY

Place floor onto prepared surface and mark position. Take into consideration drain location.

Note: Tile that may come loose over time should be removed.

Place floor adhesive onto floor and spread with provided trowel. Seal bottom with a good continuous bead along edge before setting into final resting position. Apply weight to floor while adhesive sets.

Note: Row of 3/8” holes is front of floor. Countersunk sides of holes go up.

Drill holes with rotary drill and install anchors in front row (and middle row if applicable). Drill 10MM diameter hole 1 ½” deep and remove all dust from hole. Do not drill too deep. Install anchor with provided insert tool.

Note: If concrete subfloor has additional layer of softer leveling slag and anchors do not hold, a longer anchor bolt may be necessary.

Do not install anchors at edges or corners at this time.

One good blow is better then many small taps when installing anchors.

ETL File E8138 Rev. B2006

Note: Units without Stainless Floor start here

Side Chanel

Rear Base Channel

Place wall base channels as pictured. Outside dimensions should match Specification Sheet. Mark outside edge with non permanent marker.

ASSEMBLY CONT’D

Each proofer is supplied with enough track to install a 120” deep proofer.

Holes in side channel indicate cutting points for base channels. Cut side channels short enough to leave front corners exposed.

You may need both channel pieces depending on the size of the proofer.

Side Chanel

No base channel on door side of proofer.

Optional: Seal base channels with small amount of silicone to stop leaks from developing at bottom of unit.

Press base channel to floor.

Note: Recheck dimensions to insure wall panels fit into track. Once silicone dries, base channels are hard to move. See Spec. Sheet.

See wall panel location Chart 1 for panel placement.

ETL File E8138 Rev. B2006

ASSEMBLY CONT’D

Chart 1, Panel locations

155-707 155-709 155-706 155-707

155-706-4 155-710

155-709155-705-10 155-710 155-705

Ceiling Panels should match side wall panels. Example: On a LRP2-30 you should have 1 20” ceiling and 2 20” wall panels.

71100-12 15.25” Bumper for Climitizer and 20” Panels 71100-13 23.5” Bumper for 30” Panels 71100-14 31.5” Bumper for 3 hole doors 71100-15 40” Bumper for 4 hole doors

ETL File E8138 Rev. B2006

ASSEMBLY CONT’D

Place header assembly on floor upside down.

Note: When installing Panel Assemblies inspect to insure gasket material is installed along all edges.

Gasket on all three sides

Header panel requires gasket material as shown. If gasket is missing moisture will migrate into panel sections.

All three sides pictured have grey gasket material installed.

Note: When locking a cam it may be necessary to first rotate cam all the way back until a positive click is heard. This will ready the cam for locking. DO NOT OVER TIGHTEN! Over tightening will damage the cam.

Once the cam is reset it will not click again until you attempt to lock the cam into its receiver, or onto a screwdriver shaft.

If cam will not reset or lock, lubricate cam with WD-40® or equivalent and work cam open and closed until it resets and locks.

If front corners have two screws installed, remove two screws from each front corner panel top. These screws will later be reused to secure the valance.

Screw

in top of

front

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ASSEMBLY CONT’D

Install Front Corner panel and tighten cams.

Note: Do not over tighten.

A positive click should be felt when cam is locked. If cam will not click into locked position do not over tighten. Lube cam and work until cam locks. See note on previous page.

Flip front assembly over.

Reinstall screw in top of each front corner panel securing valance.

Note: Check sides for gasket material on all sides!

Install one left and one right side to front. Place front with side panels into base track, then plumb front corners. To plumb place level on front as pictured in center photo. Cams may need to be repositioned to achieve plumb. Shim (Part #155-249) front to achieve level, left to right only. Shims, pictured below level, are provided with unit.

See Chart 1 on page 13 for correct panel placements. Continue to add side panels 90º in relation to ground. Keep the front plumb and level. Shim sides as needed. Allow top of panels to be uneven if necessary to maintain to maintain 90 º angles from ground. Drain holes on back corners go to bottom back of unit.

ETL File E8138 Rev. B2006

Shim Part # 155-249

ASSEMBLY CONT’D

Drain hole always goes to

ottom, back

Align front as necessary, then mark rear base channel position.

Remove rear corners.

Note: Drain holes on back corners go to bottom back as pictured.

Drill holes with rotary drill and install anchors in rear base channel. Drill 10MM diameter hole 1 ½” deep and remove all dust from hole. Do not drill too deep. Install anchor with provided insert tool.

Note: If concrete subfloor has additional layer of softer leveling slag and anchors do not hold, a longer anchor bolts may be necessary.

Install remaining panel assemblies maintaining 90º angles.

ETL File E8138 Rev. B2006

ASSEMBLY CONT’D

Note: Make sure all hinge mounting screws are tight.

Hang door(s). Use a 30”x 1”x 4” board (as shown) or a

Hinge Washe

dolly to lift door and move into position.

Make sure both hinges seat and hinge washers are present.

On model # LRP-2 sensor will come preinstalled inside header.

On all models push connector end through hole in door and connect to control as pictured.

Plug temperature / humidity sensor into board with flat side of connector up as pictured.

Plug connectors from control panel into connectors from

Temp/Humidity Sensor flat side up

door. Verify wire #’s on both sides of connector correspond.

Check to assure all wires in connecter seat tightly to

ether.

Screw control panel into door using supplied screws. Bend tabs as necessary to align with center set of holes.

Bezel may need to be bent slightly to create tight fit to panel.

Install bezel as shown using supplied screws. Optional: A small bead of silicone around bezel will seal bezel.

ETL File E8138 Rev. B2006

ASSEMBLY CONT’D

Install door, handles and bumpers onto door(s).

Install conduit mounting brackets and gaskets onto valance and door.

To maximize airflow over sensor install sensor 2-3 inches in front of climatizer fan. If more than one climatizer is utilized install sensor in front of climatizer closest to controller.

Leave a small amount of slack in cable at sensor end.

Route cable towards hinge side of door and install supplied cable retention clips keeping slack out of cable.

Silicone opening after sensor is installed

Install supplied cable retention clips to door and inside corner of proofer with door open all the way and no slack in cable.

Push remaining cable into door

Seal opening in the door with silicone.

ETL File E8138 Rev. B2006

ASSEMBLY CONT’D

Note: Inspect ceiling panels for gasket material on bottom.

Install ceiling panels flush with sides.

Align back corners and install one screw. Recheck door alignment and plumb of front. Shim front with part # 155-249 as needed to obtain plumb.

Align ceiling panels flush with side and install remaining 3” hex head ceiling screws.

Peel all vinyl from inside unit.

Fill cam holes with caulk and install plugs.

Check for gaps and caulk header to top seam openings.

and all other

Note: If unit is a pass through leave out 2 upper corner plugs in corner without climitizer; instead, install stiffener plate Part #155-323 in corners without climatizer installed. Stiffener plate should join corner and header and be secured with supplied stainless steel hardware.

ETL File E8138 Rev. B2006

Install left and right jam trim, and anchor bracket

Jam Tri

155-377 anchor bracke

to unit. Drill and tap bracket mounting holes. Shim if needed with 155-377-1.

Secure only with Stainless Steel screws provided.

Anchor brackets to floor; see page 16 for anchor instructions.

Caulk base channels to floor inside and out.

Install rear corners behind base molding.

Cut to fit and install base trim over corners.

Drill trim mounting holes with provided drill bit. Lube holes and tap with provided tap. Secure with provided

Stainless Steel

ASSEMBLY CONT’D

machine screws.

Install top trim part #155-745 using provided screws.

Do not over tighten.

ETL File E8138 Rev. B2006

ASSEMBLY CONT’D

Apply caulk to backside of high limit mounting bracket and install high limit and bracket.

Gasket

must be

installed

On LRP1 and LRP2 models Install 250V light bulb, gasket, and globe.

New LRP3 models will have Florescent Lamps pre-installed.

Note: If 120V bulbs are installed fuses will blow.

Remove fan guard, cover, and water line from air duct assembly.

Determine duct location.

Single Door Proofers - Back wall tight to left side. Double Door Proofers - Left side wall tight to front. Double Duct Proofers - Mount first duct on left side wall tight

to front. Mount second duct on same side tight to back. LRP3 Models – Ducts can be mounted on left or right side determine by drain location.

Remove climatizer mounting screws from applicable corner.

ETL File E8138 Rev. B2006

+ 47 hidden pages

LBC Bakery Equipment LRP-1 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual