Norlake BCF44244, BCB44244, BC40-4, BCF93558, BC80-8 Installation Manual

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL FOR

Blast Chillers/Freezers

1	09/12 Rev. B 143573

- INDEX -

1 GENERAL INSTRUCTIONS ON DELIVERY ……………………………………3

GENERAL INSTRUCTIONS ……………………………………………………………………3

TECHNICAL DATA ………………………………………………………………………………3

LIST OF REGULATION REFERENCES ……………………………………………………3

GENERAL INSTRUCTIONS ……………………………………………………………………3

SETTING UP ………………………………………………………………………………………4

MACHINE LOADING …………………………………………………………………………………………………5

POSITION OF TRAYS ………………………………………………………………………………………………5

STORAGE TIME AND TEMPERATURE …………………………………………………………………………5

CORE PROBE ………………………………………………………………………………………………………6

2 CONTROL PANEL …………………………………………………………………7

DESCRIPTION OF CONTROLS ………………………………………………………………7

3 OPERATION ..……………………….………………………………………………10

PROGRAMS .…………………….………………………………………………………………10

IFR CHILLING CYCLE ………….………….………………………………………………………………………10

RECOMMENDED WORKING CYCLES ………………….………………………………………………………11

USER’S CYCLE …………………………………………….………………………………………………………11

User’s programs ..…………….………………………………………………………………………………11 Storing User’s programs ………..……………………………………………………………………………12

Delete a User’s programs ……………………………………………………………………………………13

Rename a User’s programs …....……………………………………………………………………………13 PRE-COOLING CYCLE ……………………………………………………………………………………………14

MANUAL CYCLES .…………….………………………………………………………………15

Negative freezing cycle with core probe …………………………………………………………………16

Negative freezing cycle with timer …………………………………………………………………………16

Soft positive chilling cycle with core probe		………..……………………………………………………17
Soft positive chilling cycle with timer	……………….……………………………………………………18
Hard positive chilling cycle with core probe		………….…………………………………………………18
Hard positive chilling cycle with timer	……………………………………………………………………19

STORING CYCLES …………...………………………………………………………………20

POSITIVE STORE ………………………….………………………………………………………………………20

NEGATIVE STORE ………………………………………..………………………………………………………20

DEFROSTING ………………………….………………………………………………………21

PRINTING …………………………………….…………………………………………………21

4 MAINTENANCE ……………………………………………………………………23

MAINTENANCE AND CLEANING ……………………………………………………………23

CLEANING THE CABINET …………………………………………………………………………………………23

CLEANING THE AIR CONDENSER ……………………………………………………………………………24

STAINLESS-STEEL MAINTENANCE ……………………………………………………………………………24

DISCONTINUED USE ……………………………………………………………………………………………25

INSTALLATION …………………………………………………………………………………26

INTRODUCTION ……………………………………………………………………………………………………26

MAX ROOM TEMPERATURE ……………………………………………………………………………………26

LOCATION ….………………………………………………………………………………………………………26 WIRING ………………………………………………………………………………………………………………28

CONNECTION TO CONDENSATE DRAIN ……………………………………………………………………28

TESTING ……………………………………………………………………………………………………………28

CLOCK SETTING ………………………………………………………………………………29

LANGUAGE …….………………………………………………………………………………29

ALARMS AND FAULT ANALYSIS …………………………………………………………30

SERVICE ……………..…………………………………………………………………………32

PARAMETERS ………………………………………………………………………………………………………32

Description of parameters ……………………………………………………………………………………32

Changing parameters ………………………………………………………………………………………34

RESET MEMORY …………………………………………………………………………………………………35

RESTORING DEFAULT PARAMETERS …………..……………………………………………………………36

INPUTS/OUTPUTS ………………………….…………………………………………………37

	PRINTER INSTALLATION	………………………..…………………………………………37
	MAINTENANCE OF PANEL BOARD ………………………………………………………38
	WIRING DIAGRAM PLATE	…………………………………………………………………39

CONTROL AND SAFETY SYSTEMS ………………………………………………………39

DISPOSAL ………………………………………………………………………………………39

DOOR REVERSAL ……………………………………………………………………………40

REFRIGERANT MATERIAL SAFETY DATA SHEET………………………………………40

DIMENSIONS …………………………………………………………………………………42

APPENDIX …………………………………………………………………………44

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INFORMATION FOR THE READER

CHAPTER 0

This manual is subdivided into two parts.

1st part: covers all the information necessary to the user.

2nd part: covers all the information necessary to the qualified operators authorized to move, transport, install, service, repair and demolish the appliance.

While users are instructed to refer to the 1st part only, the 2nd part is addressed to skilled operators. They may also read the 1st part for a more complete picture of the information provided if necessary.

GENERAL INSTRUCTIONS ON DELIVERY

CHAPTER 1

GENERAL INSTRUCTIONS

Make sure that the product has not been tampered with or damaged during transport.

After unpacking the cooling cabinet make sure all sections or components have been included and specifications and conditions are as to your order.

If not, please inform the seller immediately.

We assure you have made the best choice in purchasing our products and hope you will be fully satisfied with their performance. To this purpose, we recommend you strictly follow with the instructions and regulations contained in this handbook.

Please remember that no reproductions of this handbook are allowed. Due to our constant technological updating and research, the features described in this handbook may be altered without prior notice.

TECHNICAL DATA

Please refer to the technical data of your own appliance. (tab.1a-1b), see page 44.

LIST OF REGULATION REFERENCES

The cooling cabinet we manufacture fully complies with the following regulations:

UL Listed for electrical safety

NSF standard 7 for sanitation

GENERAL INSTRUCTIONS

The quick cooler is a refrigerating appliance which can cool cooked foodstuffs to a temperature of +38 [°F] (positive quick cooling) and to 0 [°F] (negative quick cooling).

Machine capacity as to the quantity to be cooled depend on the model purchased.

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SETTING UP

Before setting to operation thoroughly clean the cooling cabinet with a suitable detergent or sodium bycarb dissolved in lukewarm water. Clean the appliance inside to remove any condensate caused by the Manufacturer's final testing.

Cooling and freezing speed depends on the following factors:

a)container shape, type and material;

b)whether container lids are used;

c)foodstuff features (density, water contents, fat contents);

d)starting temperature;

e)thermal conduction inside the foodstuffs

Positive /Negative quick cooling time depends on type of foodstuffs to be processed.

Full-speed cycle is recommended for high-density or large-sized foodstuffs. However, the following limits should never be exceeded : a 2” thickness for freezing and a 3” thickness for cooling (tab.2).

The low-speed cycle is suitable to process delicate foodstuffs, such as vegetables, creamy products, creamy desserts or low-thickness products.

We recommend making sure that any positive quick cooling cycles, to +38 [°F] to the core of the product, do not last over 180 minutes, and that negative quick cooling cycles, to 0 [°F] to the core of the product, do not last over 4 hours.

The processing room is to be pre-cooled before starting the positive and /or negative quick cooling cycle. Moreover, avoid covering the foodstuffs during the cycle, which would increase the cycle length.

We recommend using the core probe in order to have the exact core temperature reading. Do not stop the cycle before reaching a temperature of +38 [°F] during positive quick cooling and 0 [°F] during negative quick cooling.

Tab.2
	Model	Max. output/cycle			Capacity
		+160[°F] to+38[°F]	+160[°F] to +0[°F]	max shelves		pan size
	BCF44244BCB44244	44[lb]	24[lb]	5		12“x20“x1.5“
				4		12“x20“x2.5“
	BC40-4	40[lb]	-	5		12“x20“x1.5“
				4		12“x20“x2.5“
	BCF93558	93[lb]	55[lb]	14		12“x20“x1.5“
				8		12“x20“x2.5“
	BC80-8	80[lb]	-	14		12“x20“x1.5“
				8		12“x20“x2.5“
				26		12“x20“x1.5“
	BCF11514	115[lb]	55[lb]	14		12“x20“x2.5“
				13		18“x26“x1.5“
				7		18“x26“x2.5“
				26		12“x20“x1.5“
	BC113-14	113[lb]	-	14		12“x20“x2.5“
				13		18“x26“x1.5“
				7		18“x26“x2.5“
				32		12“x20“x1.5“
	BCF22020	220[lb]	110[lb]	20		12“x20“x2.5“
				16		18“x26“x1.5“
				10		18“x26“x2.5“

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MACHINE LOADING

Do not stack foodstuffs to be cooled. Thickness should be lower than 2” in negative quick cooling and lower than 3” in positive quick cooling. (pict.1)

Pict.1

Make sure air circulation is not hampered between food trays. (pict.2)

0,19”-0,79”

Pict.2

The grid-holding frame (included in those models which include trolleys) is to be located at the center of the cabinet. (pict.3)

Pict.3

POSITION OF TRAYS

Place the trays as close to the evaporator as possible. (pict.4)

If the cabinet is not full place the trays at equal distance from one another. (pict.5)

Pict.4

Pict.5

STORAGE TEMPERATURES AND TIMES

Cooled or frozen processed foodstuffs may be stored in a refrigerator for 5 days of processing without food quality degradation.

Storing time may be increased to approx. two weeks by using vacuum processing.

After a negative quick cooling cycle, foodstuffs may be stored safely for 3 to 18 months, according to the type of foodstuff processed.

It is strongly recommended to keep storing temperatures at 0[°F] or below.

A

B

C

Pict.6

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Table 3 shows the storing time rates for a few examples of frozen food.

Do not leave cooked products at room temperature before quick cooling, as this may allow the loss of moisture, which will affect food freshness.

The cooled product should be wrapped in a specific film for foodstuffs (better still, vacuum stored) and provided with a sticker reporting the content [A], date of processing [B] and expiration date [C] written in permanent type ink (pict.6).

Tab.3

Foodstuff	Storage temperature	Storage time
	[°F]	months
Pork	0	6
Beef	0	9
Poultry	0	10
Fat fish Lean	0	2
fish Peas	0	4
Strawberries	0	12
Spinach	0	12
	0	6

Note: the above storage times and temperatures are recommendations. Consult food and drug administration (FDA) documentation for current agency approved storage temperatures and times.

CORE PROBE

For proper position of the probe, refer to the following pictures.

	SINGLE-DETECTOR		MULTIS	-DETECTOR
	PROBER		PROBER

PRODUCT SURFACE

OVER SURFACE PROBE

PRODUCT CORE

UNDER SURFACE PROBE

CORE PROBE

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OFF _

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CONTROL PANEL

CHAPTER 2

DESCRIPTION OF CONTROLS

ON/OFF KEY	START/STOP KEY
ENTER KEY	UP KEY
MENU/ESC KEY	DOWN KEY

ON/OFF key

Pressing the key for 5 sec the controller turns off and the sign blinks on the

display
When this button is pressed the controller lights up
			IFR
again, preparing itself to start an IFR chilling cycle.			Esc

Enter key

Allows access to a menu or parameter selection.

Manual defrost: press the key		fro 5 s (default parameter values)
During a cycle: press the	button to display all the information regarding
the ongoing cycle. Press	to scroll through this information.

Menu/Esc key

Allows access to the main menu or return to the previous menu.

Quick IFR chilling key: press the key for 5 s (default parameter values)

Up and Down keys

Use to scroll the different menus or change parameter values.

Quick Soft posit. chilling key: press the key			for 5 s (default parameter values)
Quick negative freezing key: press the key			for 5 s (default parameter values)
Keyboard lock: press the keys		for 5s (default parameter values)
During a cycle: press the	button to display, for a few seconds, the elapsed time.

Start/Stop key

Use to start/stop a quick cooling cycle.

Quick cooling key: keep the key pressed for 5 s (default parameters)

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Programs

Manual

Store

Program selection

IFR: Automatic quick cooling program

Values setting not required. Can be activated with core probe only.

With the IFR program, there is no freezing on foodstuffs outer surface. (no risk of third-degree freezing).

The IFR program must not be used in negative quick cooling cycles.

Recommended: preset programs Meat (core probe chilling) Dairy (time-controlled chilling) Pie (time-controlled chilling) Stew (time-controlled chilling) Fish (time-controlled chilling) Poultry (time-controlled chilling) Vegetables (time-controlled chilling)

Freezing Temp (with core probe freezing) Freezing Time (time-controlled freezing)

User: 01 – 20 numbers available for programming according to the customers’ needs.

Cooling: this program cools the room before any chilling cycle.

Negative = QC with max. refrigerating air temp -13°F, max. core temp 0°F Positive Soft = QC with max. refrigerating air temp. +14°F, max. core temp. +36°F

Positive Hard = QC, 40% of time at -13°F, remaining time at +14°F, core temp. is set to +50°F. Suitable for big cuts of meat.

Automatic temp. regulation prior to ice formation on the surface.

…Core

…Time

If the core probe stays off, time-control turns on automatically.

Manual setting

Use the menu to manually configure core temperature values or the time and/or speed of the fans.

Positive = storing-cooling at + 36°F

Negative = storing-freezing at -8°F

Manual setting

Menu allows the user to set the products storing temp. after quick cooling.

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Defrost

Print

Clock Setting

Language

Alarm

Service

Inputs/Outputs

Defrost start

Select

Ok or No

Menu for printing memorized quick cooling cycles

With printer available, select:

Ok or No

Clock setting

Set date and time

Set language

Select the desired language

Menu for displaying the alarms. (reading only)

S = alarm start, E = alarm stop, Service = customer service

Appliance basic setting. Set password “-19”.

Parameters	customer service parameters
Reset Memory	memory complete deletion
Restore	default parameters restore

Menu for displaying inputs/outputs state. (reading only)

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OPERATION

CHAPTER 3

PROGRAMS

IFR CHILLING CYCLE

The IFR is an innovative patented system of positive quick cooling which allows the cycle optimization for each type of foodstuffs by preventing superficial freezing.

Temperatures are detected by a three-sensor needle probe (ref. page 6, “Core probe”).

Press menu/esc to select the desired menu

Use the keys up and down to display	Programs
	Esc
Press enter to confirm your choice.The display shows
			IFR
			Esc

Press start/stop to immediately activate the selected cycle

Notes:

- immediately after power up, the controller automatically prepares itself to start an IFR chilling cycle: simply press and the cycle will start immediately.

- from the main menu it is possible to immediately start an IFR chilling cycle: keep the pressed for 5 seconds. - during the cycle it is possible to view fan speed by pressing ; use the button to modify the value.

F	176
	140
	104
	68
	32
	-4
	-40	PRODUCT CORE
	100
	50	INTERMEDIATE
	0
F	176	PRODUCT SURFACE
	140
	104	ROOM TEMPERATURE
	68
	32
	-4	ROOM VENTILATION SPEED
	-40
	100
	50
	0
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RECOMMENDED WORKING CYCLES

Recommended working cycles are pre-programmed. Parameters cannot be changed.

Press menu/esc to select the desired menu

Use the keys up and down to display	Programs
	Esc
Press enter to confirm your choice. The display shows
			IFR
			Esc
Use the keys up and down to display
	Recommended
	Esc
Press enter to gain access to the saved programs selection		(21-29)
The display shows the program number and name			Meat
			Esc

Use the keys up and down to scroll all the saved programs

Press start/stop to immediately activate the selected cycle

The recommended programs are listed below:

	Prog	Name of the program	Positive	Time/Core	hard	Room set	time	Ventilat.
			negative			storing
	21	Meat	positive	core	yes	+35°F	120 min	100%
	22	Dairy	positive	time	no	+35°F	90 min	100%
	23	Pie	positive	time	no	+35°F	90 min	100%
	24	Stew	positive	time	no	+35°F	90 min	100%
	25	Fish	positive	time	yes	+35°F	90 min	100%
	26	Poultry	positive	time	yes	+35°F	90 min	100%
	27	Vegetables	positive	time	no	+35°F	90 min	100%
	28	Freezing Temp	negative	core	yes	-8°F	240 min	100%
	29	Freezing Time	negative	time	yes	-8°F	240 min	100%

Note: It is the responsibility of the user that the storage temperature and pull down is time appropriate for their application

	USER’S CYCLE
USER’S PROGRAMS
The saved USER programs can be activated as follows:
	Press menu/esc to select the desired menu
	Use the keys up and down to display	Programs
		Esc
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Press enter to confirm your choice. The display shows			IFR
			Esc
Use the keys up and down to display
	User
	Esc
Press enter to confirm your choice. The display shows		01 NAME
	(example)		Esc

Use the keys up and down to scroll all the saved programs

Press start/stop to immediately activate the selected cycle

STORING USER’S PROGRAMS

It is possible to save up to 20 USER programs.

Press menu/esc to select the desired menu

	Use the keys up and down to display	Manual
		Esc

Press enter to confirm your choice.

Select the manual cycle as described in the previous paragraphs, replacing the standard values with the desired ones.

Once the cycle is completely configured, the display will show.

	(example)	Neg Core
		Esc
	Keep menu/esc pressed for 5 seconds to save the program.

The display will show the first available position				Programs 03
				---------
Use buttons	to scroll through the 20				programs
and select the desired position.
Press enter to confirm the selected position.
The display shows		A _ _ _ _ _ _
		Esc

Type in the name of the program which is to be memorised using buttons to

scroll through the letters and numbers, and press to confirm and move on to the next character

Press menu/esc to save the name.

	The display shows	NAME
		Esc
	(example)

Press start/stop to immediately activate the selected cycle

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DELETE A USER’S PROGRAM

Press menu/esc to select the desired menu

Use the keys up and down to display	Programs
	Esc
Press enter to confirm your choice. The display shows
			IFR
			Esc
Use the keys up and down to display	User
	Esc
Press enter to confirm your choice. The display shows		01 NAME
			Esc

Use the keys up and down to scroll all the saved programs

Keep menu/esc pressed for 5 seconds. The display	Cancel progr
shows	Ok	No

Press enter to cancel the program

Press menu/esc to exit

RENAME A USER’S PROGRAM

Press menu/esc to select the desired menu

Use the keys up and down to display	Programs
	Esc
Press enter to confirm your choice. The display shows
			IFR
			Esc
Use the keys up and down to display	User
	Esc
Press enter to confirm your choice. The display shows		01 NAME
			Esc

Use the keys up and down to scroll all the saved programs

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Room Insert prod

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Keep menu/esc pressed for 5 seconds. The display
						Cancel progr
shows						Ok	No
Press up. The display shows
		Rename progr	No
	Ok
Press enter. The display shows		A _ _ _ _ _ _
		Esc

Type in the name of the program which is to be memorized using buttons to

scroll through the letters and numbers, and press to confirm and move on to the next character.

Press menu/esc to confirm the new name

Press menu/esc to exit

PRE-COOLING CYCLE

It is advisable to run a cooling cycle prior to selecting any chilling cycle.

Press menu/esc to select the desired menu

Use the keys up and down to display		Programs
		Esc
Press enter to confirm your choice.
The display shows	IFR
	Esc

Use the keys up and down to display	Cooling
	Esc

Press the start/stop button to immediately activate the cooling cycle

Once the temperature in the room reaches -13°F, the buzzer will sound for 10 seconds, and the “insert

-13°F

product” request will be displayed.

Closing the door terminates the cooling cycle.

Note: From the main menu it is possible to immediately activate a cooling cycle; simply keep the button pressed for 5 seconds.

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