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 |
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Soft positive chilling cycle with timer |
……………….……………………………………………………18 |
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Hard positive chilling cycle with core probe |
………….…………………………………………………18 |
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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
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PRINTER INSTALLATION |
………………………..…………………………………………37 |
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MAINTENANCE OF PANEL BOARD ………………………………………………………38 |
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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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09/12 Rev. B 143573
- OPERATION MANUAL -
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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09/12 Rev. B 143573
- OPERATION MANUAL -
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 |
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Model |
Max. output/cycle |
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Capacity |
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+160[°F] to+38[°F] |
+160[°F] to +0[°F] |
max shelves |
pan size |
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BCF44244BCB44244 |
44[lb] |
24[lb] |
5 |
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12“x20“x1.5“ |
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4 |
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12“x20“x2.5“ |
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BC40-4 |
40[lb] |
- |
5 |
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12“x20“x1.5“ |
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4 |
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12“x20“x2.5“ |
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BCF93558 |
93[lb] |
55[lb] |
14 |
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12“x20“x1.5“ |
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8 |
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12“x20“x2.5“ |
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BC80-8 |
80[lb] |
- |
14 |
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12“x20“x1.5“ |
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8 |
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12“x20“x2.5“ |
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26 |
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12“x20“x1.5“ |
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BCF11514 |
115[lb] |
55[lb] |
14 |
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12“x20“x2.5“ |
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13 |
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18“x26“x1.5“ |
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7 |
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18“x26“x2.5“ |
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26 |
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12“x20“x1.5“ |
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BC113-14 |
113[lb] |
- |
14 |
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12“x20“x2.5“ |
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13 |
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18“x26“x1.5“ |
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7 |
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18“x26“x2.5“ |
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32 |
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12“x20“x1.5“ |
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BCF22020 |
220[lb] |
110[lb] |
20 |
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12“x20“x2.5“ |
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16 |
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18“x26“x1.5“ |
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10 |
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18“x26“x2.5“ |
4
09/12 Rev. B 143573
- OPERATION MANUAL -
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 |
5
09/12 Rev. B 143573
- OPERATION MANUAL -
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 |
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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.
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SINGLE-DETECTOR |
MULTIS |
-DETECTOR |
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PROBER |
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PROBER |
PRODUCT SURFACE
OVER SURFACE PROBE
PRODUCT CORE
UNDER SURFACE PROBE
CORE PROBE
6
09/12 Rev. B 143573
- OPERATION MANUAL -
CONTROL PANEL |
CHAPTER 2 |
DESCRIPTION OF CONTROLS
ON/OFF KEY |
START/STOP KEY |
ENTER KEY |
UP KEY |
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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 |
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When this button is pressed the controller lights up |
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IFR |
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again, preparing itself to start an IFR chilling cycle. |
Esc |
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Enter key
Allows access to a menu or parameter selection.
Manual defrost: press the key |
fro 5 s (default parameter values) |
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During a cycle: press the |
button to display all the information regarding |
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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) |
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Quick negative freezing key: press the key |
for 5 s (default parameter values) |
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Keyboard lock: press the keys |
for 5s (default parameter values) |
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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)
7
09/12 Rev. B 143573
- OPERATION MANUAL -
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.
8
09/12 Rev. B 143573
- OPERATION MANUAL -
Defrost
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)
9
09/12 Rev. B 143573
- OPERATION MANUAL -
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 |
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Esc |
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Press enter to confirm your choice.The display shows |
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IFR |
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Esc |
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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 |
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140 |
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104 |
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68 |
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32 |
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-4 |
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-40 |
PRODUCT CORE |
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100 |
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50 |
INTERMEDIATE |
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0 |
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F |
176 |
PRODUCT SURFACE |
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140 |
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104 |
ROOM TEMPERATURE |
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68 |
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32 |
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-4 |
ROOM VENTILATION SPEED |
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-40 |
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100 |
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50 |
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0 |
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10 |
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09/12 Rev. B 143573 |
- OPERATION MANUAL -
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 |
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Esc |
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Press enter to confirm your choice. The display shows |
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IFR |
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Esc |
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Use the keys up and down to display |
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Recommended |
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Esc |
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Press enter to gain access to the saved programs selection |
(21-29) |
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The display shows the program number and name |
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Meat |
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Esc |
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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. |
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negative |
storing |
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21 |
Meat |
positive |
core |
yes |
+35°F |
120 min |
100% |
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22 |
Dairy |
positive |
time |
no |
+35°F |
90 min |
100% |
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23 |
Pie |
positive |
time |
no |
+35°F |
90 min |
100% |
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24 |
Stew |
positive |
time |
no |
+35°F |
90 min |
100% |
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25 |
Fish |
positive |
time |
yes |
+35°F |
90 min |
100% |
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26 |
Poultry |
positive |
time |
yes |
+35°F |
90 min |
100% |
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27 |
Vegetables |
positive |
time |
no |
+35°F |
90 min |
100% |
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28 |
Freezing Temp |
negative |
core |
yes |
-8°F |
240 min |
100% |
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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
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USER’S CYCLE |
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USER’S PROGRAMS |
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The saved USER programs can be activated as follows: |
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Press menu/esc to select the desired menu |
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Use the keys up and down to display |
Programs |
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Esc |
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11 |
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09/12 Rev. B 143573
- OPERATION MANUAL -
Press enter to confirm your choice. The display shows |
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IFR |
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Esc |
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Use the keys up and down to display |
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User |
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Esc |
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Press enter to confirm your choice. The display shows |
01 NAME |
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(example) |
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Esc |
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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 |
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Esc |
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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 |
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Esc |
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Keep menu/esc pressed for 5 seconds to save the program. |
The display will show the first available position |
Programs 03 |
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--------- |
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Use buttons |
to scroll through the 20 |
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programs |
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and select the desired position. |
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Press enter to confirm the selected position. |
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The display shows |
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A _ _ _ _ _ _ |
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Esc |
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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 |
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Esc |
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(example) |
Press start/stop to immediately activate the selected cycle
12
09/12 Rev. B 143573
- OPERATION MANUAL -
DELETE A USER’S PROGRAM
Press menu/esc to select the desired menu
Use the keys up and down to display |
Programs |
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Esc |
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Press enter to confirm your choice. The display shows |
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IFR |
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Esc |
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Use the keys up and down to display |
User |
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Esc |
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Press enter to confirm your choice. The display shows |
01 NAME |
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Esc |
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Use the keys up and down to scroll all the saved programs
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Keep menu/esc pressed for 5 seconds. The display |
Cancel progr |
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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 |
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Esc |
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Press enter to confirm your choice. The display shows |
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IFR |
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Esc |
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Use the keys up and down to display |
User |
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Esc |
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Press enter to confirm your choice. The display shows |
01 NAME |
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Esc |
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Use the keys up and down to scroll all the saved programs
13
09/12 Rev. B 143573
- OPERATION MANUAL -
Keep menu/esc pressed for 5 seconds. The display |
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Cancel progr |
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shows |
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Ok |
No |
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Press up. The display shows |
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Rename progr |
No |
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Ok |
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Press enter. The display shows |
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A _ _ _ _ _ _ |
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Esc |
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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 |
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Esc |
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Press enter to confirm your choice. |
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The display shows |
IFR |
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Esc |
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Use the keys up and down to display |
Cooling |
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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.
14
09/12 Rev. B 143573