Traulsen TBC13, TBC1H, TBC1HR, TBC2H, TCB2HR User Manual

Traulsen Refrigeration

SERVICE MANUAL #07

Instructions For The Installation,

Troubleshooting And Repair Of Traulsen

epicon® Equipped Blast Chiller Models

Undercounter Model TBC5

Reach-In Model TBC13

Roll-In/Roll-Thru Models TBC1H, TBC1HR, TBC2H & TBC2HR

-NOTICE-

This Manual is prepared for the use of trained Authorized Traulsen Service Agents and should not be used by

those not properly qualied. This manual is not intended to be all encompassing, but is written to supplement
the formal training, on-the-job experience and other product knowledge acquired by Authorized Traulsen
Service Agents. Before proceeding with any work, you should read, in its entirety, the repair procedure you
wish to perform to determine if you have the necessary tools, instruments and skills required to perform
the procedure. Procedures for which you do not have the necessary tools, instruments and skills should
be performed only by a trained Authorized Traulsen Service Agent.

Reproduction or other use of this Manual, without the express written consent of Traulsen, is prohibited.

FORM NUMBER TR99999 - REV. 8/13

I. TABLE OF CONTENTS

I. TABLE OF CONTENTS 1

II. GENERAL INFORMATION

a-Introduction 2

b-Operation 2

c-Cleaning 2

d-Applicable Models 2

e-Wiring Diagrams 2

f-Tool Requirements 2

g-The Serial Tag 2

III. SPECIFICATIONS/OPERATING DATA

a-Product Specications 3

b-Operating Data 3

c-Refrigeration System Installation 3

VIII. SERVICE PROCEDURES

a-Temperature Sensors 9

b-Expansion Valve 9-10

c-Door Perimeter Heaters 10

d-Compressor 10-11

e-Condenser Fan Assembly 11

f-Condenser Coil 11

g-Pressure Control 11

h-Evaporator Coil 11

i-Filter/Drier 12

j-Evaporator Blower 12

k-Checking For Leaks 13

l-Evacuating The System 13

m-Charging The System 14

n-System Clean-Up 14

o-Replacing The Door Gasket 15

IV. SERVICING THE EPICON CONTROL

a-Overview 4

b-The Toolbox 4

c-Setting The Clock 4

d-Service Menu 4

e-Service Menu Features 5

V. CONTROL ARCHITECTURE

a-Controller Board 6

IX. WIRING DIAGRAMS - TBC5 16

X. WIRING DIAGRAMS - TBC13 17

XI. WIRING DIAGRAMS - TBC1H MODELS 18

XII. TROUBLESHOOTING 19-20

XIII. TBC5 REPLACEMENT PARTS LIST 21

VI. COMPONENT FUNCTION 7

XIV. TBC13 REPLACEMENT PARTS LIST 22

VII. SEQUENCE OF OPERATION

a-Refrigeration System 8

b-Refrigeration System (BC compressor on TBC1H only) 8

c- IDLE Mode 8

d- Hold Mode 8

e-By Time Chill/Freeze Mode 8

f-By Temp Chill/Freeze Mode 9

g-By Product Chill/Freeze Mode 9

h-Defrost Mode` 9

XV. TBC1H REPLACEMENT PARTS LIST 23

Visit the Resource Center @ www.traulsen.com to

review the Operator’s Video for this product.

-1-

II. GENERAL INFORMATION

II. a - INTRODUCTION:

Blast Chillers are food processing refrigerators de-

signed for rapid chilling of product from 140 F to 40
F in approximately 90 minutes, for reheating and/or
serving at a later time.

These models aid in preserving food quality, texture

and nutritional value, in addition to enhancing food

safety.

All of the information, illustrations and specications
contained within this manual are based on the latest
product information available at the time of printing.

II. b - OPERATION:
Refer to the instructions contained in the Owner’s
Manual, form number TR35938, for specic operating
instructions.

II. c - CLEANING:
Detailed cleaning instructions are included with each
unit, however, special care MUST be given to the con­denser coil(s). These must be cleaned WEEKLY. This
surface must be kept free of dirt and grease for proper
system operation. This can be done with a vacuum
cleaner using a brush attachment, or a stiff brush or
wisk broom. Care must be taken not to damage the
condenser coil ns. For more information please refer
to section V. a, V. e, and V. f of the Blast Chill Owner’s
Manual.

II. d - APPLICABLE MODELS:
This manual applies to the following Traulsen models:

TBC5 Undercounter Blast Chiller
TBC13 Reach-In Blast Chiller
TBC1H & TBC2H Roll-In Blast Chillers
TBC1HR & TBC2HR Roll-Thru Blast Chillers

II. f - TOOL REQUIREMENTS (cont’d):

• Refrigeration Reclaiming Equipment

• Acetylene Torch

• Nitrogen Bottle With Gauges

• Refrigeration Gauge Manifold

• Dial-a-Charge

• Valve Core Removal Kit

• Vacuum Pump

II. g - THE SERIAL TAG:

The serial tag is a permanently afxed sticker on which is
recorded vital electrical and refrigeration data about your
Traulsen product, as well as the model and serial number.
This tag is located inside all blast chiller models. An ex­ample is shown below.

FORT WORTH, TX.

SERIAL MODEL
VOLTS Hz PH

TOTAL CURRENT AMPS
MINIMUM CIRCUIT AMPS
MAXIMUM OVERCURRENT PROTECTION AMPS
LIGHTS WATTS
HEATERS AMPS

REFRIGERANT TYPE OZ
DESIGN PRESSURE HIGH LOW

REFRIGERANT TYPE OZ
DESIGN PRESSURE HIGH LOW

370-60294-00 REV (A)

PLEASE NOTE: This manual refers to the above
models built after June 2012, equipped with the epi-

con® control. For information regarding models built

prior to that date please contact the factory.

II. e - WIRING DIAGRAMS:
Refer to the wiring diagrams on pages 16 thru 18 for
any service work performed on the unit. Should you

require another copy, please contact Traulsen Service

at [phone], and provide the model and serial
number of the unit involved.

II. f - TOOL REQUIREMENTS:
For most jobs a standard set of hand tools, a VOM
with AC current tester, electrically conductive eld
service grounding kit, along with a temperature tester
or thermometer are adequate. However in some cases
the following additional tools may be required as well:

READING THE SERIAL TAG

• Serial = The permanent ID# of your Traulsen

• Model = The model # of your Traulsen

• Volts = Voltage

• Hz = Cycle

• PH = Phase

• Total Current = Maximum amp draw

• Minimum Circuit = Minimum circuit required

• Lights = Light wattage

• Heaters = Heater amperage

• Refrigerant = Refrigerant type used

• Design Pressure = High & low side operating

pressures and refrigerant charge

• Agency Labels = Designates agency listings

-2-

III. SPECIFICATIONS/OPERATING DATA/INSTALLATION

III. a - PRODUCT SPECIFICATIONS:

DIMENSIONS TBC5 TBC13 TBC1H TBC1HR TBC2H TBC2HR

Length - Overall in. 54 41 48-1/2 48-1/2 48-1/2 48-1/2
Depth - Overall in. 34-7/16 34-1/2 37-5/8 41-1/4 71-5/6 75-1/4
Height - Overall in. 34 74 90-3/8 90-3/8 90-3/8 90-3/8
Capacity 12 x 20 Pans 10 26 1 Rack 1 Rack 2 Racks 2 Racks
Capacity 18 x 26 Pans 5 13 1 Rack 1 Rack 2 Racks 2 Racks
Capacity Product Weight 100 lbs. 200 lbs. 300 lbs. 300 lbs. 600 lbs. 600 lbs.

III. b - OPERATING DATA:

DATA TBC5 TBC13 TBC1H TBC1HR TBC2H TBC2HR

Single or Dual System Single Dual Dual Dual Dual Dual
Remote Chill Compressor n/a No Yes Yes Yes(2) Yes(2)

H.P.1 1 1/2 1/2 1/2 1/2(2) 1/2(2)
BTU/HR1 4300 2820 2820 2820 2820(2) 2820(2)
H.P.2 n/a 1-1/4 4 4 4(2) 4(2)
BTU/HR2 n/a 5710 18,700 18,700 18,700(2) 18,700(2)

Refrigerant Type R-404A R-404A R-404A R-404A R-404A R-404A
Refrigerant Charge oz. 29 31 25 25 25(2) 25(2)

Refrigerant Charge2 n/a 45 See Note3 See Note3 See Note3 See Note

Condenser RLA1 11.7 5.1 10.5 10.5 10.5(2) 10.5(2)
Condenser RLA2 n/a 9.3 See Note3 See Note3 See Note3 See Note
Unit Voltage 115 208/115 115 115 115(2) 115(2)

Phase 1 1 1 1 1 1
Hz 60 60 60 60 60 60

Full Load Amps 13.3 13.4 14.9 14.9 14.9(2) 14.9(2)
NEMA Plug Type 5-20 14-20 Hard Wire Hard Wire Hard Wire Hard Wire

1= Self-Contained Holding or Primary Compressor.
2= Blast Chilling or Secondary Compressor.
3= Varies with remote system.

3

3

III. c - REFRIGERATION SYSTEM INSTALLATION:
All Traulsen blast chillers, with the exception of model TBC5, require
the use of a oor drain or oor mounted condensate evaporator for
condensate removal. Refer to Section IV. h of the blast chill owner’s
manual for more information.

Remote refrigeration installation requirements apply only to models
TBC1H/TBC1HR and TBC2H/TBC2HR. A remote condensing unit, op­erating on R-404A refrigerant, is required for Blast Chill operation on
these models. The remote condensing unit(s) should be capable of
providing 18,700 BTU/hr @ -10°F evaporator temperature and 90°F
ambient.

Air-cooled and water-cooled remote condensing units are available
from Traulsen as an optional accessory. Please note that these
should be adequate for any installation within a 25 foot radius from
the cabinet. Beyond this distance, the actual capacity of the remote
condensing unit and line sizing may change depending upon the
length and layout of the connecting piping from the remote condens­ing unit to the Blast Chiller. These utilize a 1/2” liquid and 1-1/8”
suction lines. Proper specication of the remote condensing unit
needed and line sizing should be dened by a qualied refrigeration
engineer or technician, based on the jobsite installation needs.

The low pressure cut-out of the remote condensing unit should be
adjusted to obtain an evaporator coil temperature NO LOWER THAN

-15°F. If the length of the connecting piping is 40 feet or less, the
condensing unit low pressure cut-out settings will be approximately
15 +/- 2 PSIG cut-out and 25+/- 3 PSIG cut-in.

For more information please contact the factory.

-3-

IV. SERVICING THE EPICON CONTROL

IV. a - OVERVIEW:
Traulsen’s TBC Series blast chillers are equipped with
the epicon microprocessor control. This is protected
from damage by a surrounding heavy gauge metal be­zel. It includes several diagnostic features built within
the TOOLBOX’s SERVICE menu. The control itself has
no serviceable parts. Should you encounter a faulty or
damaged control, it will need to be replaced.

IV. b - THE TOOLBOX:
The TOOLBOX can be accessed by pressing the
MANUAL tab, and then the TOOLBOX icon on top of
the MANUAL menu screen.

From the MANUAL
menu screen press
the TOOLBOX icon.

The control will now display the TOOLBOX menu. It
includes three security levels.

Press USER for operator level
access. This provides open
access allowing you to: Set the
Clock, Adjust Defrost Time and
Settings, Download Cycle Data,

Search Chill Cycle History, and
Upload Recipes to the

PRODUCT menu.

IV. c - SETTING THE CLOCK (continued):
To adjust the Date and time settings:

1) Press DAY - MONTH -
YEAR - HOUR - MINUTE
as needed (after doing so
the eld will be
highlighted).

2) Toggle the LEFT/RIGHT
arrows at bottom to
adjust this parameter

3) Proceed to the next
parameter.

4) Press SAVE TIME to save
these settings.

IV. d - SERVICE MENU:
Press SERVICE to access the service menu. Note that
this is password protected. The factory default code
is 4401. Enter the access code to proceed.

Press SUPERVISOR for
supervisor access. Note

that this not intended for
every day access and

adjustments and so is
password protected

Enter your access code to

proceed. The factory
default code is 1234. This can

be changed in the

SUPERVISOR level.

IV. c - SETTING THE CLOCK:
Begin by pressing MANUAL - TOOLBOX - USER, then
press SET DATE/TIME. The display will change to the
SET DATE/TIME screen.

The SERVICE menu will appear.

-4-

IV. SERVICING THE EPICON CONTROL (cont’d)

IV. e - SERVICE MENU FEATURES:
CALIBRATE: This features allows for calibration of the touchscreen’s accuracy. Press CALIBRATE than each of the
ve plus symbols (+) as closely as possible to do so. Note use of a stylus is highly recommended.

NOTE: The units are calibrated from the
factory and should only be recalibrated
if necessary. Exercise extreme caution
when recalibrating as improper inputs while
calibrating can result in difcultly navigating
the control.

Touch

Point 1

Touch

Point 2

Touch

Point 3

Touch

Point 4

PRINTERS: This feature allows you to
check each printer for proper operation.

Press PRINT CHART to test the record
printer.

Press PRINT LABEL to test the label
printer on models supplied with the
optional label printer.

TEMPERATURES:
Displays key temperature sensor data. Expected values
for each should be in similar to those shown below...

AMBIENT 66°F
CABINET 34°F
MAINT EVAP IN 63°F
MAINT EVAP CORE 42°F
BLAST EVAP IN 32°F
BLAST EVAP CORE 37°F
BLAST EVAP OUT 32°F
BLAST LIQUID LINE 66°F
MAINT LIQUID LINE 66°F

SOFTWARE: Select this feature when updating the control’s
operating software.

The current software versions are displayed at the top
of the TOOLBOX main menu. Contact Traulsen at (800)
825-8220 to verify if you have the latest software versions.

To update the control, insert a thumb drive containing the
latest software into the USB port. Note all les must be
located in the root directory. Updates should be performed
in the following order (if necessary)...

Update I/O Board
Update UI Board

Update HTML

Follow the instructions provided with the software update
and any on screen instructions. Do not remove the thumb
drive until all updates have been completed.

Touch

Point 5

PARAMETERS:
Press START DEFROST to initiate an
on demand defrost cycle.

Press DOWNLOAD SERVICE DATA to
transfer all temperature data (as shown
on the TEMPERATURE menu) through
the USB port to a thumb drive.

Press DOWNLOAD RAW DATA to
transfer all data in memory through the
USB port to a thumb drive. NOTE: this
feature requires use of special software
available from Traulsen.

DIAGNOSTICS:
Press each OUTPUT one at a time in
order to change test status from OFF
to ON. Record the reading and then
turn the OUTPUT off before proceeding
to the next one.

NOTE: If you do not turn each OUTPUT
off before proceeding to the next one
you can potentially cause damage to
that component.

Normal readings for each OUTPUT
should be...

LS EVAP FANS = 3.7A +/- .55A
HS EVAP FANS = 3.9A +/- .15A
MAINT COND FAN = 1.15A +/- .25A
BLAST COND FAN =
MAINT COMP = 7.5A +/- 1.5A
BLAST COMP =
DEFROST VALVE = n/a
BUZZER = n/a

NOTE: The maintenance compressor
has an anti-cycling feature of 1-minute.
Allow the cabinet to idle for at least
1-minute before beginning a test.

-5-

V. CONTROL ARCHITECTURE

LEGEND

1. UI Power 5. Label Printer Communication

2. USB Port (used) 6. Paper Printer Power

3. USB Port (unused) 7. Paper Printer Communica-

tion

4. Label Printer Power

-6-

VI. COMPONENT FUNCTION

Compressor Pumps refrigerant through refrigeration lines and components.

Condenser Fan Draws air across condenser coil to aid in removing heat from the refrigerant and
moves air across compressor to aid in cooling the compressor.

Dual Pressure Control Low side monitors suction pressure at compressor. Shuts compressor OFF when

(TBC1H & TBC2H only) low pressure setting is reached (cut-out). Allows compressor to run when

pressure rises to cut-in setting.
High side monitors discharge pressure at compressor. Shuts compressor OFF
when high side pressure setting is reached (cut-out). Allows compressor to run
when pressure returns to cut-in setting.
The differential is the difference in pressure between open and closed states of the
pressure switch.

Start Capacitor Wired in series with the start windings to help start compressor motor.

Run Capacitor Continually in circuit to help compressor motor during operation.

Thermal Overload Removes power from compressor if the internal temperature of the compressor
becomes too high (auto reset).

Start Relay Senses current of run winding of compressor motor. Normally open contacts
close when run winding draws a high amperage at start and brings the start
capacitor and start windings into the circuit. As the motor reaches operating
speed (less amperage through run winding), the normally open contacts open and
removes the start capacitor and start windings from the circuit.

Evaporator Fan Draws air from the cabinet and moves air through the evaporator coil.

Defrost Heater Defrosts evaporator coils and prevents water droplets from evaporator coil from
freezing before they can drain to the condensate pan. Operates only during
defrost cycle.

Air Temperature Sensor Monitors air temperature inside the cabinet.

Coil Temperature Sensor Monitors the suction line temperature at evaporator during defrost cycle.

Food Temperature Probe Monitors temperature of food product.

Solenoid Valve Normally closed. When energized, allows refrigerant to ow from receiver to
evaporator coil.

Door Perimeter Heater Prevents condensate on door frame.

Controller Performs the following functions:
a) Displays all data for the current mode of operation.
b) Cycles refrigeration system to maintain cabinet temperature.
c) Monitors power failures.

Power Supply Boards Provides DC voltage to control system.

Relay Board Performs the following functions:
a) Cycles fans.
b) Controls outputs to heaters and compressor relays.

Thermal Fuse TBC1H, TBC1HR, TBC2H and TBC2HR only. Monitors cabinet air temperature.
Opens circuit to defrost heater if cabinet temperature exceeds 230°F.

-7-