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Blast chiller Service Manual

Rev 07/04/2015

Disconnect the wire leads and remove the defective heater.
Insert the replacement heater in the channel and connect the wire leads.

Replace the plastic cover strips and snap them in place by hand.

4.9 REPLACING THE RELAY BOARD

a)  Disconnect the power supply.
b)  M ark and remove all wires.
c)  The board is mounted with 6 plastic clips. Squeeze the tabs of each clip and

remove the board.

PLASTIC

CLIPS

Содержание GBC-15

Страница 1: ...Service Manual Blast Chiller...

Страница 2: ...Rev 07 04 2015 2...

Страница 3: ...Blast chiller Service Manual 3 Rev 07 04 2015...

Страница 4: ...cal electrical codes Failure to comply with this procedure can cause property damage injury or death WARNING Before connecting the unit to the electrical supply verify that the electrical connection a...

Страница 5: ...damage injury or death General Safety WARNING Desmon accepts no responsibility for any situation resulting from work carried out in an unprofessional manner or from the incorrect interpretation or ap...

Страница 6: ...he Electrical LOCKOUT TAGOUT Procedure is used to protect personnel working on an electrical appliance Before performing any maintenance or service that requires exposure to electrical components foll...

Страница 7: ...ms 0 C 32 F Chart Table 12 3 2 DOOR SWITCH 13 3 2 1 Checking the door switch 13 3 3 PRESSURE SWITCH 14 3 3 1 Pressure Switch Working Principles Alarm Connection 14 3 3 2 Pressure Switch Working Princi...

Страница 8: ...PRESSURE SWITCH 45 4 8 REPLACING THE DOOR FRAME HEATER 46 4 9 REPLACING THE RELAY BOARD 47 4 10 REPLACING THE KEYPAD 48 5 VACUUM AND CHARGE PROCEDURE 49 5 1 VACUUM AND CHARGING INSTRUCTION 49 5 1 1 S...

Страница 9: ...display alarms and failure codes that will assist in identifying the cause of a problem and direct attention to the components and circuits involved In addition a diagnostic service menu allows techni...

Страница 10: ...g to P37 AH HIGHT ROOM TEMPERATURE None AL LOW ROOM TEMPERATURE None Err MOTHER BOARD KEYBOARD CONNECTION FAILURE 2 None Res POWER FAILURE DURING RUNNING OF CYCLE Cycle will restart when power is rest...

Страница 11: ...the UP and DOWN arrow keys to scroll through the previous failure codes Press the SERVICE MENU CONFIGURATION PARAMETER configuration parameter The service menu can be accessed only during OFF mode fo...

Страница 12: ...end temperature with reference to the needle probe 3 P11 set temperature freeze end temperature with reference to the needle probe 18 P12 temperature at which the hard chill switches from the first s...

Страница 13: ...st is requested see P31 7 8 also 30 P31 elapsed time between the defrost request and activation of the solenoid valve only if P22 1 and on condition that the compressor is off when defrosting is reque...

Страница 14: ...emperature below which the condenser fan is switched off in the presence of the condenser probe P61 1 and on condition that the compressor is on with reference to the condenser probe see also P54 20 P...

Страница 15: ...hich the minimum temperature alarm is activated during post freezing storage with relation to P8 i e P8 P66 with reference to the cabinet probe 0 no alarm 0 P67 temperature above which the maximum tem...

Страница 16: ...nd temperature with reference to the needle probe 3 P11 set temperature freeze end temperature with reference to the needle probe 18 P12 temperature at which the hard chill switches from the first ste...

Страница 17: ...st is requested see P31 7 8 also 30 P31 elapsed time between the defrost request and activation of the solenoid valve only if P22 1 and on condition that the compressor is off when defrosting is reque...

Страница 18: ...emperature below which the condenser fan is switched off in the presence of the condenser probe P61 1 and on condition that the compressor is on with reference to the condenser probe see also P54 20 P...

Страница 19: ...hich the minimum temperature alarm is activated during post freezing storage with relation to P8 i e P8 P66 with reference to the cabinet probe 0 no alarm 0 P67 temperature above which the maximum tem...

Страница 20: ...nd temperature with reference to the needle probe 3 P11 set temperature freeze end temperature with reference to the needle probe 3 P12 temperature at which the hard chill switches from the first step...

Страница 21: ...st is requested see P31 7 8 also 30 P31 elapsed time between the defrost request and activation of the solenoid valve only if P22 1 and on condition that the compressor is off when defrosting is reque...

Страница 22: ...emperature below which the condenser fan is switched off in the presence of the condenser probe P61 1 and on condition that the compressor is on with reference to the condenser probe see also P54 20 P...

Страница 23: ...hich the minimum temperature alarm is activated during post freezing storage with relation to P8 i e P8 P66 with reference to the cabinet probe 0 no alarm 0 P67 temperature above which the maximum tem...

Страница 24: ...perature with reference to the needle probe 3 P11 set temperature freeze end temperature with reference to the needle probe 3 P12 temperature at which the hard chill switches from the first step to th...

Страница 25: ...st is requested see P31 7 8 also 30 P31 elapsed time between the defrost request and activation of the solenoid valve only if P22 1 and on condition that the compressor is off when defrosting is reque...

Страница 26: ...emperature below which the condenser fan is switched off in the presence of the condenser probe P61 1 and on condition that the compressor is on with reference to the condenser probe see also P54 20 P...

Страница 27: ...hich the minimum temperature alarm is activated during post freezing storage with relation to P8 i e P8 P66 with reference to the cabinet probe 0 no alarm 0 P67 temperature above which the maximum tem...

Страница 28: ...when the unit is struggling to reach the cabinet temperature setpoint i e 40 F This may indicate that the evaporator coil is not being supplied with sufficient refrigerant With a cabinet setpoint of...

Страница 29: ...the printer and enable communication Set configuration parameter P71 to 1 to enable the printer port on the Main Board In addition ensure that the following parameters are set as shown P76 1 P75 2 An...

Страница 30: ...rm list the controller must be in the OFF mode Press the PROGRAM key for five 5 seconds f the printer communication has been enabled the first display shown is the alarm code press the PROGRAM key To...

Страница 31: ...edle probe soft chilling Needle probe freezing Needle probe hard chilling Time soft chilling Time freezing Time hard chilling Programmed cycle Push on the printer front panel the cover will open allow...

Страница 32: ...Rev 07 04 2015 32...

Страница 33: ...s that will assist in identifying the cause of a problem and direct attention to the components and circuits involved In addition a diagnostic service menu allows technicians to quickly check the temp...

Страница 34: ...This alarm it s not a critical one however it could be avoided by setting LBT as high as possible i e 40 C 72 F DEFROSTING TIME Means that the defrost process has not terminated within the maximum de...

Страница 35: ...detected a failure on Relay 1 2 8 Call Service TRIAC BROKEN The electronic board detected a failure on the PWM output for evaporator fan variable speed Call Service BLACK OUT The system recorded a po...

Страница 36: ...Rev 07 04 2015 36 2 2 FAILURE CODE DETAILS When an alarm is occurring an alert icon will blink on the screen and the buzzer will activate Click on the alarm icon to see details...

Страница 37: ...Blast chiller Service Manual 37 Rev 07 04 2015 2 3 SERVICE MENU CONFIGURATION PARAMETERS 2 3 1 Entering the configuration parameter From the HOME screen press MORE then press SERVICE...

Страница 38: ...Rev 07 04 2015 38 Insert the 4 digits password 2810 and hit OK to enter the menu Click on PARAMETERS...

Страница 39: ...er Service Manual 39 Rev 07 04 2015 Press the left or right arrow to scroll pages Press on the parameter to check or change value Use the keyboard to change the parameter value and press OK to confirm...

Страница 40: ...Rev 07 04 2015 40...

Страница 41: ...ion C F 0 0 0 0 MNT number of trays of blast chiller num 15 15 15 15 DAC compressor stop delay sec 3 3 3 3 ADL minimum time of stop compressor sec 60 60 60 60 ASS start compressor delay at power on se...

Страница 42: ...14 14 COS average power factor of equipment num 5 5 5 5 PR1 declared power connected to relay1 num 0 0 0 0 PR2 declared power connected to relay2 num 0 0 0 0 PR3 declared power connected to relay3 nu...

Страница 43: ...peed in prechilling num 10 10 10 10 PFA cabinet set point in prefreezing C F 22 22 22 22 PFF evaporator fan speed in prefreezing num 10 10 10 10 DWA load tolerance on relays 20 20 20 20 STO max storag...

Страница 44: ...wing cycle C F 43 43 43 43 PFT evaporator fan speed in pre thawing cycle 10 10 10 10 PAC air temperature in pre soft cooking cycle C F 43 43 43 43 PFC evaporator fan speed in pre soft cooking cycle 6...

Страница 45: ...Blast chiller Service Manual 5 Rev 07 04 2015 2 3 3 Temperature Probes Display From the HOME screen press MORE OPTIONS and I O...

Страница 46: ...Rev 07 04 2015 6 All relevant temperature values and input output status will show in this screen...

Страница 47: ...s Failure to comply can cause property damage injury or death If upon first inspection the cause of a problem is not obvious a more thorough troubleshooting may be necessary The unit may need to be un...

Страница 48: ...the Ohm reading is 0 Probe circuit is shorted between the two wires Replace the probe Ohm reading is infinity Probe is open Replace the probe Reading matches the resistance chart at a known temperatu...

Страница 49: ...m may exist in the main board internal circuits or in the mother board processor The main board should be replaced 3 1 2 NTC 10kOhms 25 C 77 F Diagram 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 kOhm...

Страница 50: ...Rev 07 04 2015 10 20 10 0 10 20 30 40 kOhms C kOhmsVsTempChart NTC 10kOhms 25 C ZOOM...

Страница 51: ...21 5 8 73 99 26 78 8 9 63 73 163 4 2 05 20 4 70 37 27 80 6 9 28 74 165 2 1 99 19 2 2 66 96 28 82 4 8 94 75 167 1 93 18 0 4 63 74 29 84 2 8 62 76 168 8 1 87 17 1 4 60 69 30 86 8 31 77 170 6 1 82 16 3 2...

Страница 52: ...5 941 20 10 14 960 90 5 23 980 40 0 32 1000 00 5 41 1019 50 10 50 1039 00 15 59 1058 50 20 68 1077 90 25 77 1097 30 30 86 1116 70 C F Ohms 35 95 1136 10 40 104 1155 40 45 113 1174 70 50 122 1194 00 5...

Страница 53: ...door one at the top and one at the bottom This allows the door to be reversed only for non Touch Screen version Checking the door switch If the magnetic sensor is faulty or if the wires are broken or...

Страница 54: ...ch is used for pump down purpose also 3 3 1 Pressure Switch Working Principles Alarm Connection The pressure switch has normally closed contacts that will open if the High or Low pressure limits are e...

Страница 55: ...itch will cut out compressor contactor s coil in this case either for low pressure pump down or high pressure safety NOTE No high pressure alarm message will be displayed from the controller in case o...

Страница 56: ...K7 Load7 CONDENSER FAN MOTOR CONTACTOR COIL K8 Load8 DOOR FRAME HEATER K9 Load9 LIGHT K10 Load10 ALLARM Depending on the unit s voltage rating each load is directly connected to either L1 or Neutral L...

Страница 57: ...Blast chiller Service Manual 17 Rev 07 04 2015 L1 L2...

Страница 58: ...not light Keypad faulty All connections are present but display does not work 3 7 MAIN BOARD TOUCH SCREEN CONTROLLER Each unit is equipped with a Main Board where the electrical components are connec...

Страница 59: ...cking Relay Outputs The Touch Screen Controller is able to show actual state of relays through I O menu explained at paragraph 2 3 3 Furthermore the controller is able to force relay to activate and c...

Страница 60: ...ng the PLAY button below LOAD U1 ON will appear The relay 1 output N U1 on the relay board will be excited Wait few seconds until the power board will feed a signal back to the display to prove that t...

Страница 61: ...supplied by relay 1 and how much the absorption is NOTE When using an additional contactor or power relay connected on the power board the power absorption will not show the actual power pulled by the...

Страница 62: ...n be monitored by looking at signals Ext Int on the left bottom side of the Display Both signals are blinking Blue if communication is OK One or both will blink Red if some error is occurring Check th...

Страница 63: ...results in a reading of 0 1 barg This could be the correct pressure if the cabinet temperature is at the minimum 40 C and the evaporator temperature is at 45 C If this is not the case the evaporator...

Страница 64: ...y damage injury or death This chapter deals with repairing replacing instruction of both mechanical and electrical components 4 1 REMOVE THE FRONT PANEL 4 1 1 Units from 5 to 18 shelves a Insert a scr...

Страница 65: ...ce Manual 25 Rev 07 04 2015 4 1 2 GBF GN2 3 smallest self contained unit a Open the door b Remove the two screws on the door frame side of the panel c Remove the panel to access the condenser coil key...

Страница 66: ...f contained 5 to 18 pans Effective June 2014 The latest version of Blast Chillers have a new snap in front panel No tools are required to remove the front panel There is a removable and washable clean...

Страница 67: ...HE DOOR SWING ONLY NON TOUCH SCREEN As long as there is no controller installed on the door the door on each model can be reversed so that it is hinged on the right or left Remove the front panel and...

Страница 68: ...the upper hinge Lift the door up pull it out and set it aside Rev bracket and take it off by removing the hinge pin from the square hole pull it out and set it aside SQUARED HOLE UPPER HINGE ev 07 04...

Страница 69: ...ast chiller Service Manual 29 Rev 07 04 2015 Remove the lower hinge pin and plastic bushing from the door Remove the foam insulation from the upper door hole 1 2 3 UPPER HINGE BOTTOM HINGE PLASTIC CAP...

Страница 70: ...to the opposite ends of the Place the plastic filler caps in the screw holes that previously held the lower hinge ove the locking pin by fitting it in hole on the opposite side of the frame and nylon...

Страница 71: ...of the square hole will allow proper loading of the hinge spring when the door is closed providing better sealing pressure on the gasket Turn the door over and fit the upper hinge Fit the bottom hinge...

Страница 72: ...g corner screws b Remove the front panel and unscrew the left and right side bolts from the compressor base plate at the sides of the condenser c Disconnect the keypad wires and loosen or cut the cabl...

Страница 73: ...Blast chiller Service Manual 33 Rev 07 04 2015 e Move the drain duct so that it will not interfere with sliding out the compressor base plate f Remove the caps from the corner stainless steel angles...

Страница 74: ...Rev 07 04 2015 34 g With the caps removed loosen the inner screws Do not remove them This is done at a 45 angle to the back panel 45 INTERNAL EXTERNAL...

Страница 75: ...Blast chiller Service Manual 35 Rev 07 04 2015 h Unscrew the right and left bolts from the compressor base plate INSULATED PIPES INTERNAL HOOK LOOSEN ONLY EXTERNAL MOTHERSCREW...

Страница 76: ...k Flexible tubing lines allow movement Rev ift the front edge of the base plate by pushing it forward to clear From the rear slide the base plate out as needed Flexible tubing lines allow movement FLE...

Страница 77: ...part of the unit s structure The procedure for accessing these components is different from that for the model previously described However the first eight steps are the same a Follow the instruction...

Страница 78: ...ss the condensing unit Rev Keep the cabinet base in place and push the cabinet body from back to front enough to access the components smallest self contained unit side panel 3 screws and the back rig...

Страница 79: ...1 GBF40GN2 1 GBF Remote units have the condensing unit in a separate box To access the HOW TO ACCESS EVAPORATOR ASSEMBLY All units including remote and self contained models are equipped with one eva...

Страница 80: ...Rev 07 04 2015 40 TX VALVE LIQUID LINE EVAPORATOR FEEDING LINE DEFROST LINE EQUALIZATION CIRCUIT TX BULB EVAPORATOR OUTPUT TX VALVE BULB CAPILLARY DEFROST PROBE CABLE DEFROST PROBE BULB...

Страница 81: ...remove the plastic mounting tie remove the probe wires from the main control terminals Cut off the probe bulb and all wire ties Attach the wires from the replacement probe wires to the wires of the e...

Страница 82: ...be wires to the wires of the existing probe From the controller side pull the wire of the existing probe to route the new probe wires correctly Attach the wires to the Main Board Mount the probe into...

Страница 83: ...controller side pull the wire of the existing probe to route the new probe wires correctly e Attach the wires to the Main Board Needle Probe Latest Version Effective June 2014 A quick connection plug...

Страница 84: ...to the old wires and pull the wires from the control compartment to route them correctly f Remove the old wires g Connect the wires to the terminal block h Close the panel i Reinstall the fan guard 4...

Страница 85: ...and an hP alarm will be displayed even though the pressures are good a To replace the pressure switch the capillary tubes must be disconnected b The high pressure capillary tube is connected to the li...

Страница 86: ...upted power supply Test the power supply before replacing the heater Test the heater using the following specifications 115V 220V Length 2 4 m 2 m Heated Resistance 1 4 k 2 4 k Current 80 mAmps 90 mAm...

Страница 87: ...lacement heater in the channel and connect the wire leads Replace the plastic cover strips and snap them in place by hand 4 9 REPLACING THE RELAY BOARD a Disconnect the power supply b M ark and remove...

Страница 88: ...are set correctly see Parameter List 4 10 REPLACING THE KEYPAD a Remove the front panel 3 1 and unscrew the keypad b Disconnect the wiring harness c Remove the mounting nuts lock washers and flat wash...

Страница 89: ...f solenoid valve body Replacement of condenser Replacement of evaporator Replacement of thermal expansion valve Replacement of liquid receiver or oil separator Replacement of a filter Leak repair Repl...

Страница 90: ...d in this section A vacuum can then be pulled on the evaporator section Connect both suction and liquid lines to the evaporator to pull a vacuum into them as well Once the system has been pumped down...

Страница 91: ...Blast chiller Service Manual 51 Rev 07 04 2015 6 SCHEMATICS 6 1 SCHEME OF COMPONENTS...

Страница 92: ...6 2 AIRFLOW 6 2 1 Self Contained FRONT SIDE Rev AIRFLOW REQUIREMENTS Self Contained Airflow Requirements FRONT SIDE Air flow ev 07 04 2015 52 Airflow Requirements BACK SIDE Air flow...

Страница 93: ...Blast chiller Service Manual 53 Rev 07 04 2015 Clearance 6 2 2 Remote Airflow Requirements Air flow CONDENSER BOX CONDENSER BOX TOP VIEW REFRIGERANT CONNECTION ELECTRICAL CONNECTION...

Страница 94: ...e condenser box is installed in a false ceiling Better than a n extraction fan is recommended for those ambient where the may exceed 43 C 110 F 1000 39 3 8 AMBIENT MAX TEMP 43 C CONDENSER BOX 1000 39...

Страница 95: ...cooling The quick fittings in the above picture are self closing type allowing hermetic seal of the evaporator circuit The cabinet is already evacuated and tested in the factory hence not requiring a...

Страница 96: ...ll the mentioned components are single phase therefore the unit requires only two hot lines or 1 line and neutral depending on the mains voltage The voltage among lines must be 208V or 220 240V either...

Страница 97: ...Blast chiller Service Manual 57 Rev 07 04 2015...

Страница 98: ...GBF 7 18 11 S GBF 7 24 17 S GBF 10 28 20 S GBF 10 35 25 S GBF 12GN2 1 80 65 S GBF 12GN2 1 110 95 S GBC 15 40 NO FREEZING S GBF 15 40 30 S GBF 15 65 50 S GBC 18 51 NO FREEZING S GBF 18 51 35 S GBF 18...

Страница 99: ...V 50 Hz 1Ph 8 0 R404A 0 870 GBF 7 230V 50 Hz 1Ph 10 5 R404A 0 870 GBF 10 230V 50 Hz 1Ph 11 0 R404A 2 20 GBF 10 400V 50 Hz 3Ph 4 5 R404A 2 20 GBF 12GN2 1 400V 50 Hz 3Ph 4 5 R404A 2 50 GBF 12GN2 1 400V...

Страница 100: ...Rev 07 04 2015 60...

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