Traulsen SmartChill RBC50 User manual

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Traulsen Refrigeration
SERVICE MANUAL
Instructions For The Installation,
Troubleshooting And Repair Of Traulsen
SmartChillTM Equipped Blast Chiller Models
50 lb. Capacity Undercounter Models
100 lb. Capacity Reach-In Models
200 lb. Capacity Roll-In & Roll-Thru Models
-NOTICE-
This Manual is prepared for the use of trained Authorized Traulsen Service Agents and should not be used
by those not properly qualified. 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.
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I. TABLE OF CONTENTS
I.
TABLE OF CONTENTS
1
II.
GENERAL INFORMATION
2
a- Applicable Models
2
b-Introduction
2
c- Operation
2
d-Cleaning
2
e-Wiring Diagrams
2
f-Tool Requirements
2
g-The Serial Tag
2
III.
SPECIFICATIONS
3
a-Equipment Specifications
3
b-Operating Data
3
c-Installation
3
IV.
SMART CHILL CONTROL
4
a-Sequence of Operation
4
a.1 Control Revision Numbers
4
a.2 System Idle
4
a.3 Chill Cycle
4
a.4 Holding
4
a.5 Defrost
4
b-Manual Defrost
4
c-Printing Control Data
4
c.1 Cycle/Batch Data
4-5
c.2 12 Hr Data Log
5
d-SERVICE MENU ACCESS
5
d.1 Introduction
5
d.2 Access Service Menu (75)
5-6
d.3 Access Service Menu (Push Button)
6
f-SERVICE MENU NAVIGATION
6
f.1 Refrigeration Test (REFR/AIR)
6-7
f.2 Probe & Alarm Test (PROBES/ALARM)
7
f.3 Printer(s) Test (PRINTER)
7-8
f.4 Defrost Test (DEF/COIL)
8
f.5 Evaporator Fan Test (FAN)
8
f.6 Display LED Test (DISPLAY)
8-9
g-DIAGNOSTICS MENU
9
g.1 Accessing the Diagnostics Menu
9
g.2 Using the Diagnostics Menu
9
h-FACTORY MENU ACCESS
9
h.1 Introduction
9
h.2 Accessing the Factory Menu (85)
9-10
h.3 Accessing the Factory Menu (Push
Button)
10
i-NAVIGATING THE FACTORY MENU
10
i.1Reset and Serial Number Entry
10
i.2 Printer Selection
10
i.3 Refrigeration Settings
10
i.4 Defrost Settings
11
i.5 Security Code Entry
11
i.6 Machine Size Selection
11
j-ERROR CODES
11
j.1 Current Probe is Bad
11
j.2 Chill Time Exceeded
11
j.3 Defrost Sensor Failure
11-12
j.4 No Product Probes
12
j.5 Over Temperature
12
j.6 Product Detected
12
j.7 Air Temp Sensor Not Reading
12
j.8 Record Printer Media
12
j.9 Label Printer Media
12
V.
CONTROL COMPONENTS
13
a-COMPONENT IDENTIFICATION & OPERATION
13
a.1 Control /Relay Box
13
a.2 Relay Board
14
a.3 Power Supply
15
a.4 Smart Chill Control (Mother Board)
16
a.5 Control/Relay Box RBC50 2008 –
Current
17
a.6 Relay Board RBC50 2008-Current
18
VI.
SERVICE PROCEDURES RBC50
19
a. Indentify 2008 –Current vs Pre 2008
19
b. Sensors & Probes
19
b.1 Air & Coil Sensor Locations RBC50
(pre 2008)
19
b.2 Air & Coil Sensor Locations RBC50
(2008 –Current)
19
b.3 Sensor & Probe Troubleshooting
19
c. RBC50 Power Pack Removal (Pre 2008)
19
d. RBC50 Evaporator Access (Pre 2008)
20
e. RBC50 Evaporator Access (2008 –Current)
20
VII.
SERVICE PROCEDURES RBC100
20
a. Sensors & Probes
20
a.1 Air & Coil Sensor Locations RBC100
20
a.2 Sensor & Probe Troubleshooting
20
b. Access Evaporator/Refrig Sys
20
b.1 RBC100 Exploded View
20
b.2 Accessing the Evaporator Sensors
20
b.3 Access the Evaporator, Defrost Heater
& Thermal Fuse
20
b.4 Remove Refrigeration System
21
VIII.
SERVICE PROCEDURES RBC200
21
a. Sensors & Probes
21
a.1 Air & Coil Sensor Locations RBC200
21
a. 2 Sensor & Probe Troubleshooting
21
b. RBC200 Evaporator Access
21
IX.
WIRE DIAGRAM RBC50 2008-CURRENT
22
X.
WIRE DIAGRAM RBC50 2003-2007
23
XI.
WIRE DIAGRAM RBC100
24
XII.
WIRE DIAGRAM RBC200
25
XIII.
TROUBLESHOOTING
26-30
XIV.
QUICK REFERENCE GUIDE
31
XV.
DATA LOG DIAGNOSTICS
32
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II. GENERAL INFORMATION
II. a - APPLICABLE MODELS:
This manual applies to the following Traulsen models:
RBC50 Undercounter Blast Chiller Models
RBC100 Reach-In Blast Chiller Models
RBC200 Roll-In Blast Chiller Models
RBC200RT Roll-Thru Blast Chiller Models
PLEASE NOTE: This manual refers to the above mod-
els built after June 2003, equipped with the Smart Chill
control. For information regarding models built prior to
that date please contact the factory.
In addition, models UBC50, RBC400 and RBC400RT are
not covered by the procedures listed in this manual.
Please contact the factory for more information.
II. b - INTRODUCTION:
Blast Chillers are food processing refrigerators de-
signed for rapid chilling of product from 135 F to 37 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
specifications contained within this manual are based
on the latest product information available at the time
of printing.
II. c - OPERATION:
Refer to the instructions contained in the Owner’s
Manual, form number TR35850, for specific operating
instructions.
II. d - 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 whisk broom. Care must be taken not to
damage the condenser coil fins. For more information
please refer to section “IV. a - IV c” of the Blast Chill
Owner’s Manual.
II. e - WIRING DIAGRAMS:
Refer to the wiring diagrams on pages 20 thru 22 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 field 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:
II.f - TOOL REQUIREMENTS (CONT):
•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 affixed 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 at
the front top corner on the right interior wall on all
blast chiller models. An example is shown below.
FORT WORTH, TX.
SERIAL
MODEL
VOLTS
Hz
PH
TOTAL CURRENT
AMPS
MINIMUM CIRCUIT
AMPS
MAXIMUM OVER CURRENT 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)
R
R
AW-03118
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
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III. SPECIFICATIONS
III. a - EQUIPMENT SPECIFICATIONS:
DIMENSIONS
RBC50
(2003 -2007)
RBC50
(2008 - CURRENT)
RBC100
RBC200
RBC200RT
Length - Overall in.
57-1/2
54
34
48-1/2
48-1/2
Depth - Overall in.
34-1/4
34-7/16
41-5/8
37-1/2
41-1/8
Height - Overall in.
341
34
80-1/8
89-1/2
89-1/2
1= Height shown to work top, height over
control is 53”.
III. b - OPERATING DATA:
DATA
RBC50
(2003 -2007)
RBC50
(2008 - CURRENT)
RBC100
RBC200
RBC200RT
H.P.1
1/2 HP
1 HP
1/2 HP
3/4 HP
3/4 HP
BTU1
1350
4400
2280
3880
3880
H.P.2
1/2HP
n/a
1-1/4 HP
n/a3
n/a3
BTU (-10 degree F evaporator)
2
1350
n/a
5460
18,700
18,700
Refrigerant1
R-404A
R-404A
R-404A
R-404A
R-404A
Refrigerant2
R-404A
n/a
R-404A
n/a3
n/a3
Refrigerant Charge1
20 oz.
28 oz.
49 oz.
20 oz.
20 oz.
Refrigerant Charge2
20 oz.
n\a.
64 oz.
n/a3
n/a3
Cond Unit Amp Draw (RLA)
1
n/a
11.7
9.6
15.2
15.2
Cond Unit Amp Draw (RLA)
2
n/a
n/a
5.7
30.7
30.7
Unit Voltage
115/60/1
115/60/1
220/115
115/60/1
1
115/60/11
Full Load Amps
9.3 (per unit)
13.3
15.1
15.21
15.21
1= Self-Contained Holding or Primary Compressor.
2= Blast Chilling or Secondary Compressor.
3= These may vary depending upon type of remote condensing
III. c - REFRIGERATION SYSTEM INSTALLATION:
All Traulsen blast chillers, with the exception of model
RBC50, require the use of a floor drain or floor
mounted condensate evaporator for condensate
removal. Refer to “Section III. h” of the blast chill
owner’s manual for more information.
Remote refrigeration installation requirements apply
only to models RBC200 and RBC200RT. A remote con-
densing unit, operating on R-404A refrigerant, is re-
quired for Blast Chill operation on these models. The
remote condensing unit(s) should be capable of pro-
viding 18,700 BTU/hr @ -10 F suction and 90 F ambi-
ent at the evaporator coils of the Blast Chill section.
4 HP air-cooled and 3 HP water-cooled remote con-
densing units are available from Traulsen as an op-
tional accessory, but please note that these are rated
for use only within a 25 foot radius of the cabinet.
III. c - REF’N SYSTEM INSTALLATION (CONT):
Actual capacity of the remote condensing unit and line
sizing will depend on the length and layout of the con-
necting piping from the remote condensing unit to the
Blast Chill unit. These utilize a 1/2” liquid and 1-1/8”
suction lines. Proper line sizing should be defined by a
qualified refrigeration engineer or technician.
The low pressure cut-out of the remote condensing unit
should be adjusted to obtain an evaporator coil
temperature NO LOWER THAN -
the connecting piping is 40 feet or less, the condens-
ing unit low pressure cut-out settings will be approxi-
mately 15 +/- 2 PSIG cut-out and 25+/- 3 PSIG cut-in.
For more information please contact the factory (800-
825-8220).
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IV. SMART CHILL CONTROL
IV.a –SEQUENCE OF OPERATION:
a.1 –Control Revision Numbers
There are multiple versions of the Smart Chill Control
V1.08 - V2.11. Largely troubleshooting on all versions
will be the same.
a.2 –System Idle:
The Smart Chill control is meant to maintain a median
operating temperature of 37F - 40F when in idle (no
active batches). During this time only the
“Maintenance” or holding system is active with the
exception of the RBC200 which runs the Blast system
ever other cycle. Anytime the display shows to be at
the “Main Menu” the system is in idle.
a.3 –Chill Cycle:
When a standard chill cycle or batch is started the unit
will maintain a median temperature of 10F-14F until all
product is chilled to 37F, if using food probes, or until
preset time is complete. During this time both the
“Maintenance” and “Blast” systems will be active.
a.4 –Holding:
Once all product reach 37F or below, or the preset time
is completed, the unit will begin what is called a
“Holding” mode. During “Holding” the unit will again
maintain 37F - 40F but both systems continue to
operate because of the known product load. Once the
operator removes the product and acknowledges the
removal of product via the control the system returns
to idle or the “Main Menu”.
a.5 –Defrost:
Models RBC100, RBC200, and RBC200RT have electric
defrost. Models RBC50 have hot gas defrost. On all
units defrost is scheduled to occur every 3 hrs and
terminates at a 50F coil temperature. RBC100, RBC200
and RBC200RT have a max defrost duration 40 minutes
while the RBC50 has a max defrost duration of 15
minutes. Once a defrost is initiated it cannot be
overridden or terminated by any method other than
meeting control parameters (time or temperature). The
Smart Chill control WILL NOT initiate a defrost cycle
during a chill cycle. Rather it will flash DEF REQD in
the top left portion of the display screen when a defrost
is required during a chill cycle. Once the chill cycle
completes the unit will then initiate a defrost. The
Smart Chill control WILL initiate a defrost during a Hold
mode.
For more information regarding additional operating
modes and conditions please reference the Owner’s
Manual.
IV.b –Manual Defrost:
To initiate a manual defrost the system must be in
idle and at the main menu. Once a defrost is
initiated it cannot be overridden and terminated by
IV.b –MANUAL DEFROST (CONT):
any method other than meeting control parameters
(time or temperature).
1. From the “MAIN MENU” select “MORE”
2. Select “DEFROST”
3. Select “START” the unit should now be in a defrost.
IV.c –PRINTING CONTROL DATA:
c.1 –Cycle/Batch Data:
All batches run “BY TEMP” or using “EASY START”
will be stored in memory. At any time we can access
this data and reprint Cycle/Batch data using the
following instructions.
1. From the “MAIN MENU” select “MORE””
2. Select “Print”
(Continued on next page)
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V. SMART CHILL CONTROL
IV.c –PRINTING CONTROL DATA (CONT) IV.c –PRINTING CONTROL DATA (CONT)
3. Select desired probe to retrieve data from, 1,2, or, 3,
then select date and time of Cycle/Batch
4. Select “PRINT”. A full log of the selected
Cycle/Batch should print.
c.2 –12 Hr Data Log:
The Smart Chill control records data from all inputs and
outputs in five minute increments. At any time this
data can be retrieved in the form of a 12 Hr data log. A
12 Hr data log is a useful tool when troubleshooting
intermittent errors or when all other avenues have been
exhausted. You may analyze the data yourself using
the reference on page 33, Data Log Diagnostics
Explanation or you may contact Traulsen Technical
Support and we will analyze it for you. Ph. 800-825-
8220 Fax. [phone]. To print a data log follow the
instructions below.
1. From the “MAIN MENU” select “MORE”
2. Select “Print”
3. Select “PRINT: CYCLE” will change to “PRINT:
DATA”
4. Select appropriate date and time to begin the 12 Hr
log
5. Select “PRINT” a 12 Hr log should begin to print via
the record printer
IV.d –SERVICE MENU ACCESS:
d.1 - Introduction
The service menu can be used to assist in
troubleshooting a Blast Chiller. There are two ways to
access the service menu (see d.2 & d.3). Once the
service menu has been accessed all relay outputs
should de-energize. A technician may then cycle
components individually for troubleshooting purposes.
d.2 –Access Service Menu (75)
To access the Service Menu via the control touch pad
reference the following instructions.
1. From the “MAIN MENU” select “MORE”
(Continued on next page)
PRINT: CYCLE
4/30 08:00
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6
IV. SMART CHILL CONTROL
IV.d –SERVICE MENU ACCESS (CONT):
2. Select “SET UP”
3. Change the “PASSWORD (PIN)” to “75” using the up
or down arrow adjacent to “PASSWORD (PIN)”
(Note: “PRESET SUPERVISOR” must be selected.)
4. Press and release the TOP LEFT, TOP RIGHT, and
BOTTOM RIGHT buttons, all three simultaneously.
5. The display will advance to the “LAST DATE OF
SERVICE” screen. From this screen you can update
the service date by selecting “UPDATE, set the internal
clock by selecting “SET CLOCK” (see owner’s manual
for set clock instructions), or Select “NEXT” to advance
to the “SERVICE MENU”.
6. You should now have access to the “SERVICE
MENU” (See section IV.f –Service Menu Navigation, for
more information on the Service Menu).
d.3 Access Service Menu (Push Button)
To a access the service menu without using the control
IV.d –SERVICE MENU ACCESS (CONT)
WARNING: This procedure requires that the control
box be open while the power is supplied to the unit.
Exercise extreme caution at all times.
CAUTION: Electro-static discharge will damage the
control board. Use an anti-static grounding kit when
servicing the computer control box.
1. Remove thumb screws and control cover.
2. Remove five phillips head screws from control
mounting brackets to access the rear of the control.
3. Disconnect power to the control by unplugging the 3
pin connector (wire color: red, white, black) labeled
J12, PWR on the mother board.
4. Locate the push button labeled TEST on the control
mother board.
5. Push and hold the TEST button, then reconnect the 3
pin connector, J12 PWR, while still holding the TEST
button. Once power has been restored release the test
button and check control display. You should now
have access to the “SERVICE MENU” (See section IV.f -
Service Menu Navigation, for more information on the
Service Menu).
IV.f –SERVICE MENU NAVIGATION:
f.1 –Refrigeration Test (REFR/AIR)
Select “REFR/AIR” from the “SERVICE MENU” to
access the refrigeration test menu.
touchpad reference the following instructions.
75
75
LAST DATE OF SERVICE
XX/XX/XXXX
UPDATE
SET CLOCK NEXT
SERVICE MENU EXIT
REFR/AIR DEF/COIL
PROBES/ALARM FAN
PRINTER DISPLAY
J12
PWR
TEST
SERVICE MENU EXIT
REFR/AIR DEF/COIL
PROBES/ALARM FAN
PRINTER DISPLAY
REFR/AIR
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IV. SMART CHILL CONTROL
IV.f –SERVICE MENU NAVIGATION (CONT):
Pressing the button next “SOLENOID” will cycle
refrigeration in the following order starting from the
OFF position:
Press Once: Maintenance compressor only
Press Twice: Maintenance compressor and Low Fan
(NOTE: Low Fan relay energizes High Speed on Blower(s))
Press Three Times: Maintenance compressor, Blast
Compressor, and High Fan
Press Four Times: Return to all OFF
Select “BACK” to return to the “SERVICE MENU” and
you may select “EXIT” from the “SERVICE MENU” to
return to the “MAIN MENU”
Selecting “COMP USAGE” will advance the display to
the “CLEANED CONDENSER COIL” screen.
The “CLEAN CONDENSER COIL” screen gives a value
in hours and minutes of the maintenance compressors
run time. This can be reset to 0 by selecting
“CLEANED COIL”. Select “BACK” to return to the
“REFRIGERATION TEST” menu.
f.2 –Probe Alarm Test (PROBES/ALARM)
Select “PROBES/ALARMS” from the “SERVICE
MENU” to access the product probe and audible
alarm test menu.
IV.f –SERVICE MENU NAVIGATION (CONT):
Product probes 1,2,&3 will be displayed in real time. If
a probe is shorted - - - will be displayed next to the
probe number. If a product probe is open or dis-
connected nothing will be displayed next to the probe
number.
Pressing the button next to “ALARM=OFF” will activate
the audible alarm test. Pressing the button next to
“ALARM=ON” will deactivate the audible alarm test.
Select “BACK” to return to the “SERVICE MENU”.
f.3 –Printer(s) Test (PRINTER)
Select “PRINTER” from the “SERVICE MENU” to
access the printer(s) test menu.
Note: If no Label printer present “LABEL: READY” will not
be displayed
Pressing the button next to “RECORD READY” or
“LABEL READY” will run a test print for the printer
selected. The test print will include a system
diagnostic as shown below.
REFRIGERATION TEST:
SOLENOID: OFF
CABINET TEMP: 37F
COMP USAGE BACK
SOLENOID: OFF
REFRIGERATION TEST:
SOLENOID: OFF
CABINET TEMP: 37F
COMP USAGE BACK
COMP USAGE
CLEAN CONDENSER COIL:
24 DAYS & 20 HRS
SINCE LAST CLEANING
CLEANED COIL BACK
SERVICE MENU EXIT
REFR/AIR DEF/COIL
PROBES/ALARM FAN
PRINTER DISPLAY
PROBES/ALARM
PRODUCT PROBE TEMPS:
1 45 F 44 F 3
2 44 F
ALARM=OFF BACK
PRODUCT PROBE TEMPS:
1 - - - 3
2 44 F
ALARM=OFF BACK
SERVICE MENU EXIT
REFR/AIR DEF/COIL
PROBES/ALARM FAN
PRINTER DISPLAY
PRINTER
PRINTER TEST:
RECORD: READY
LABEL: READY
BACK
SOFTWARE VERSION: 2.11
RUN CYCLES: 5 CYCLES
SINCE DEF: 5 CYCLES
MAXIMUM AIR: 78F
MINIMUM AIR: 0F
FAILURES:
PRINTER YES
PROBE NO
INTERRUPTED NO
CONTROL NO
OVER TEMP NO
SYSTEM FAIL NO
DEFR. HEAT YES
FLASH MEM. NO
(Continued on next page)
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IV. SMART CHILL CONTROL
IV.f –SERVICE MENU NAVIGATION (CONT):
Upon completion on a successful print the control will
display “SUCCESS” or “ERROR” if the print is
unsuccessful.
Select “BACK” to return to the “SERVICE MENU”.
f.4 Defrost Test (DEF/COIL)
Select “DEF/COIL” from “SERVICE MENU” to access
the defrost test menu.
IV.f –SERVICE MENU NAVIGATION (CONT):
normally displayed. If a coil temperature sensor is
shorted, - - - will be displayed were the temperature
value is normally displayed.
Select “BACK” to return to the “SERVICE MENU”.
f.5 Evaporator Fan Test (FAN)
Select “FAN” from the “SERVICE MENU” to access the
evaporator fan test menu.
Pressing the button next “HEATER: OFF” will cycle the
defrost heaters in following order starting from the
“OFF” position.
Press Once: Blast Coil Heaters
Press Twice: Maintenance Coil Heaters
Press Three Times: Both Coil Heaters
Press Four Times: Return to all Off
(Note: RBC50 will only cycle “BOTH” due to hot gas defrost
vs electric on RBC100 & RBC200)
The defrost test menu will also display both coil
temperatures in real time.
Pressing the button next to “FANS: OFF” will cycle the
evaporator fans in the following order starting from the
“OFF” position.
Press Once: Low fan relay
Press Twice: High fan relay
Press Three Times: Return to all Off
Select “BACK” to return to the “SERVICE MENU”.
f.6 Display Test (DISPLAY)
Select “DISPLAY” from the “SERVICE MENU” to initiate
a display LED test.
If a coil temperature sensor is open the the temperature
value will display no value or, depending on revision,
will display “OPEN” were the temperature value is
(Continued on next page)
PRINTER TEST:
RECORD: SUCCESS
LABEL: ERROR
BACK
SERVICE MENU EXIT
REFR/AIR DEF/COIL
PROBES/ALARM FAN
PRINTER DISPLAY
DEF/COIL
DEFROST TEST:
HEATER: OFF
BLAST= 37F
MAINT=32F BACK
DEFROST TEST:
HEATER: OFF
BLAST= 37F
MAINT=32F BACK
HEATER: OFF
DEFROST TEST:
HEATER: OFF
BLAST= OPEN
MAINT= - - - BACK
DEFROST TEST:
HEATER: OFF
BLAST= 37F
MAINT=32F BACK
SERVICE MENU EXIT
REFR/AIR DEF/COIL
PROBES/ALARM FAN
PRINTER DISPLAY
FAN
EVAP FAN TEST:
FANS: OFF
BACK
EVAP FAN TEST:
HEATER: OFF
BACK
FANS: OFF
SERVICE MENU EXIT
REFR/AIR DEF/COIL
PROBES/ALARM FAN
PRINTER DISPLAY
DISPLAY
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IV. SMART CHILL CONTROL
IV.f –SERVICE MENU NAVIGATION (CONT):
All LED’s should be illuminated. Press any button to
return to the “SERVICE MENU”.
IV.g –DIAGNOSTICS MENU:
g.1 Accessing the Diagnostics Menu
To access the Diagnostics Menu begin by accessing
the Service Menu, see section IV.d (page 5). From the
Service Menu select “SERVICE MENU” to access the
Diagnostics Menu.
g.2 Using the Diagnostics Menu
The Diagnostics Menu consist of 5 available para-
meters to aid in the troubleshooting and diagnosis
processes.
1. “MAXIMUM” = Maximum air temp recorded
2. “MINIMUM” = Minimum air temp recorded
3. “RUN CYCLES” = Total compressor run cycles
4. “SINCE DEF” = Total compressor run cycles since
the last defrost
5. “FAILURE” = Any error codes the control has exper-
ienced (for more information on error codes see pg 11.)
The value of each parameter will be displayed in the
bottom left corner of the menu when selected. To select
a parameter press the corresponding button. When
selected a parameters value can be reset by pressing
clear. It is advisable to clear these parameters every
time a unit is serviced so the next time service is
needed the parameter values are valid and useful.
When selecting “FAILURE” press the bottom left button
to scroll though all error codes. If none is displayed
then no error codes have been recorded since last
cleared.
To return to the “SERVICE MENU” select “DIAGNO-
STIC”.
IV.f –DIAGNOSTIC MENU (CONT):
Select “EXIT” to return to the “MAIN MENU”.
IV.h –FACTORY MENU ACCESS:
h.1 Introduction
The Factory Menu is used to set up basic equipment
parameters such as; printer function, temperature
differentials, defrosts schedule, machine size, and
machine serial number. There are two ways to access
the Factory Menu (see h.2 & h.3). Once the service
menu has been accessed all relay outputs should de-
energize.
h.2 Access the Factory Menu (85)
To access the Fervice Menu via the control touch pad
reference the following instructions.
1. From the “MAIN MENU” select “MORE”
2. Select “SET UP”
3. Change the “PASSWORD (PIN)” to “85” using the up
or down arrow adjacent to “PASSWORD (PIN)”
(Note: “PRESET SUPERVISOR” must be selected.)
(Continued on next page)





SERVICE MENU EXIT
REFR/AIR DEF/COIL
PROBES/ALARM FAN
PRINTER DISPLAY
SERVICE MENU
DIAGNOSTIC MAXIMUM
RUN CYCLES MINIMUM
SINCE DEF FAILURE
24 CYCLES CLEAR
DIAGNOSTIC MAXIMUM
RUN CYCLES MINIMUM
SINCE DEF FAILURE
24 CYCLES CLEAR
DIAGNOSTIC
SERVICE MENU EXIT
REFR/AIR DEF/COIL
PROBES/ALARM FAN
PRINTER DISPLAY
85
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IV. SMART CHILL CONTROL
IV.h –FACTORY MENU ACCESS (CONT):
4. Press and release the TOP LEFT, TOP RIGHT, and
BOTTOM RIGHT buttons, all three simultaneously.
5. The display will advance to the “FACTORY
SETTINGS VERSION #.##” screen. You now have
access to the “FACTORY MENU”. (See section IV.I –
Factory Menu Navigation, for more information on the
Factory Menu).
IV.h.3 –FACTORY MENU ACCESS
Exercise extreme caution at all times.
CAUTION: Electro-static discharge will damage the
control board. Use an anti-static grounding kit when
servicing the computer control box.
1. Remove thumb screws and control cover.
2. Remove five phillips head screws from control
mounting brackets to access the rear of the control.
3. Disconnect power to the control by unplugging the 3
pin connector (wire color: red, white, black) labeled
J12, PWR on the mother board.
4. Locate the push button labeled FACT on the control
mother board.
5. Push and hold the FACT button, then reconnect the 3
pin connector, J12 PWR, while still holding the TEST
button. Once power has been restored release the test
button and check control display. You should now
have access to the “FACTORY MENU” (See section
IV.I–Factory Menu Navigation, for more information on
the Factory Menu).
IV.i - NAVIGATING THE FACTORY MENU
i.1 Reset and Serial Number Entry
Upon accessing the Factory Menu you will be at the
Reset and Serial Number Entry screen. Here can reset
all default settings by pressing the button labeled
“RESET”. After doing this you may need to re-enter the
serial number of the unit. (Note: serial number is for
reference only and is not critical to unit function).
To enter the serial number use the to change the
value of the current digit. Press the to advance to
the next digit. For serial numbers with 5 digits between
the T and the A leave the digit after the T at 0. Press
“NEXT” to advance to the Printer Selection Screen.
i.2 Printer Selection
The Printer Selection Screen allows you to turn on or
off specified printers. Depending on revision you
options may differ slightly. Most versions only allow
the Label printer to be turned on or off. Version 2.11 or
higher will allow for both Label and Record Printers to
be toggled on or off. To turn a printer on or off select
button to the left or right of the printer you wish to edit.
“YES” to activate printer “NO” to deactivate printer.
Press “NEXT” to advance to the Refrigeration Settings
Screen or “BACK” to return to the previous screen.
i.3 Refrigeration Settings
The Refrigeration Settings Screen allows you to adjust
the following settings
Blast or chilling temperature differential
Holding or maintenance temperature
differential
Compressor Anti Short cycle
To adjust any of these settings use the up or down
arrows next to the appropriate parameter.
Press “NEXT” to advance to the Defrost Settings
Screen or “BACK” to return to the previous screen.
85
J12
PWR
FACT
FACTORY SETTINGS
VERSION 2.11
S/N: T 0 0 0 0 0 0 A 0 0
RESET NEXT
RECORD PRINTER [YES]
LABEL PRINTER [NO ]
BACK NEXT
BLASTING DIFF [4 ] F
HOLDING DIFF [3 ] F
ANTI-SHORT [1 ]
BACK NEXT
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IV. SMART CHILL CONTROL
IV.i - NAVIGATING THE FACTORY MENU (CONT):
i.4 Defrost Settings
The Defrost Settings Screen allows you to adjust the
following settings
Defrost Duration (minutes)
Defrost Termination Temp (degrees F)
Defrost Frequency (hours)
To adjust any of these settings use the up or down
arrows next to the appropriate parameter.
Press “NEXT” to advance to the Security Code Entry
Screen or “BACK” to return to the previous screen.
i.5 Security Code Entry
From here you can choose to exit and save your
current settings or enter the security code to advance
to the Machine Model Selection Screen.
To exit the Factory Menu select “EXIT”. To advance to
the Machine Model Selection Screen enter the security
code by using the to change the current digit. Use
the to advance to the next digit. Select “ENTER”
when the correct code has been entered.
The security code is the first 6 numerical digits in the
serial number after the T reversed.
If the security code is entered incorrectly the following
will be displayed.
i.6 Select Machine Size
When the correct security code is entered the screen
will advance to the Machine Model Selection Screen.
Selecting “RESET” will default the “MACHINE SIZE”
to 100. To change the machine size select the
IV.i- NAVIGATING THE FACTORY MENU (CONT):
or next to “MACHINE SIZE” to switch between 50,
100, and 200. When done select “EXIT”.
When exiting the Factory Menu you will be prompted to
save any settings changes you may have made.
Select “YES” to save changes or “NO” to omit any
changes made.
IV. j –ERROR CODES
j.1 Current Probe is Bad
In the event a Food Probe error (open or short) during a
“BY TEMP” or “EZ START” cycle, the control
automatically switches to a “BY TIME” cycle. The timer
will begin to countdown from 90 minutes, at which time
the cycle will be complete. A failure of one probe will
force the entire batch into a “BY TIME” cycle and all
recorded cycle data will be lost for that batch.
j.2 Chill Time Exceeded
In the event maximum chill time of 6hrs is exceeded,
the control switches to the holding mode. Maximum
allowable chill time to ensure safe product chilling
according to HACCP standards is 6hrs.
j.3 Defrost Sensor Failure
(Continued on next page)
DEFROST TIME [4 0]
DEFR. TEMP [ 5 0] F
DEFR. INTVL. [3 ]
BACK NEXT
ENTER SECURTIY CODE
FOR NEXT SETTINGS:
[0 0 0 0 0 0]
EXIT ENTER
INCORRECT CODE!
PLEASE CALL TRAULSEN
FOR INFORMATION
NEXT
MACH. MODEL [RBC ]
MACHINE SIZE [100 ]
RESET EXIT
FACTORY SETTINGS
DO YOU WISH TO SAVE
THESE NEW SETTINGS?
NO YES
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12
IV. SMART CHILL CONTROL
IV. j –ERROR CODES (CONT)
Defrost Sensor Failure occurs whenever a coil sensors
fails (open or short) during a defrost cycle or if one or
both coil sensors do not reach the 50F termination
temperature before defrost times out.
j.4 No Product Probes
No Product Probes occurs when a “BY TEMP” or “EZ
START” cycle is selected but no probes are connected.
The unit will return to idle.
j.5 Over Temperature
In the event the cabinet air temperature reaches 160F
for 10 minutes or more the control will shut down all
relays and lock out until power to the unit is cycled.
This is to guard against possible damage caused by a
complete refrigeration failure.
j.6 Product Detected
Product Detected occurs when a food probe rises 40F
above cabinet temp for more than 10 minutes
indicating someone has introduced hot product into
the chill but failed/forgot to start a chill cycle. The unit
automatically switches to a refrigeration holding mode.
j.7 Air Temp Sensor Not Reading
In the event the cabinet air temperature sensor opens
or shorts the control will trigger the “AIR TEMP
SENSOR” alarm, shut down all relays and lock out until
IV –ERROR CODES (CONT)
the power the unit is cycled. The defective sensor
must be repaired or the alarm will reoccur on power up.
i.8 Record Printer Media Error
“RECORD PRINTER MEDIA ERROR” occurs anytime
the Record Printer fails to print.
i.9 Label Printer Media Error
“LABEL PRINTER MEDIA ERROR” occurs anytime the
Record Printer fails to print.
PRINTER ERROR
RECORD PRINTER ERROR
CHECK PRINTER MEDIA
PRINTER ERROR
LABEL PRINTER ERROR
CHECK PRINTER MEDIA
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V. CONTROL COMPONENTS
V. a –COMPONENT IDENTIFICATION & OPERATION
(CONT)
a.1 Controls/Relay Box
Controls/Relay Box Operation
House all control components except Smart
Chill Control.
Ledger
1
Toggle Switch ON/OFF (Control Voltage Only!)
2
RS232 Communication Port
3
Relay Board
4
DC Power Supply
5
Terminal Board
6
4.0 mF Run Capacitors For Blowers
7
1CR Maintenance Compressor Relay
8
2CR Blast Compressor Relay
9
3CR Maintenance Defrost Relay
10
4CR Blast Defrost Relay (RBC200 Only)
1
2
3
4
5
6
7
8
9
10
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V. CONTROL COMPONENTS
V. a –COMPONENT IDENTIFICATION & OPERATION
(CONT)
a.2 Relay Board
Relay Board Operation
Conditions and distributes DC power for the
DC control components
Receives DC signals from Smart Chill control
and actuates Triacs to energize control relay
coils
LED indicators on board indicate which Triac is
energized
Jumper Pins adjacent to LED indicators to
manually operate Triacs
Ledger
1
14VDC input
2
115vac Triac Outputs to Control Relays
3
High Fan Relay
4
Low Fan Relay
5
12VDC Triac gate signal from Smart Chill
6
LED indicators & Jumper
7
Pins DC power distribution to controls
8
Voltage test points
3
4
1
2
5
7
6
8
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V. CONTROL COMPONENTS
V. a –COMPONENT IDENTIFICATION & OPERATION
(CONT)
a.3DC Power Supply
DC Power Supply Operation
115vac input/primary
14-15VDC output/secondary
Ledger
1
115vac input
2
14-15VDC output
3
Output adjustment pot
4
4amp 250vac glass fuse
1
2
4
3
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V. CONTROL COMPONENTS
V. a –COMPONENT IDENTIFICATION & OPERATION
(CONT)
a.4 Smart Chill Control (Mother Board)
Mother Board Operation
Performs all control logic
Send/Receives information to/from printers
Receives input from Food Probes and Air
and Coil Sensors
Send/Receives information from Smart Chill
touch pad and display
Sends 12VDC signal to activate Triacs on
Relay Board
Push button override to Service and Factory
Menus
Ledger
1
Display Power
2
Ribbon Cable to Touch Pad
3
Expansion Port (For Optional NAFEM Daughter Board)
4
Factory Menu Push Button
5
Service Menu Push Button
6
Program Port (Unused in Field)
7
Real Time Clock Battery
8
Food Probe Inputs
9
System Sensor Inputs
10
5VDC & 12VDC Control Power Input
11
12VDC Control Outputs
12
RS232 Communication Port
13
8.5VDC Printer Power Input
14
Label Printer Power Port (PTR 2, RED)
15
Record Printer Power Port (PTR 1, RED)
16
Record Printer Communication Port (PTR 1, WHT)
17
Label Printer Communication Port (PTR 2, WHT)
1
2
3
4
5
6
7
8
9
10
11
12
13
16
17
15
14
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V. CONTROL COMPONENTS
V. a –COMPONENT IDENTIFICATION & OPERATION
(CONT)
a.5 RBC50 Control/Relay Box 2008-Current
RBC50 Controls/Relay Box Operation
House all control components except Smart
Chill Control.
House start components for compressor
Ledger
1
RS232 Communication Port
2
Relay Board
3
DC Power Supply
4
Compressor Start Capacitor
5
Compressor Run Capacitor
6
Terminal Block
7
4.0 mF Run Capacitors For Blowers
8
Compressor Start Relay
9
Condenser Fan Motor Relay
10
1CR Compressor Relay
11
2CR Defrost Relay
1
2
3
4
5
6
7
8
9
10
11
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V. CONTROL COMPONENTS
V. a –COMPONENT IDENTIFICATION & OPERATION
a.6 Relay Board RBC50 2008-Current
Relay Board Operation
Conditions and distributes DC power for the
DC control components
Receives DC signals from Smart Chill control to
energize 12VDC control relay coils
LED indicators on board indicate which 12VDC
output is energized
Jumper Pins adjacent to LED indicators to
manually operate 12VDC outputs
Ledger
1
14VDC input
2
High Fan 115vac output
3
12VDC outputs to control relays
4
12VDC output signal from Smart Chill
5
LED indicators & jumper pins
6
DC power distribution to controls
7
Voltage Test Points
1
2
3
4
5
6
7
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VI. SERVICE PROCEDURES RBC50
VI.a –IDENTIFY 2008 –CURRENT vs PRE 2008
Pre 2008
2008 –Current
VI.b - SENSORS AND PROBES
b.1 Air & Coil Sensor Locations RBC50 (pre 2008)
Air Sensor: Green
Located in the return air of duct of the left or
maintenance system
Maintenance Coil Sensor: Blue
Located in the evaporator coil of the left or
maintenance system
Blast Coil Sensor: Yellow
Located in the coil of the evaporator coil of
the right or blast system
(No image available.)
b.2 Air & Coil Sensor Locations RBC50 (2008-Current)
1. Air Sensor: Green
Located in the evaporator housing in the
return air stream
2. Maintenance Coil Sensor: Blue
Located in the top center of the evaporator
coil
3. Blast Coil Sensor: Blue
Located in the top center of the evaporator
coil
VI.b - SENSORS AND PROBES (CONT)
b.2 Air & Coil Sensor Locations RBC50 (2008-Current)
b.3 Sensor and Probe Troubleshooting
All probes and sensors should return an Ohm
reading of 32.7K Ohms at 32F or 0C. Test by placing
the sensor or probe tip in ice with a little bit of water
and checking Ohm reading with an Ohm meter.
VI.c –RBC50 POWER PACK REMOVAL(pre 2008)
c.1 RBC50 Power Pack Removal (right or left side)
1. Remove louver assembly
2. Disconnect power and mullion heater plugs
from chassis (bottom right)
3. Remove 4 Phillips head screws securing the
power pack to the cabinet frame.
4. Remove tray slides from interior wall of unit.
5. Remove return air grill located at the bottom of
interior and interior supply plenum located at
top back of interior.
6. Remove return and supply air duct
7. Disconnect all wiring between the power pack
assembly and the control tower.
8. Pull power pack out from the front.
9. Reinstall in reverse order.
EVAP COIL SENSORS(2,3)
CAB SENSOR(1)
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