GEMM BCB15USN Blast Chiller User Manual

INSTRUCTIONS FOR USE

5-10-15 US TRAYS BLAST CHILLER

Serie “NEW RUNNER”

EVJS-824 Control panel version

BCB/05US

BCB/10US

BCB/15US

Manual BCB US Rev00 09-2024

www.gemm-srl.com

BCB US Rev.00 09-2024 pag. 2

Serial Number

BCB US Rev.00 09-2024 pag. 3

INDEX

SAFETY

1.1 – Symbols used

1.2 – General warnings

1.3 – Residual risks

1.4 – Personnel

1.5 – Improper use

1.6 – Safety devices

1.7 – Stop functions

GENERAL INFORMATION

2.1 – Marking

2.2 – Warranty

2.3 – After-sales service

2.4 – How to use and keep the manual

MACHINE DESCRIPTION

3.1 – Technical data

3.2 – Description of blast chiller and it use

3.2.1 – Main parts

3.3 – Noise

3.4 – Ambient conditions

TRANSPORT AND HANDLING

4.1 – Transport

4.2 – Handling the packed blast chiller

4.2.1 – Weight and dimensions

4.2.2 – Means requie

BCB US Rev.00 09-2024 pag. 4

INSTALLATION

5.1 – Preparation for installation

5.2 – Unpacking

5.2.1 – Means required

5.2.2 – Unpacking procedure

5.3 – Handling the blast chiller

5.3.1 – Means required

5.3.2 – Handling the unpacked blast chiller

5.4 – Blast chiller assembly

5.5 – Removal, evacuation and charging procedures

5.6 – Recovey

SETTING UP

6.1 – Connections

6.1.1 – Electrical connection

6.2 – Preliminary checks

6.2.1 – Regulation

USE

7.1 – Use forseen

7.2 – Unforseen use

7.3 – Control panel

7.4 – Control procedures

7.5 – Use procedures

7.6 – Chilling and Freezinh cycle

7.7 – Hard chilling and Soft Freezing cycle

7.8 – Special uses

7.8.1 – Pre-cooling function

7.8.2 – Defrost

7.8.3 – Fish sanitization

7.8.4 – Ice cream hardening

7.8.5 – Recipes

MAINTENANCE AND REPAIR

8.1 – Special precautions

8.2 – Routine maintenance

8.2.1 – Routine maintenance table (tab. 5)

8.2.2 – Cleaning the chamber

8.2.3 – Cleaning the outside of the appliance

BCB US Rev.00 09-2024 pag. 5

8.2.4 – Cleaning the condenser

8.2.5 – Cleaning the core probe

8.3 – Extraordinary maintenance

8.3.1 – Refrigerant equipment

8.3.2 – Electrical components

8.3.3 – Sealed components

8.3.4 – Intrnsically safe components

8.3.5 – Cabling

8.3.6 – Detection of flamable refrigerant

8.3.7 – Reoval and evacuation

8.3.8 – Charging procedures

8.3.9 – Recovery

8.4 – Operating anomalies and faults

8.4.1 – Alarms

8.4.2 – Errors

DECOMISSIONING

10.

9.1 – Preparation for decomissioning

9.2 – Removal and evacuation

9.3 – Recovery

9.4 – Labbeling

DISPOSAL

10.1 – Disposal method

11.

SPARE PARTS

11.1 – Ordering spare parts

12.

APPENDICES

BCB US Rev.00 09-2024 pag. 6

1. – SAFETY

1.1 – SYMBOLS USED

This symbol indicates information and warnings which if not observed could damage the appliance or

compromise the safety of personnel.

This symbol indicates information and warnings regarding electrical devices which if not observed

could damage the appliance or compromise the safety of personnel.

To identify any terminal which is intended for connection to an external conductor for protection

against electric shock in case of a fault, or the terminal of a protective earth (ground) electrode.

To identify the terminals which, when connected together, bring the various parts of an equipment or

of a system to the same potential, not necessarily being the earth (ground) potential, e.g. for local

bonding.

This symbol indicates that the appliance uses flammable refrigerantes.

1.2 – GENERAL WARNINGS

IMPORTANT: before using the appliance read this manual carefully and follow the technical operating

instructions and indications to the letter. The operator must know the position and function of all the

control devices and the characteristics of the blast chiller.

The blast chiller complies with current safety regulations, but improper use may cause damage to

persons and things.

At the time of installation all operatives must be suitably trained in accident hazards, operator safety

devices, general accident prevention regulations described in international directives and the current

law in the countries where the appliance is used. Start-up and use of the appliance must be exclusively

in the hands of trained personnel. The behaviour of operators must in any case scrupulously observe

accident prevention regulations in the country where the appliance is used.

Do not remove or deface the plates fitted to the appliance by the manufacturer.

The blast chiller must not be used if the control panel or any other part is damaged.

Do not obstruct the front and/or rear air vents on the appliance; do not place food to be processed up

against the ventilation grilles or air ducts, or directly on the bottom of the chamber.

Promptly report any anomalies in operation.

Use only accessories recommended by the manufacturer.

BCB US Rev.00 09-2024 pag. 7

Do not store explosive substances such as aerosol cans with a flammable propellant inside the

appliance.

WARNING: Do not use mechanical devices or other means to accelerate the defrosting

process, other than those recommended by the manufacturer.

WARNING: The appliance shall be stored in a room without continuously operating ignition sources

(for example: open flames, an operating gas appliance or an operating electric heater.

WARNING: Do not pierce or burn.

WARNING: Be aware that refrigerants may not contain an odour

WARNING: Do not damage the refrigerating circuit

This appliance is not intended for use by persons (including children) with reduced physical, sensory or

mental capabilities, or lack of experience and knowledge, unless they have been given supervision or

instruction concerning use of the appliance by a person responsible for their safety. Children should be

supervised to ensure that they do not play with the appliance.

Do not expose the appliance to rain or sprays of water.

Routine and extraordinary maintenance that require the electrical box to be opened or even partial

dismantling of the blast chiller must be carried out only after the appliance has been disconnected.

If the supply cord is damaged, it must be replaced with an identical one by the manufacturer, its service

agent or similarly qualified persons in order to avoid a hazard - risk of electric shock.

The manufacturer has no responsibility in the following cases:

− the maintenance plan is not carried out;

− unauthorized alterations and/or operations:

− spare parts used are not original;

− failure to observe even part of the contents of this manual;

− improper use of the appliance.

Any tampering with or unauthorized replacement of one or more appliance parts or components and use of

accessories and consumables different from the original ones can constitute a hazard and relieve the

manufacturer of any civil or penal responsibility.

If in doubt about operation of the appliance, refrain from using it and contact the manufacturer.

1.3 – RESIDUAL RISKS

LOW TEMPERATURE BURN HAZARD

During its operation the appliance runs extremely low temperatures: avoid direct contact with

the internal parts immediately after opening the door.

BCB US Rev.00 09-2024 pag. 8

1.4 – PERSONNEL

This manual is for the use of operators, authorized fitters and maintenance engineers.

Operators must not carry out operations reserved for maintenance engineers or specialised

technicians.

The manufacturer accepts no responsibility for damage deriving from failure to observe this

rule.

- Appliance operator: specialised person who can operate the appliance in normal working conditions by using

the relevant controls. The operator must also be capable of carrying out simple routine maintenance (cleaning,

loading) and starting or resetting the appliance after a power failure.

- Specialised electrician: specialised electrician who has been trained by the manufacturer to work on the

appliance. The specialised electrician must be capable of installing the appliance and operating it in normal

conditions; s/he is qualified to carry out all electrical and mechanical adjustments, maintenance and repairs. S/he

is able to operate with live electrical control boxes and connector blocks.

- Qualified fork-lift operator: person qualified in handling materials on the company’s premises, holder of a licence

for the use of fork-lift trucks.

BCB US Rev.00 09-2024 pag. 9

1.5 – IMPROPER USE

The blast chiller must not be used:

− for purposes different from those given in paragraph 3.2 “Description of blast chiller and its use”;

− with safety systems not working;

− after badly done installation;

− by untrained personnel;

− when maintenance has not been carried out, or has been carried out badly;

− when non-original spare parts are used;

− with damaged power lead and/or electrical socket;

− with obstructed air ducts (ref. 1 fig. 1);

− with the food to be processed placed against the ventilation grilles (ref. 1 fig. 1), air ducts, or on the bottom of the

chamber (ref. 2 fig. 1).

Fig. 1

BCB US Rev.00 09-2024 pag. 10

1.6 – SAFETY DEVICES

Personnel exposed to the hazards inherent in moving parts are protected by special safety devices on the appliance.

− grilles covering the cooling fans (ref. 1 fig. 2);

− grilles covering the condenser unit (ref. 2 fig. 2).

The appliance is also provided with devices to protect the food during processing. Below is a list of the safety devices on

the appliance.

− Sensor reads and signals door opening. If the doors remains open for a presetted time, it will appear on the

display the message “ DOOR OPEN ” combined with a acoustic alarm and the compressor will switch off.

− Sensor (ref. 3 fig. 2) located on cooling circuit signals any overheating of the equipment and places the machine

on standby.

− Differential magnetothermal overload relay for compressor protection: only in three phase equipment.

Fig. 2

BCB US Rev.00 09-2024 pag. 11

1.7 – STOP FUNCTIONS

The entire appliance is controlled by an electronic circuit board. The stop function is represented by the button (ref.

1 fig. 3). Whatever condition the machine is in, holding down the button for 3 seconds sets in standby the machine.

Fig. 3

2 – GENERAL INFORMATION

BCB US Rev.00 09-2024 pag. 12

Thank you for choosing a blast chiller of our production.

Read this manual very carefully and make sure it is available to those who will install, use and maintain the equipment.

2.1 – MARKING

The ID plates are located on the outside of the appliance, in the bottom right-hand corner of the front: Fig. 4 below shows

copies.

Fig. 4

BCB US Rev.00 09-2024 pag. 13

2.2 – WARRANTY

The warranty covering the various parts of the appliance is valid from the date on the relative delivery note and is as

described in the sales agreement.

The warranty does not cover damage to the appliance caused by:

- transport and/or handling;

- operator errors;

- lack of the maintenance described in this manual;

- faults and/or breakages that cannot be traced to faulty operation of the appliance;

- maintenance operations carried out by unqualified personnel;

- improper use.

2.3 – AFTER-SALES SERVICE

Please contact the manufacturer directly for any needs regarding use, maintenance or ordering of spare parts, and specify

the identification of the appliance given on the ID plate.

2.4 – HOW TO USE AND KEEP THE MANUAL

The purpose of this manual is to provide all the information necessary to ensure proper use of the appliance in complete

safety and independence.

The manual is sub-divided into chapters with paragraphs and sub-paragraphs: the contents page is easily consulted to find

any aspect of interest.

The material in this document is provided exclusively for the purpose of information and may be altered without notice.

Although great attention is paid to drawing up the manual, the manufacturer is not responsible for damage deriving

from errors, omissions or the use made of the information herein.

Keep this manual and all the documentation in the appendices in good condition, legible and complete in all its parts; keep

it close to the equipment in an accessible place known to all operators.

BCB US Rev.00 09-2024 pag. 14

3 – MACHINE DESCRIPTION

3.1 –TECHNICAL DATA

Model

BCB/05US

BCB/10US

External

dimensions

inches

33.9 X 32.4 X 37.8

33.8 X 34.7 X 61.4

Weight

238

348

Trays

No.

5 (26X18'')

10 (26X18'')

Max load for trays

Chamber

temperature

°F

203 / - 40

Output

44 (+ 149 °F ÷ + 37 °F); 26 (+ 149 °F ÷ 0 °F)

75 (+ 149 °F ÷ + 37 °F); 48.5 (+ 149 °F ÷ 0

°F)

Gas

R290

R404A

Compressor power

1 1/2

Max. absorbed

courrent

Power supply

voltage

Volt 1x115 ~ 60 Hz

Volt 1x230 ~ 60 Hz

Electricity supply

3x12AWG – NEMA 5-20P – 9ft

3x12AWG – NEMA 6-20P – 9ft

Tab. 1/a

Fig. 5/a

BCB US Rev.00 09-2024 pag. 15

Fig. 5/b

BCB US Rev.00 09-2024 pag. 16

Model

BCB/15US

External dimensions

inch

33.9 X 34.6 X 61.4

Weight

500

Trays

No.

15 (26X18'')

Max load for trays

Chamber temperature

°F

203 / - 40

Output

81.5 (+ 149 °F ÷ + 37 °F); 53 (+ 149 °F ÷ 0 °F)

Gas

R290

Compressor power

2 X 1 1/4

Max. absorbed courrent

Power supply voltage

Volt 3x230 ~ 60 Hz

Tab. 1/c

Fig. 5/c

BCB US Rev.00 09-2024 pag. 17

3.2 – DESCRIPTION OF BLAST CHILLER AND ITS USE

Blast chillers are appliances with a powerful refrigeration system that can rapidly reduce the temperature at the core of

food. Ideal for use in kitchens, bakeries and ice cream establishments.

The machine’s main work cycles are CHILLING and FREEZING. Each cycle includes two different end of cycle modes at

the point at which holding commences: temperature controlled (the probe inserted into the core of the product ends the

cycle when it reaches the set temperature) or time controlled (the cycle ends as soon as the set time expires).

3.2.1 – MAIN PARTS

The appliance comprises the following parts:

− body;

− condenser unit (ref. 2, fig. 6);

− evaporator unit (ref. 1, fig. 6);

− control panel (ref. 3, fig. 6)

Fig. 6

BCB US Rev.00 09-2024 pag. 18

3.3 – NOISE

The appliance is designed and built to keep its noise level as low as possible.

3.4 –AMBIENT CONDITIONS

Installation site

Bakeries, confectioner’s, ice cream makers, and kitchens in general

Relative humidity

< 80% without condensation

Climatic class

*The Climatic class 5 indicates that the appliance does work properly in an environment which remains below 104°F and 40% Hr

Tab. 2

BCB US Rev.00 09-2024 pag. 19

4 – TRANSPORT AND HANDLING

4.1 – TRANSPORT

The packing used is suitable for the type, dimensions and weight of the appliance and ensures that it is protected and

remains undamaged during transport and delivery to the purchaser.

The blast chiller must be placed in position and kept upright on a pallet and surrounded by its packing box throughout its

journey.

The blast chiller is handed over to the carrier ready to be handled.

The appliance must never be overturned.

The packing must be well placed on the platform of the means of transport and secured by

appropriate ropes.

Take the utmost care when lifting and positioning the blast chiller, so as to avoid serious damage

to persons or things. The manufacturer declines all responsibility if the indications for lifting

and transport the blast chiller are not observed.

Ambient temperature must never drop below 39°F during transport.

Once the blast chiller has been unpacked, the packing material must be eliminated and/or re-used in compliance with

current waste disposal regulations in the countries where the appliance will be used.

4.2. – HANDLING THE PACKED BLAST CHILLER

Take great care when lifting and handling the blast chiller; there is an injury hazard in handling

loads, which may also be fatal.

All handling and lifting operations must be carried out with great caution, making sure that all

personnel is strictly at a safety distance and that no-one stands under suspended loads, be they

still or in motion.

Before starting the operation, check the whole appliance handling area to identify any

dangerous points.

Ambient temperature must never drop below 39°F during transport.

BCB US Rev.00 09-2024 pag. 20

AUTHORIZED PERSONNEL

Specialised fork-lift truck operator.

Individual safety devices:

- safety shoes;

- safety gloves.

Personnel carrying out such operations must not wear rings, wrist watches, jewellery, loose or unfastened garments, such

as, for example, ties, torn garments, scarves, unbuttoned jackets or blouses with open zips, etc. In general, personnel

must wear safety apparel.

4.2.1 – WEIGHT AND DIMENSIONS

Model

BCB/05US

BCB/10US

BCB/15US

Dimensions

inches

33.9 X 32.4 X 37.8

33 7/8 X 33 7/8 X 61 3/8

33 7/8 X 33 7/8 X 74 7/8

Weight

238

348

500

Tab.3

4.2.2 – MEANS REQUIRED

- To lift the appliance use a fork-lift truck of suitable minimum capacity.

The use of unsuitable equipment can cause accidents to those involved in the operation and/or

damage to the appliance.

The manufacturer declines all responsibility for improper non-compliant use of equipment for

lifting, transport and handling.

BCB US Rev.00 09-2024 pag. 21

5 – INSTALLATION

Use the utmost care in handling the appliance, so as to avoid damage to persons or things.

Servicing shall be performed only as recommended by the manufacturer

Do not start the appliance if there are faults on the control panel or parts are damaged.

Servicing shall be performed only as recommended by the manufacturer

Do not start the appliance if there are faults on the control panel or parts are damaged.

The appliance is to be installed in accordance with the Safety Standard for Refrigeration

Systems, ANSI/ASHRAE 15

WARNING:

Do not use means to accelerate the defrosting process or to clean, other than those

recommended by the manufacturer.

The appliance shall be stored in a room without continuously operating ignition sources

(for example: open flames, an operating gas appliance or an operating electric heater.

Do not pierce or burn.

Be aware that refrigerants may not contain an odour.

The minum distance between the walls and the appliance must be at least 30cm/0.4inch

Positioning near other equipment that reaches high temperatures is not recommended.

If it is necessary, provide a space of at least 50 cm/ 19.6 inch on the side and 70 cm/ 27.6 inch in the

back or erect an insulating wall.

AUTHORIZED PERSONNEL

Specialised electrician.

Individual safety devices:

− safety shoes;

− safety gloves.

Personnel carrying out such operations must not wear rings, wrist watches, jewellery, loose or unfastened garments, such

as, for example, ties, torn garments, scarves, unbuttoned jackets or blouses with open zips, etc. In general, personnel

must wear safety apparel.

5.1 – PREPARATION FOR INSTALLATION

BCB US Rev.00 09-2024 pag. 22

Work shall be undertaken under a controlled procedure so as to minimise the risk of a

flammable gas or vapour being present while the work is being performed.

The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure

the technician is aware of potentially toxic or flammable atmospheres

Ensure that the leak detection equipment being used is suitable for use with all applicable refrigerants,

i.e., nonsparking, adequately sealed, or intrinsically safe.

Under no circumstances shall potential sources of ignition be used in the searching for or

detection of refrigerant leaks. A halide torch (or any other detector using a naked flame)

shall not be used.

The area must provide good support, with a solid flat floor whose finish will ensure a suitable and safe

working place for personnel.

Ensure that the area is in the open or that it is adequately ventilated before breaking into the system

or conducting any hot work. A degree of ventilation shall continue during the period that the work is

carried out. The ventilation should safely disperse any released refrigerant and preferably expel it

externally into the atmosphere

If any hot work is to be conducted on the refrigerating equipment or any associated parts, appropriate

fire extinguishing equipment shall be available on hand. A dry chemical or CO2 fire extinguisher

should be adjacent to the charging area.

Positioning near other equipment that reaches high temperatures is not recommended.

Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration,

sharp edges, or any other adverse environmental effects. The check shall also take into

account the effects of aging or continual vibration from sources such as compressors or

fans.

For installation prepare an area of manoeuvre suitable for:

− the dimensions of the appliance (see fig. 5),

− the chosen lifting equipment.

Choose an installation site:

− with all the connecting systems required for the appliance to work;

− with requisites that will allow the appliance to be used safely;

− with natural and/or artificial light suitable for the operations to be carried out (in compliance with specific

regulations).

5.2 – UNPACKING

Check that the packing has not been damaged during transport.

5.2.1 – MEANS REQUIRED

Use a fork-lift truck or equivalent equipment to lift the appliance.

BCB US Rev.00 09-2024 pag. 23

The use of unsuitable equipment can cause accidents to those involved in the operation and/or

damage to the appliance.

The manufacturer declines all responsibility for improper non-compliant use of equipment for

lifting, transport and handling.

BCB US Rev.00 09-2024 pag. 24

5.2.2 – UNPACKING PROCEDURE

All the handling and unpacking operations must be carried out with extreme care, making sure

that all personnel is strictly at a safety distance and that no-one stands under suspended loads,

be they still or in motion.

To unpack the appliance just remove its cardboard wrapping. Take the appliance off the pallet, lifting it by means of a

suitable fork-lift truck; the forks should be placed under the appliance taking care not to damage the two water tray

runners.

AFTER INSTALLING THE APPLIANCE, WAIT AT LEAST TWO HOURS BEFORE TURNING IT ON.

5.3 – HANDLING THE BLAST CHILLER

5.3.1 – MEANS REQUIRED

See paragraph 5.2.1.

The use of unsuitable equipment can cause accidents to those involved in the operation and/or

damage to the appliance.

The manufacturer declines all responsibility for improper non-compliant use of equipment for

lifting, transport and handling.

5.3.2 – HANDLING THE UNPACKED BLAST CHILLER

All the handling and unpacking operations must be carried out with extreme care, making sure that all

personnel is strictly at a safety distance and that no-one stands under suspended loads, be they still or in

motion.

All possible ignition sources, including cigarette smoking, should be kept sufficiently far away from the

site of installation, repairing, removing and disposal, during which refrigerant can possibly be released to

the surrounding space.

Prior to work taking place, the area around the equipment shall be surveyed to make sure that there are

no flammable hazards or ignition risks. “No Smoking” signs shall be displayed.

No person carrying out work in relation to a REFRIGERATING SYSTEM which involves exposing any

pipe work shall use any sources of ignition in such a manner that it may lead to the risk of fire or explosion.

To move blast chillers on wheels, release the brakes on the wheels and push, taking care to block the brakes again when

the appliance is in its permanent position.

To move blast chillers on feet, lift them with a suitable fork-lift truck; the forks should be placed under the appliance, taking

care not to damage the two water tray runners.

5.4 – BLAST CHILLER ASSEMBLY

The blast chiller is delivered to the customer assembled in all its parts.

Remove the water tray from the chamber and place it in position along the runners placed under the appliance between

the feet.

BCB US Rev.00 09-2024 pag. 25

5.5 – REMOVAL, EVACUATION and CHARGING PROCEDURES

WHEN BREAKING INTO THE REFRIGERANT CIRCUIT TO MAKE REPAIRS – OR FOR ANY

OTHER PURPOSE – CONVENTIONAL PROCEDURES SHALL BE USED. HOWEVER, FOR

FLAMMABLE REFRIGERANTS IT IS IMPORTANT THAT BEST PRACTICE BE FOLLOWED, SINCE

FLAMMABILITY IS A CONSIDERATION.

The following procedure shall be adhered to:

a) safely remove refrigerant following local and national regulations;

b) purge the circuit with inert gas;

c) evacuate (optional for A2L);

d) purge with inert gas (optional for A2L);

e) open the circuit by cutting or brazing.

The refrigerant charge shall be recovered into the correct recovery cylinders if venting is not allowed by local and

national codes. For appliances containing flammable refrigerants, the system shall be purged with oxygen-free nitrogen

to render the appliance safe for flammable refrigerants. This process might need to be repeated several times.

Compressed air or oxygen shall not be used for purging refrigerant systems.

For appliances containing flammable refrigerants, refrigerants purging shall be achieved by breaking the vacuum in the

system with oxygen-free nitrogen and continuing to fill until the working pressure is achieved, then venting to

atmosphere, and finally pulling down to a vacuum. This process shall be repeated until no refrigerant is within the

system. When the final oxygen-free nitrogen charge is used, the system shall be vented down to atmospheric pressure to

enable work to take place.

Ensure that the outlet for the vacuum pump is not close to any potential ignition sources

and that ventilation is available.

In addition to conventional charging procedures, the following requirements shall be followed.

a) Ensure that contamination of different refrigerants does not occur when using charging equipment. Hoses or lines

shall be as short as possible to minimise the amount of refrigerant contained in them.

b) Cylinders shall be kept in an appropriate position according to the instructions.

c) Ensure that the REFRIGERATING SYSTEM is earthed prior to charging the system with refrigerant.

d) Label the system when charging is complete (if not already).

e) Extreme care shall be taken not to overfill the REFRIGERATING SYSTEM.

Prior to recharging the system, it shall be pressure-tested with the appropriate purging gas. The system shall be leak-

tested on completion of charging but prior to commissioning. A follow up leak test shall be carried out prior to leaving the

site.

5.6 RECOVERY

When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good practice that

all refrigerants are removed safely.

When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed.

Ensure that the correct number of cylinders for holding the total system charge is available. All cylinders to be used are

designated for the recovered refrigerant and labelled for that refrigerant (i.e., special cylinders for the recovery of

refrigerant). Cylinders shall be complete with pressure-relief valve and associated shut-off valves in good working order.

Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs.

The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at

hand and shall be suitable for the recovery of all appropriate refrigerants including, when applicable, FLAMMABLE

REFRIGERANTS. In addition, a set of calibrated weighing scales shall be available and in good working order. Hoses

shall be complete with leak-free disconnect couplings and in good condition. Before using the recovery machine, check

that it is in satisfactory working order, has been properly maintained and that any associated electrical components are

sealed to prevent ignition in the event of a refrigerant release. Consult manufacturer if in doubt.

The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and the relevant

waste transfer note arranged. Do not mix refrigerants in recovery units and especially not in cylinders.

If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to

make certain that FLAMMABLE REFRIGERANT does not remain within the lubricant. The evacuation process shall be

carried out prior to returning the compressor to the suppliers. Only electric heating to the compressor body shall be

employed to accelerate this process. When oil is drained from a system, it shall be carried out safely

BCB US Rev.00 09-2024 pag. 26

6 – SETTING UP

AFTER INSTALLING THE APPLIANCE, WAIT AT LEAST TWO HOURS BEFORE TURNING IT ON.

6.1 – CONNECTIONS

6.1.1 – ELECTRICAL CONNECTION

Electrical connection must be made by a specialised electrician.

− Check that the power supply voltage given on the ID plate corresponds to that available at the

installation site.

− Connections must be made to current regulations; the supply mains must have an efficient

earthing system compliant with electricity regulations in the country; this is a responsibility of

the customer.

− Do not make tight bends on the power lead and do not place any object whatsoever on top of

it.

The manufacture declines all responsibility for damage or accidents caused by failure to

observe such regulations.

ELECTRICAL CONNECTION PROCEDURE

The appliance is supplied by the manufacturer complete with power plug. Just connect the power plug to a socket at the

installation site; the system must be carried out to current regulations.

The electricity supply at the installation site must have the following requisites:

− Voltage: 1x115 Vac BCB/05US(R404A); 1x230 Vac BCB/05US(R449A); BCB/10US(R404A/R449A);

3x230 Vac (BCB15US)

− Frequency: 60 Hz

The connection to the power supply network must comply with the regulations in force in the country of the equipment

installation and must be carried out by a specialized electrician authorized by the Manufacturer.

Failure to comply with these rules may cause damage and injury, void the warranty and release the Manufacturer from all

liability.

Before proceeding with the electrical connection, always compare the system data with those shown on the

technical data plate.

When the appliance is in operation, the value of the supply voltage must not differ by +/-10% of the value shown

on the technical data plate.

Depending on the model, different electrical connections are required:

BCB/05US

BCB/10US

BCB/15US

The equipment is supplied by the

manufacturer complete with a power

cord and plug.

Connected the equipment to a power

outlet in the installation’s site

The equipment is supplied with a power cord and is NOT

supplied with a plug. A specialized electrician authorized

by the Manufacturer must connect an electrical cable

to own electrical panel

Supply voltage

1x115 Volt ~ 60 Hz

plug NEMA 5-20P / 5-15P

cable length 2.5 m [98.4” ]

1x220 Volt ~ 60 Hz

3x220 Volt ~ 60 Hz

Make sure that the cable:

- has no tight kinks;

- is not crushed by objects or other equipment;

- is not in contact with sharp or hot objects;

- does not hinder the passage of people.

BCB US Rev.00 09-2024 pag. 27

Upstream, the equipment must be provided with an easily accessible switch installed in the system according

to the regulations in force in the country of installation of the equipment. This switch must have an omnipolar contact

separation so as to guarantee complete disconnection under overvoltage category III.

A correct earth connection is mandatory and the earth cable must not be interrupted in any case by the protection switch.

When there are several appliances in the same room.

The effectiveness of the equipotential system must be properly checked according to what is stated in the current

legislation.

If it is necessary to disconnect the power plug, first make sure that the card is positioned to OFF on the display.

The manufacturer declines all responsibility for damage or accidents caused by failure to comply with these standards.

6.2 – PRELIMINARY CHECKS

The electrician fitter shall train the operator in the correct use of the blast chiller and give the basic notions of maintenance.

METHOD

The operations to prepare the blast chiller for initial start-up must be carried out by a specialised engineer, in the presence

of the operator, who can acquire information to carry out certain routine maintenance and cleaning.

Before starting up the appliance, a series of checks and inspections must be carried out for the purpose of preventing

errors or accidents during start-up.

− Check that the appliance has not been damaged during transport.

− Check with special care for any damage to the electrical box, push button control panel, wiring and pipes.

− Check that all external power sources have been connected properly.

− Check that the machine is perfectly level.

6.2.1 – REGULATION

Regulation carried out by unauthorized personnel may damage the appliance and expose the

operator to serious hazards. Regulation carried out by unauthorized personnel is considered

tampering with the appliance and as such null the warranty and relieve the manufacturer of any

responsibility.

BCB US Rev.00 09-2024 pag. 28

7 – USE

WARNING: Do not use electrical appliances inside the food/ice storage compartments unless

they are of the type recommended by the manufacturer

7.1 – USE FORSEEN

Blast chillers are appliances with a powerful refrigeration system that can rapidly reduce the temperature at the core of

food. Ideal for use in kitchens, bakeries and ice cream establishments.

The machine’s main work cycles are CHILLING and FREEZING. Each cycle includes two different end of cycle modes at

the point at which holding commences: temperature controlled (the probe inserted into the core of the product ends the

cycle when it reaches the set temperature) or time controlled (the cycle ends as soon as the set time expires).

- SOFT CHILLING. Positive “delicate” temperature reduction (+37°F). Food just out of the oven is quickly taken to

a temperature of 37°F in no longer than 90’, thus inhibiting bacterial proliferation and avoiding dehydration of the

cooked food due to evaporation. Food treated in this way can be preserved perfectly for 5-7 days without altering

its original qualities.

- HARD CHILLING. Positive “rapid” temperature reduction (+37°F). Also lasts for a maximum of 90’. This type

of process is used when the food to be chilled is thicker than an inch (i.e. large joints) and with dense or fatty

food. During this phase the appliance reaches -4°F air temperature and provides to accelerate penetration of

the cold into the food.

- FREEZING. Deep freezing or freezing (0°F). During this phase the appliance reaches -40°F air temperature.

This work cycle will take the core of the food to a temperature of 0°F in less than four hours (240’). The speed of

the process avoids the formation of macrocrystals, ensuring that when it is used the thawed food has its original

consistency, colour and quality.

- HOLDING. At the end of both the chilling and freezing cycles the machine will automatically go to the set holding

temperature.

7.2 – UNFORSEEN USE

Blast chillers cannot be used for purposes other than those described in point 7.1. In particular the appliance is not suitable

for storing food for an indefinite period.

BCB US Rev.00 09-2024 pag. 29

7.3 – CONTROL PANEL

Fig. 7

BCB US Rev.00 09-2024 pag. 30

The buttons on the control panel are as follows:

START BUTTON

Short press: starts the selected function or gives access to the

selected menu page.

Long press for 2 seconds: interrupts the cycle in progress.

During a setting: allows you to make the value you want to change

editable, while a subsequent press of the same confirms the set

value.

CHILL BUTTON

Allows you to quickly select a blast chilling cycle.

Once a blast chilling cycle has been selected, it allows you to switch

from temperature-based blast chilling to time-based blast chilling and

vice versa.

During the quick selection of a blast chilling/freezing cycle: touching

the button 3 times consecutively takes the controller back to the

stand-by page.

Inside a menu or during a setting: acts as an "ESC" button and takes

the controller back to the upper page.

Warning: when a cycle is in progress, the button is not active; to

interrupt the cycle, press the "START" button for 2 seconds.

FREEZE BUTTON

Allows you to quickly select a freezing cycle.

Once you have selected a freezing cycle, it allows you to switch

from freezing by temperature to freezing by time and vice versa.

HARD BUTTON

Once the blast chilling/freezing cycle to be performed has been

selected, it allows you to switch from hard to soft mode and vice

versa.

MENU BUTTON

From the Home page: gives access to the machine settings menu.

Inside a menu: allows navigation downwards.

During a setting: decreases the value of the quantity you want to

change.

AUX BUTTON

From the Home page: gives access to the machine's special cycle

selection menu.

Inside a menu: allows navigation upwards.

During a setting: increases the value of the quantity you wish to

modify.

The icons on the control panel display are:

CABINET TEMPERATURE

ICON

CHILLING CYCLE ICON

ON when a chilling cycle is selected

HARD CHILLING CYCLE

ICON

ON when a hard chilling cycle is selected

FREEZING CYCLE

ON when a freezing cycle is selected

SOFT FREEZING CYCLE

ICON

ON when a soft freezing cicle is selected

BCB US Rev.00 09-2024 pag. 31

CYCLE BY TIME ICON

ON when the cycle by time is selected

CYCLE BY TEMPERATURE

ICON

On when the cycle by temperature is selected

COMPRESSOR ICON

ON when the compressor is running

CYCLE IN PROGRESS

ICON

ON when a cicle cycle is in progress

DOOR OPEN ICON

ON when the door is open. The display will automatically

disappear the next time the door is closed or a button is

pressed

FISH SANIFICATION ICON

ON when a fish sanification cycle is in progress

ICE CREAM ICON

ON when a ice cream cycle is in progress

THAWING ICON

ON when a fish thawing cycle is in progress

NUMER OF PHASES

Indicate the the running phase of the cycle

BLAST CHILLING /

FREEZING CYCLE

SUCCESSFULLY

COMPLETED

ON when a cycle has completed successfully

BLAST CHILLING /

FREEZING CYCLE NOT

COMPLETED

SUCCESSFULLY

ON when a cycle has not completed successfully

CUSTOM RECIPE

STORAGE

7.4 – CONTROL PROCEDURES

The entire device is controlled by an electronic board.

Connect the power supply to the device: a neutral system loading screen will be displayed.

Once loading is complete, the device will return to the state it was in before being disconnected, i.e.:

- on the Home screen without any power failure message;

- in cycle execution, with POWER FAILURE message indicating the power failure.

If a power failure occurs when no function is in progress, when the power is restored the device will return to the state it

was in before the power failure.

If a power failure occurs when a function is active, when the power is restored the device will behave as follows:

- with a blast chilling or freezing in progress, the cycle is resumed taking into account the duration of the power failure

- with a conservation in progress, the cycle continues maintaining the same settings.

If the power failure was long enough to cause the clock error (code “RTC”), it will be necessary to set the day and real time

again.

To silence the buzzer, simply press any key.

BCB US Rev.00 09-2024 pag. 32

7.5 – USE PROCEDURES

Clean the inside of the chamber before using the machine.

After installation or a prolonged idle period, it is good practice to operate the empty appliance until it reaches the set

temperature. To achieve good output from the blast chiller it is advisable to place the food inside in such a way as to assist

air circulation: do not obstruct the fan, do not stack trays on top of each other, distribute the load neatly and do not cove r

the containers with lids or cling film.

In order to avoid altering the food, it is also advisable not to overload the machine beyond the permitted load, not to use

pieces thicker than 2-3” and to limit door opening as much as possible.

Clean and sterilise the core probe before use. The probe must be placed in the centre of the largest joint or piece, taking

care that the point does not go right through the food to come into contact with the tray.

To improve the efficacy of the working cycle is recommended to perform a pre-cooling of the cell, by turning on

the machine at least 15 min before insert the product, both in killing and freezing.

When a temperature controlled cycle is selected the electronic circuit board checks the temperature read by the

chamber probe and core probe to assess correct insertion of the probe (AUTOMATIC probe identification). This

check lasts just over two minutes, at the end of which the cycle proceeds normally if the probe is properly inserted.

This check lasts just over 2 minutes, accordingly with established parameters, at the end of which the cycle

proceeds with a temperature controlled cycle if the probe is properly inserted. In this case the temperature of the

probe will be showed and the icon will remain turned on.

If the test has a negative result, after a minute of buzzer’s alarm, the display will show the icon and the cycle

will proceed with a time controlled cycle.

BCB US Rev.00 09-2024 pag. 33

7.6 – CHILLING and FREEZING CYCLE

Load the machine suitably with the food to be chilled, place the core probe into the food and close the door.

With the appliance on STANDBY press the or buttons to select a blast chilling cycle or a freezing cycle

respectively.

The device will propose a cycle by time .

To switch from this mode to cycle by probe , press the button the or again.

The selected cycle will propose either the preloaded settings for that cycle.

By pressing , it will be possible to quickly modify, within the permitted ranges, the value of a single piece of

data.

Once the modification is complete, press to run the cycle button .

If the cycle is by probe, the test is performed to verify the correct insertion of the needle probe into the food to be chilled.

If the test is not passed, the cycle automatically switches to timed mode: the buzzer emits a sound and the type of cycle

control is converted from temperature to time on the display.

BCB US Rev.00 09-2024 pag. 34

7.7 – HARD CHILLING and SOFT FREEZING CYCLE

Load the machine suitably with the food to be chilled, place the core probe into the food and close the door.

With the appliance on STANDBY press the or buttons to select a blast chilling cycle or a freezing cycle

respectively.

The device will propose a cycle by time .

To switch from this mode to cycle by probe , press the button the or again.

Once the desired cycle has been selected, by pressing the button it is possible to add a phase (hard for chilling, soft

for freezing) which will be carried out before the standard phase, thus switching from one-phase cycles to two-phase cycles.

The selected cycle will propose either the preloaded settings for that cycle.

By pressing , it will be possible to quickly modify, within the permitted ranges, the value of a single piece of

data.

Once the modification is complete, press to run the cycle button .

If the cycle is by probe, the test is performed to verify the correct insertion of the needle probe into the food to be chilled.

If the test is not passed, the cycle automatically switches to timed mode: the buzzer emits a sound and the type of cycle

control is converted from temperature to time on the display.

BCB US Rev.00 09-2024 pag. 35

7.8 – SPECIAL USES

7.8.1 – PRE-COOLING FUNCTION

If the temperature of the food to be chilled is very high (above 149°F) it is advisable to pre-chill it in the following way:

Access the SPECIAL CYCLES menu from the button and select PRECOOLING.

At this point the work SETPOINT setting screen appears, and it can be changed using the keys

Press the button and cycle will start.

7.8.2 – DEFROST

The defrost can be activated when the machine is on STANDBY and the evaporator temperature does not exceed 46°F,

Access the SPECIAL CYCLES menu from the button and select DEFROST, press the button : at this point the

word DEFROST will be displayed and the next time you press the button the cycle will start.

Defrosting is also performed automatically during the storage or pre-cooling phases.

7.8.3 – FISH SANITIZATION

The fish sanitization cycle is only available if the needle probe is present.

This is a special cycle consisting of the following phases:

1. blast chilling by probe with cell setpoint equal to -36°F and with product temperature setpoint equal to -4°F;

2. maintenance by time of duration equal to 24 hours and cell setpoint equal to -4°F;

The needle probe insertion test is always performed at the beginning of the cycle: if the test is not completed, the buzzer

sounds and the cycle is interrupted.

To start this cycle access the SPECIAL CYCLES menu from the button and select FISH SANITATION, press the

button : at this point the start screen is displayed and the next time you press the button the cycle will start.

BCB US Rev.00 09-2024 pag. 36

During the execution of a sanitization, the device will always display the cell temperature and, depending on the phase in

progress, the end blast chilling temperature or the duration of the maintenance.

7.8.4 – ICE CREAM HARDENING

This type of cycle is mainly used in the ice cream and pastry sectors to give a “thermal shock” to the products being

processed.

It is a continuous freezing cycle, in which each time the door is opened, the decrease in the time set with 10 minutes will

restart regardless of the value of the setpoint -40°F.

To start this cycle access the SPECIAL CYCLES menu from the button and select ICE CREAM HARDENING ,

press the button : at this point the start screen will be displayed from which you can use the buttons to

change the timer time. When you press the next time the button , the cycle will start and the timer will expire and the

buzzer will sound. The cycle will continue in any case until you press the button for 2 seconds.

7.8.5 – RECIPES

There are 7 pre-set programs ready to use that offer a series of cycles optimized for the type of food.

These 7 recipes can be modified before the start of the cycle, but cannot be saved or overwritten.

To view the list of available blast chilling/freezing programs, access the SPECIAL CYCLES menu from the button

and select RECIPES. Use the buttons to select the desired recipe, change the setpoint if necessary and

start by pressing the button .

In addition to the 7 standard recipes (not modifiable), the controller provides 20 additional programs (from P1 to P20) that

can be used by the user to save the settings of their own recipe.

These 20 programs are listed after the 7 preset recipes and identified with the label “- - -” to indicate that the position is

empty.

When the user saves the settings of a recipe, the label “Px” will automatically appear based on the position in which it is

saved.

To save or overwrite one of the 20 recipes, proceed as follows:

1. Place the cursor in the position where you want to save the recipe, press the button ;

2. Use the button to change the mode from chilling cycle by time to chilling cycle by temperature and vice versa

BCB US Rev.00 09-2024 pag. 37

or use the button to change the mode from freezing cycle by time to freezing cycle by temperature and vice

versa;

3. Use the button to change the mode from SOFT to HARD and vice versa;

4. Use the button to enter the cycle value editing and scrolling mode;

5. Use the button to enter the selected value, modify it with the buttons and confirm by pressing

again or exit without modifying by pressing the button ;

6. When you return to the main screen to start the cycle, the icon appears on the display as a reminder to save the

recipe; press the button to save it;

7. Press the button to start the cycle.

BCB US Rev.00 09-2024 pag. 38

8 – MAINTENANCE AND REPAIR

8.1 – SPECIAL PRECAUTIONS

Servicing shall be performed only as recommended by the manufacturer

Contact the manufacturer for any anomalies not described in this manual; contact the manufacturer

also for any doubts during the maintenance operations described herein.

WARNING

Do not use means to accelerate the defrosting process or to clean, other than those recommended

by the manufacturer.

The appliance shall be stored in a room without continuously operating ignition sources (for

example: open flames, an operating gas appliance or an operating electric heater).

Do not pierce or burn.

Be aware that refrigerants may not contain an odour.

Maintenance carried out by unauthorized personnel may damage the appliance and expose the

operator to serious hazards. Maintenance carried out by unauthorized personnel is considered

tampering with the appliance and therefore nulls the warranty and relieves the manufacturer of any

responsibility.

Any routine or extraordinary maintenance operation that requires the electric box to be opened or

the machine to be dismantled, even partially, must be carried out only after the appliance has been

switched off, on the display, and unplugged.

Any maintenance operations carried out on a live machine may cause people serious accidents

which may also be fatal.

The safety devices must be deactivated only by authorized personnel, who will guarantee safety for

people and avoid damage to the machine. The safety devices must be carefully activated again after

carrying out maintenance.

During maintenance or repairs unauthorized persons must keep a safe distance from the appliance.

Observe the intervals prescribed or indicated in this manual for making inspections.

At the end of maintenance or repairs the appliance can be started only after the specialist engineer

has made sure that:

- all the work has been fully carried out;

- the safety systems are active;

- the appliance is working perfectly;

- no-one is working on the appliance.

8.2 – ROUTINE MAINTENANCE

8.2.1 – ROUTINE MAINTENANCE TABLE (TAB. 5)

Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary to ensure that the

risk of ignition is minimised. For repair to the REFRIGERATING SYSTEM, Clauses ‘Work procedure’ to ‘No ignition

sources’ shall be completed prior to conducting work on the system.

BCB US Rev.00 09-2024 pag. 39

Work Procedure:

Work shall be undertaken under a controlled procedure so as to minimise the risk of a

flammable gas or vapour being present while the work is being performed.

The area shall be checked with an appropriate refrigerant detector prior to and during

work, to ensure the technician is aware of potentially toxic or flammable atmospheres.

Ensure that the leak detection equipment being used is suitable for use with all applicable

refrigerants, i.e., nonsparking, adequately sealed, or intrinsically safe.

If any hot work is to be conducted on the refrigerating equipment or any associated parts,

appropriate fire extinguishing equipment shall be available on hand. A dry chemical or CO2

fire extinguisher should be adjacent to the charging area.

No Ignition Sources:

No person carrying out work in relation to a REFRIGERATING SYSTEM which involves

exposing any pipe work shall use any sources of ignition in such a manner that it may lead

to the risk of fire or explosion. All possible ignition sources, including cigarette smoking,

should be kept sufficiently far away from the site of installation, repairing, removing and

disposal, during which refrigerant can possibly be released to the surrounding space. Prior

to work taking place, the area around the equipment shall be surveyed to make sure that

there are no flammable hazards or ignition risks. “No Smoking” signs shall be displayed.

Ensure that the area is in the open or that it is adequately ventilated before breaking into

the system or conducting any hot work. A degree of ventilation shall continue during the

period that the work is carried out. The ventilation should safely disperse any released

refrigerant and preferably expel it externally into the atmosphere.

Component

Type of operation

Timing

Responsibility

Method

Chamber

Cleaning

When needed

Appliance operator

See para. 8.2.2

External part

Cleaning

When needed

Appliance operator

See para. 8.2.3

Condenser

Cleaning

Every 30 days

Appliance operator

See para. 8.2.4

Core probe

Cleaning

Every cycle

Appliance operator

See para. 8.2.5

Tab. 5

8.2.2 –CLEANING THE CHAMBER

Carry out this operation whenever necessary.

APPLIANCE STATUS:

- I/O main switch in position “O” (OFF);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Appliance operator.

BCB US Rev.00 09-2024 pag. 40

METHOD

Clean very carefully the internal part of the chamber, the door closure surface (ref. 1 fig. 8) and gasket (ref. 2 fig. 8), using

a non-abrasive sponge soaked in neutral detergent. Rinse with a sponge soaked in water and dry with a clean cloth.

Proper cleaning of the inside of the appliance prevents the formation of bad odour which could affect the end product

negatively.

Use exclusively water and non-abrasive neutral detergent for cleaning. The use of different products

could damage the surface of the appliance and compromise the quality and healthiness of the

product being processed.

Do not use abrasive sponges.

When cleaning do not use cloths that leave lint.

Do not use water jets to clean the appliance.

Fig. 8

BCB US Rev.00 09-2024 pag. 41

8.2.3 – CLEANING THE OUTSIDE OF THE APPLIANCE

Carry out this operation whenever necessary.

APPLIANCE STATUS:

- I/O main switch in position “O” (OFF);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Appliance operator.

METHOD

Clean the outer surface of the appliance (steel base and panelling), using a non-abrasive sponge soaked in neutral

detergent. Rinse with a sponge soaked in water and dry with a clean cloth.

Use exclusively water and non-abrasive neutral detergent for cleaning. The use of different products

could damage the surface of the appliance and compromise the quality and healthiness of the

product being processed.

Do not use abrasive sponges.

When cleaning do not use cloths that leave lint.

BCB US Rev.00 09-2024 pag. 42

8.2.4 – CLEANING THE CONDENSER

Carry out this operation every 30 days.

APPLIANCE STATUS:

- I/O main switch in position “O” (OFF);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Appliance operator.

METHOD

To ensure that the appliance works properly and efficiently, the air condenser (ref. 1 fig. 9) must be kept clean so that the

air can circulate freely. This operation should be carried out every 30 days. Remove the control panel by loosening the

screws (ref. 2 and 3 fig. 9). Clean with a non-metal brush to remove all the dust and fluff from the fins. It is advisable to

use a vacuum cleaner so that dust does not float in the air. If there are greasy deposits, eliminate with a brush soaked in

alcohol. DO NOT SCRAPE THE SURFACES WITH POINTED OR ABRASIVE OBJECTS.

Fig. 9

The condenser has sharp edges. When carrying out the operations mentioned above, wear safety

gloves, goggles and face masks.

Do not use direct water jets to clean the appliance.

BCB US Rev.00 09-2024 pag. 43

8.2.5 – CLEANING THE CORE PROBE

Carry out this operation at every cycle.

APPLIANCE STATUS:

- I/O main switch in position “O” (OFF);

AUTHORIZED PERSONNEL

Appliance operator.

METHOD

The core probe (ref. 1 fig. 10) must always be cleaned before a new cycle so as to avoid polluting the product in any way.

Remove all residue by means of a sponge soaked in neutral detergent. Rinse with lots of water and apply a sterilising

product.

Fig. 10

Do not pull the probe wire; you may damage it.

The probe has a very pointed end. During cleaning always wear safety gloves and take the utmost

care.

BCB US Rev.00 09-2024 pag. 44

8.3 – EXTRAORDINARY MAINTENANCE

8.3.1- REFRIGERANT EQUIPMENT

Where electrical components are being changed, they shall be fit for the purpose and to the

correct specification. At all times, the manufacturer’s maintenance and service guidelines

shall be followed. If in doubt, consult the manufacturer’s technical department for

assistance..

APPLIANCE STATUS:

- ON/OFF button on OFF ( on the display);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Specialized electrician.

METHOD

The following checks shall be applied to installations using FLAMMABLE REFRIGERANTS:

a) the actual REFRIGERANT CHARGE is in accordance with the room size within which the refrigerant containing

parts are installed;

b) the ventilation machinery and outlets are operating adequately and are not obstructed;

c) if an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of

refrigerant;

d) marking to the equipment continues to be visible and legible. Markings and signs that are illegible shall be

corrected;

e) refrigerating pipe or components are installed in a position where they are unlikely to be exposed to any

substance which may corrode refrigerant containing components, unless the components are constructed of

materials which are inherently resistant to being corroded or are suitably protected against being so corroded.

8.3.2- ELECTRICAL COMPONENTS

APPLIANCE STATUS:

- ON/OFF button on OFF ( on the display);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Specialized electrician.

METHOD

Repair and maintenance to electrical components shall include initial safety checks and component inspection

procedures. If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until

it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, an

adequate temporary solution shall be used. This shall be reported to the owner of the equipment, so all parties are

advised.

Initial safety checks shall include:

a) that capacitors are discharged: this shall be done in a safe manner to avoid possibility of sparking;

b) that no live electrical components and wiring are exposed while charging, recovering or purging the system;

c) that there is continuity of earth bonding

8.3.3- SEALED COMPONENTS

During repairs to sealed components, all electrical supplies shall be disconnected from the

equipment being worked upon prior to any removal of sealed covers, etc. If it is absolutely

necessary to have an electrical supply to equipment during servicing, then a permanently

operating form of leak detection shall be located at the most critical point to warn of a

potentially hazardous situation.

BCB US Rev.00 09-2024 pag. 45

APPLIANCE STATUS:

- ON/OFF button on OFF ( on the display);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Specialized electrician.

METHOD

Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not

altered in such a way that the level of protection is affected. This shall include damage to cables, excessive number of

connections, terminals not made to original specification, damage to seals, incorrect fitting of glands, etc.

Ensure that the apparatus is mounted securely.

Ensure that seals or sealing materials have not degraded to the point that they no longer serve the purpose of preventing

the ingress of flammable atmospheres. Replacement parts shall be in accordance with the manufacturer’s specifications.

8.3.4- INTRINSICALLY SAFE COMPONENTS

Do not apply any permanent inductive or capacitance loads to the circuit without ensuring

that this will not exceed the permissible voltage and current permitted for the equipment in

use.

APPLIANCE STATUS:

- ON/OFF button on OFF ( on the display);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Specialized electrician.

METHOD

Intrinsically safe components are the only types that can be worked on while live in the presence of a flammable

atmosphere. The test apparatus shall be at the correct rating.

Replace components only with parts specified by the manufacturer. Other parts can result in the ignition of refrigerant in

the atmosphere from a leak.

NOTE: The use of silicon sealant can inhibit the effectiveness of some types of leak detection equipment. Intrinsically safe components

do not have to be isolated prior to working on them.

8.3.5- CABLING

APPLIANCE STATUS:

- ON/OFF button on OFF ( on the display);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Specialized electrician.

METHOD

Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges, or any other

adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from

sources such as compressors or fans.

BCB US Rev.00 09-2024 pag. 46

8.3.6- DETECTION OF FLAMMABLE REFRIGERANTS

Under no circumstances shall potential sources of ignition be used in the searching for or

detection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall

not be used.

APPLIANCE STATUS:

- ON/OFF button on OFF ( on the display);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Specialized electrician.

METHOD

The following leak detection methods are deemed acceptable for all refrigerant systems.

Electronic leak detectors may be used to detect refrigerant leaks but, in the case of FLAMMABLE REFRIGERANTS, the

sensitivity might not be adequate, or might need recalibration. (Detection equipment shall be calibrated in a refrigerant-

free area.) Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used.

Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the

refrigerant employed, and the appropriate percentage of gas (25 % maximum) is confirmed.

Leak detection fluids are also suitable for use with most refrigerants but the use of detergents containing chlorine shall be

avoided as the chlorine can react with the refrigerant and corrode the copper pipe-work.

NOTE Examples of leak detection fluids are

– bubble method,

– fluorescent method agents.

If a leak is suspected, all naked flames shall be removed/extinguished.

If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or

isolated (by means of shut off valves) in a part of the system remote from the leak. Removal of refrigerant shall be

according to 8.3.7 “REMOVAL AND EVACUATION”.

8.3.7- REMOVAL AND EVACUATION

APPLIANCE STATUS:

- ON/OFF button on OFF ( on the display);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Specialized electrician.

METHOD

When breaking into the refrigerant circuit to make repairs – or for any other purpose – conventional procedures shall be

used. However, for flammable refrigerants it is important that best practice be followed, since flammability is a

consideration. The following procedure shall be adhered to:

a) safely remove refrigerant following local and national regulations;

b) purge the circuit with inert gas;

c) evacuate;

d) purge with inert gas;

e) open the circuit by cutting or brazing.

The refrigerant charge shall be recovered into the correct recovery cylinders if venting is not allowed by local and

national codes. For appliances containing flammable refrigerants, the system shall be purged with oxygen-free nitrogen

to render the appliance safe for flammable refrigerants. This process might need to be repeated several times.

Compressed air or oxygen shall not be used for purging refrigerant systems.

For appliances containing flammable refrigerants, refrigerants purging shall be achieved by breaking the vacuum in the

system with oxygen-free nitrogen and continuing to fill until the working pressure is achieved, then venting to

BCB US Rev.00 09-2024 pag. 47

atmosphere, and finally pulling down to a vacuum (optional for A2L). This process shall be repeated until no refrigerant is

within the system (optional for A2L). When the final oxygen-free nitrogen charge is used, the system shall be vented

down to atmospheric pressure to enable work to take place.

Ensure that the outlet for the vacuum pump is not close to any potential ignition sources and that ventilation is available.

8.3.8- CHARGING PROCEDURES

APPLIANCE STATUS:

- ON/OFF button on OFF ( on the display);

- power supply plug disconnected from the mains.

AUTHORIZED PERSONNEL

Specialized electrician.

METHOD

In addition to conventional charging procedures, the following requirements shall be followed:

a) Ensure that contamination of different refrigerants does not occur when using charging equipment. Hoses or

lines shall be as short as possible to minimise the amount of refrigerant contained in them.

b) Cylinders shall be kept in an appropriate position according to the instructions.

c) Ensure that the REFRIGERATING SYSTEM is earthed prior to charging the system with refrigerant.

d) Label the system when charging is complete (if not already).

e) Extreme care shall be taken not to overfill the REFRIGERATING SYSTEM.

Prior to recharging the system, it shall be pressure-tested with the appropriate purging gas. The system shall be leak-

tested on completion of charging but prior to commissioning. A follow up leak test shall be carried out prior to leaving the

site.

If the appliance needs extraordinary maintenance, or if operating anomalies occur that are not described in this manual,

contact the manufacturer.

8.3.9- RECOVERY