RAPID WATER CHILLER RAPIDMAC 50. ISO 9001 Cert. N 0412/2 OUR SYSTEMS COMPLY WITH DIRECTIVES 73/23 EEC - 89/336 EEC INSTRUCTION MANUAL

Cod. 71503589 - 03/2004

INSTRUCTION MANUAL

RAPID WATER CHILLER

RAPIDMAC 50

OUR SYSTEMS COMPLY WITH DIRECTIVES 73/23 EEC - 89/336 EEC

ISO 9001 Cert. N° 0412/2

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CONTENTS

1. GENERAL DOCUMENTATION

1.1 General information page 4

1.2 Installation page 4

1.3 Transport and handling page 4

1.4 Unpacking - disposal of packing page 5

1.5 General safety regulations page 5

2. INSTALLATION

2.1 Dataplate information page 5

2.2 Positioning page 5

2.3 Ambient temperature and air circulation page 6

2.4 Electrical connections page 6

2.5 Cooling connections page 7

2.6 Overflow drain connection page 7

2.7 Notes for the installer page 7

2.8 Safety and control systems page 7

2.9 Appliance disposal page 7

3. TECHNICAL CHARACTERISTICS page 8

4. PROGRAMMING INSTRUCTIONS

4.1 Keys page 9

4.2 Self-test on start-up and microprocessor reset page 9

4.3 Temperature set-point and management page 9

5. OPERATION

5.1 Description and general operating principles page 10 5.2 Stand-by function, compressor/resistance management page 10

5.3 Water heating function page 10

5.4 Electric power failure page 11

5.5 Rapidmac version with pump page 11

5.6 Rapidmac manual version page 11

6. ALARM MANAGEMENT,

6.1 List of other operating faults not indicated page 12

7. MAINTENANCE AND CLEANING

7.1 Basic safety regulations page 13

1. GENERAL DOCUMENTATION

• This manual is an integral part of the product and provides all the information necessary for ensuring correct appliance installation, operation and maintenance. • Read the manual carefully, making refer-ence to it for machine operation. Keep the manual in a well-known place acces-sible to all authorised operators (installers, users and maintenance per-sonnel)

The machine has been constructed in compliance with the directives 73/23/CEE (low-voltage), 89/336/CEE (electromagnetic compatibility) and 98/37/CE (machines; for certain models only).

• The machine has been designed for pro-fessional applications only and should only be operated by qualified personnel. • The appliance must only be used for its

designed purpose, i.e. for preserving food products.

The machine must not be used for prod-ucts requiring constant temperature con-trol and recording, such as

heat-sensitive chemicals medicines

- blood products

• The manufacturer declines all responsi-bility for any damage caused by incor-rect or unreasonable machine use, such as:

• improper use by untrained persons • technical modifications or operations not

suited to specific models

• use of non-original or non-specific spare parts

• failure to follow the instructions given in this manual

1.2 Installation

The machine must be installed by a spe-cialised authorised technician in compli-ance with the instructions enclosed. (see installation drawing enclosed Fig.1)

1.3 Transport and handling

• Loading or unloading the appliance from/onto the means of transport can be done with a lift truck or fork lift pallet truck equipped with forks at least half the length of the cabinet.

Select the lifting equipment suited to the weight and overall dimensions of the packaged machine/components.

• All precautions must be taken to avoid damage to the appliance, in accordance with the warnings on the packaging (Fig.2). 300 mm 600 mm 600 mm 1200 mm Fig.1 Fig.2

2.1 Data plate information

• Check that the data specified on the plate correspond to the characteristics of the power supply (V, kW, Hz, no. phases and power available).

• The dataplate with appliance specifications is located at the rear exterior of the machine.

2.2 Positioning

• The machine must be installed and com-missioned in complete compliance with current safety regulations, procedures and laws in the country of installation.

• The installation technician bears the responsibility of ensuring compliance with fire safety requirements; seek all necessary advice from the local fire-fighting authority • Position the appliance in the allocated site • Adjust the machine feet until the appliance

is perfectly level. In the case of particularly heavy equipment, use appropriate lifting means

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THESE OPERATIONS MUST BE PERFORMED BY A CERTIFIED INSTALLATION

TECHNICIAN ONLY

2. INSTALLATION

• Remove all cardboard, wood or other materials from the wood base on which the machine is set. Lift the machine with suitable means (e.g. lift truck), remove the wood base, then position the machine in the allocated site.

• After removing the packing, check the integrity of the appliance

• Remove the protective PVC film from all sides (Fig.3)

• Always wear protective gloves when handling packing material and the wood base.

• NB: Dispose of packing materials in com-pliance with disposal regulations applied in the country where the machine is to be installed. Never dispose of materials in the environment.

1.5 General safety regulations

Failure to observe the recommendations made by the present manual will be at the entire responsibility of the machine user. The main safety regulations are as follows: - do not touch the machine with moist or wet hands or feet

- never operate the machine while bare-foot

- do not insert screwdrivers, cooking utensils or any other object between the guards and moving parts

- before performing cleaning or routine maintenance operations, disconnect the machine from the power supply by oper-ating the main switch, also disconnect-ing the main knife-switch (if present) - never pull on the power cable to dis-connect the machine from the power supply

Fig.3

(Fig.4)

• If the appliance is not levelled, this may impair correct operation.

INFORMATION ON THE WALL USED FOR MOUNTING THE BRACKET

IMPORTANT:

The wall on which the bracket is to be fitted must be suitable to guarantee holding of the anchor plugs and ade-quate structural properties in relation to the loads applied as specified in the table below. As regards the civil struc-ture (wall) the relative conditions added to the load applied by the bracket and device must fully comply with specifica-tions of Italian Ministerial Decree no. 9 of January 1996

Wall-mounting bracket.

Acting forces (binding reactions) in mounting bracket area:

Fy= -1711 N Vertical force Fz= 747 N Horizontal traction in lower support area:

Fz= 747 N Horizontal compression AVOID

• direct exposure to sunlight

• closed sites with high temperatures and poor air circulation

• Do not install the machine near sources of heat (fig. 5)

2.3 Ambient temperature and air circulation

For air-condensed refrigerating units, the maximum ambient temperature for opera-tion is 32°C. Correct operaopera-tion cannot be guaranteed at higher temperatures. The machine may operate safely to a max-imum temperature of 38°C.

In any case, sufficient air interchange must be guaranteed

2.4 Electrical connections

A differential thermal-magnetic circuit breaker complete with disconnecting switch must be installed upline of every appliance, complete with disconnect switch, in accordance with current regula-tions in the country of installation

• Connected electrical cables must corre-spond to the technical data (as specified on electrical drawings provided by the

Fig.5

Fy Fz

Fz

posizione mensola

struttura civile su cui

si va a fissare la mensola

Bracket position

installation technician)

The earth wire must be correctly con-nected to an efficient earthing system. THE MANUFACTURER DECLINES ALL LIABILITY AND GUARANTEE OBLIGA-TIONS IN THE EVENT OF INJURY TO PERSONS OR DAMAGE TO EQUIP-MENT AND OBJECTS DUE TO INCOR-RECT INSTALLATION AND/OR FAILURE TO COMPLY WITH STANDING INSTAL-LATION REGUINSTAL-LATIONS.

2.5 Water and cooling circuit connections See diagram enclosed Fig.7

2.6 Overflow drain connection

All models require a drain hose to collect overflow water. Fig.6

2.7 Information for the installation technician

Before starting up the machine, check that it has been correctly installed and commissioned (test report)

3. Check all mains wiring connections 6. Check the water connections

7. Ensure that the machine reaches the set temperature.

• Inform the customer of the exact use of the appliance, with specific reference to the use and requirements of the cus-tomer. Installation and commissioning must be carried out by authorised per-sonnel

2.8 Safety and control systems • Card protection fuses:

• Safety pressure switch: intervenes in the event of overpressure of the refrigerant circuit.

• Auxiliary component protection fuse • Heating resistance safety thermostat 2.9 Appliance disposal

Demolish and dispose of the machine in compliance with the regulations applied in the country of installation, particularly in regards to refrigerant gas and compressor lubricant oil. A B C D E F G H I L N INGRESSO ACQUA ACQUA USCITA REFRIGERATA A F Symbol Description A Overflow drain B Domestic water inlet C Electric power cable D Chilled water outlet

E Control panel connection cable F Remote control panel

Symbol Description A condenser Fan B Liquid receiver C Dryer filter D Compressor E Drain pump F Litre counter

(on manual version only) G Water drain solenoid valve H Water inlet solenoid valve I Water circulation motor L Evaporator coil M Water level sensor N Insulated tank Fig.7 Fig.6 7 WATER INLET CHILLED WATER OUTLET

1200 mm 600 mm 600 mm 300 mm

3. TECHNICAL CHARACTERISTICS

Tank and coil AISI 304

Control panel Remote 5 metre

Net weight approx. 130 kg

Exterior finish Grey plastic-coated steel- optional: AISI 304 steel exterior finish Accessories supplied as standard Wall mounting bracket

TECHNICAL SPECIFICATIONS

Electric power supply 400V / 3N / 50Hz

Condenser unit Built-in

Refrigerant R404a

Water fittings 3 1/4 GAS

Control panel function Temperature control Litre counter Water drain

Cold/hot water selection

NOISE LEVEL: Db detect from 1 m 67 Db Db detect from 3 m 64 Db Outside dimensions mm. micro-relay card

display-control card in remote panel located at a maximum distance of 5 metres. Software:

1. Water temperature control (cooling/heating) 2. Self-test and alarm management

3. Pump (and litre counter) control 4. Water inlet control.

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4.1 KEYS:

Pushbutton 1 = Increase (plus sign)

Pushbutton 2 = Decrease (minus sign) (alarm shutoff)

Pushbutton 3 = SET enables entry of SetPoint and access by password only.

Pushbutton 4 = Cooling On/Off - Heating On/Off (if pressed and held, sets to Stand-By). Pushbutton 5 = Automatic water inlet filling disable On/Off

Pushbutton 6 = Pump On/Off (litre counter control).

4.2 Self-test on start-up and microprocessor reset

When the machine is switched on, all leds light up simultaneously on display. If the electronic card self-test is successful, a beep is activated for 5” followed by illumination of all leds. If a pushbutton is pressed during the self-test, an alarm is tripped. The self-test cycle can be repeated by turning the machine off and then on again. Press and hold down push-buttons “ ” and “ ” and then press , to display the text “RES” which resets the microproces-sor, clears the memory and sets the default parameters.

4.3 Set-point (water temperature value entry).

Press for 3” to show the factory setting of the set-point value, which flashes on display. The set-point value can be increased or decreased as required using the keys or and confirming the new water temperature setting by pressing .

The machine is fitted with a differential between compressor start-up and shutdown: E.g. : set +10°C , diff. 2°C. The compressor is activated at +12°C and shut down at +10°C;

The resistance is activated at +8°C and shut off at +10°C in heating mode.

4. PROGRAMMING INSTRUCTIONS

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3

2

5

4

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5. OPERATION

principles

RAPIDMAC 50 is a water chiller equipped with a 50-litre tank with an immersed coil con-veying the refrigerant (as well as a heating resistance).

- control of the water temperature is by means of a sensor. Normally the display shows the water temperature.

- Control of the maximum water level is by means of floats with on/off output.

- A pump is available (optional) for rapid water drainage.

- A pressure relief (safety) valve with on/off output is fitted

- An internal litre counter (optional) is avail-able (on manual version only)

5.2 Stand-by function, compressor/resis-tance management.

When the machine is switched on (power delivered to card) after the self-test, the card sets to the status previously applied before power was shut off.

Press key 4 to set the machine to cooling mode: the relative led 4 illuminates (green). (N.B. the compressor is started up after the set delay. During this interval led 4

flashes).

- the display shows the temperature read by the water sensor

- The water inlet solenoid valve is ener-gised, if necessary, until the max. water level is reached.

- Led 5 illuminates to indicate activation of the automatic filling cycle.

- Once the max. water level is reached, the compressor, if the water temperature is above the set value, starts up.

- The compressor shuts down when the set value is reached.

- In these conditions led 4 remains lit to indicate that compressor operation is controlled by the thermostat.

5.3 Water heating function.

Alternatively, if key 4 is pressed twice (double click) the machine sets to heating mode: the relative led 4 illuminates (red). - the display shows the temperature read

by the water sensor

- The water inlet solenoid valve is ener-gised, if necessary, until the max. water level is reached.

- Led 5 illuminates to indicate activation of the automatic filling cycle.

- Once the max. water level is reached, the resistance is activated if the water tem-perature is below the set value.

In any event the resistance cannot be activated unless the max. water level is reached.

The resistance shuts off when the set value is reached. In these conditions led 4 remains lit to indicate that heater operation is controlled by the thermostat.

- In both these operating modes, key 4 causes shutdown of the compressor or resistance and deactivation of led 4 . - All the other functions (temp. on display,

pump, etc.) remain enabled.

If key 4 is pressed and held the machine exits the operating routine and sets to stand-by status.

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GB

5.4 Electric power failure

In the event of a power failure, either momen-tary or prolonged, the machine must resume operation from the same conditions in which it stopped: if it was in stand-by phase it resumes this status; if the compressor, heat-ing resistance or fillheat-ing solenoid valve were in

operation, these resume operation. However,

this does not apply to the pump: even if in operation prior to the power failure, it remains off when the system is restarted.

5.5 Rapidmac version with pump a0) Pump and litre counter control

Pump operation depends on the maxi-mum pump activation time (3’), after which the pump shuts down and delivery is stopped.

If the pump is disabled the relative push-button is also disabled.

a1) Litre counter disabled, Remote per-missive disabled (machine without litre

counter, without dispenser and without external dispenser/mixer but with pump): Press key 6 to illuminate the relative led and activate the pump outlet.

Press key 6 again to turn off the led and shut down the pump.

a2) Litre counter disabled, Remote

per-missive enabled (machine without litre

counter, but with dispenser or external dispenser/mixer and with pump):

On closure of the remote permissive input for the dispenser/mixer, the pump outlet is acti-vated and the led of key 6 illuminates. a3) Litre counter enabled: (machine with

litre counter, but without dispenser or external dispenser/mixer and without pump).

When pressed once, key displays the number of litres already present in the mem-ory, led 6 flashes (the value can be mod-ified by means of the / keys)

When pressed twice key 6 confirms the set value and activates the water outlet. At the end of the count of litres on output (shown on the display) the tank is emptied. 5.6 Rapidmac manual version

Litre counter enabled, Remote permissive and pump disabled: (machine with litre

counter, but without pump, dispenser or external dispenser/mixer)

- In this configuration, if key 6 is pressed the litre counter is set to count the litres delivered: the display shows the value 00 and as soon as the pulses are sent from the litre counter, the count of litres delivered is started and shown on the display.

- In any event, in the same configuration, as soon as the pulses are sent from the litre counter, the count of litres delivered is started and shown on the display. If key 6 is pressed this exits the count of the litres delivered. On subsequent delivery the litre counter will start from 00.

After 30 seconds in which the litre counter no longer sends pulses, the display returns to the temperature reading.

6.1 List of other operating faults not indicated:

FAULT CAUSE SOLUTION

Compressor does not operate 1 - Power failure 1 - Check connection to power lines 2 - Thermal cutout trip 2 - Wait for automatic restart interval Condenser fan does not operate 1 - Power failure 1 - Check connection to power lines

2 - Fan fault 2 - Seek assistance from a service technician 3 - Air condenser dirty or clogged 3 - Clean the condenser

Electronic card does 1 - Power failure 1 - Check connection to power lines

not switch on 2 - Protective fuse broken 2 - Seek assistance from a service technician Compressor operates but does 1 - Shortage of refrigerant gas 1 - Seek assistance from a service technician not cool tank water 2 - Condenser soiled 2 - Clean the condenser

Water pump does not operate 1 - Power failure 1 - Check connection to power lines

2 - Mechanical seizure 2 - Seek assistance from a service technician Litre counter does not operate 1 - Mechanical seizure 1 - Seek assistance from a service technician

2 - Electronic card faulty 2 - Seek assistance from a service technician Alarm “AL1” on display 1 - Temperature sensor faulty with 1 - Replace sensor

compressor shutdown

Alarm “AL2” on display 1 - Maximum pressure switch trip 1 - Seek assistance from a service technician 2 - Fan faulty 2 - Seek assistance from a service technician 3 - Condenser is soiled 3 - Clean the condenser

Allarm “AL3” 1 - Water level sensor faulty 1 - Close the water filling valve Seek assistance (water outlet from overflow) from a service technician

2 - Water filling solenoid valve faulty 2 - Seek assistance from a service technician Allarm “AL4” 1 - Membrane keypad faulty 1 - Seek assistance from a service technician

1 Alarm (AL1) temperature sensor faulty 2. Alarm (AL2)

(Maximum pressure switch tripped) man-ual reset

3. Alarm (AL3)

(no water or level sensor faulty) 4. Alarm t(AL4)

Membrane keypad faulty

A NOTE ON ALARMS:

During alarms, the beeper sounds and the display shows the type of alarm. The alarm message remains on the display even when the beeper has been silenced, until the cause has been eliminated

In the case that more than one alarm has been activated, each one is alternately dis-played. The alternating frequency of display enables reading of each text.

When the beeper sounds, the user can stop it by means of the shutoff button.

6. ALARMS, SIGNALS, BEEPER, AND SHUTOFF

PUSHBUTTON MANAGEMENT

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The information and instructions given in this section address all persons operating the appliance: the user, the maintenance techni-cian and non-specialised personnel.

Ensure that the electrical power to the system has been disconnected before carrying out any cleaning or maintenance work on the appliance.

7.1 BASIC SAFETY REGULATIONS

To safely carry out all cleaning and rou-tine maintenance operations, follow these rules.

- do not touch the machine with moist or wet hands or feet.

- never operate the machine while bare-foot.

- do not insert screwdrivers, cooking uten-sils or any other object between the guards and moving parts.

- before performing cleaning or routine maintenance operations, disconnect the machine from the power supply at the master switch and by pulling out the plug.

- Never pull on the power cable to discon-nect the machine from the power supply. Removal of guards and safety devices for the purposes of routine maintenance is strictly prohibited. The manufacturer declines all responsibility for accidents caused by failure to observe the above regulation.

7.2 CLEANING THE CONDENSER

1) Progressive accumulation of dust on the front section of the condenser will gradu-ally reduce efficiency of the cooling cir-cuit.

PERFORM THIS OPERATION ONLY AFTER THE APPLIANCE HAS BEEN SHUT DOWN

Therefore make frequent inspections of the condenser and clean with a non-metal brush or vacuum cleaner.

2) At least once a year, check for deposits of lime scale on the cooling coil inside the container: this will avoid wasteful energy consumption and cooling output. To remove these deposits, use a solution of water and citric acid.

3) Drain the water from the tank if the machine is not used for prolonged inter-vals.

4) Periodically clean the water filter car-tridge (optional).

5) IMPORTANT

The condenser has sharp edges. Use protective gloves when cleaning.

7. MAINTENANCE AND CLEANING

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THESE OPERATIONS MUST BE PERFORMED BY A CERTIFIED INSTALLATION

I - 31033 Castelfranco Veneto (TV) Italy Tel. +39.0423.738451 Fax. +39.0423.722811 E-mail: [email protected] Web-site: www.castelmac.it Cod. 71503589/0 - 03/2004