Operations and Technical Manual - MFR Eng€¦ · Date of Issue January 08 Operations and Technical...

Date of Issue January 08

Operations and

Technical Manual

Multigen III Series

Date of Issue January - 08

Table of Contents

Section Content Page No.

1. Introduction ................................................................................................................. 8

1.1. Introduction ............................................................................................................ 8 1.2. Help: Who to Call ................................................................................................... 9 1.3. Acknowledgement of Purchase Order ................................................................ 10 1.4. Equipment Installation ......................................................................................... 10

1.4.1. Cart Placement Drawing ........................................................................... 10 1.4.2. Electrical Supply Requirement ................................................................. 10 1.4.3. Cart Receiving and Installation Guideline ................................................ 11

2. Installation and Start-up Schedule ......................................................................... 12

2.1. Implementation Time Table ................................................................................. 12 2.1.1. Physical Changes/Equipment ................................................................... 12 2.1.2. Operational Changes/Training .................................................................. 13 2.1.3. Human Resources Plan ............................................................................ 14 2.1.4. Public Relations ........................................................................................ 14

2.2. Go-live Schedule - Last 2 Weeks ........................................................................ 15

3. Pre-start-up planning activities ............................................................................... 16

3.1. Planning Operational Activities ............................................................................ 17 3.1.1. Planning Worksheet .................................................................................. 17 3.1.2. Retherm/Meal Delivery and Pick-up Schedule......................................... 26 3.1.3. Retherm/Loading Schedule ...................................................................... 27 3.1.4. Bulk Retherm Cycle Times ....................................................................... 28

3.2. Implementation Checklist - Bulk Retherm Cart ................................................... 29 3.3. Forms and Samples............................................................................................. 31

3.3.1. Sample Nursing Information Session Agenda ......................................... 31 3.3.2. Sample poster - "Meal Service Gets a New Look" ................................... 32 3.3.3. Food Temperature Recording Chart 1 ..................................................... 33 3.3.4. Food Temperature Recording Chart 2 ..................................................... 34 3.3.5. Food Temperature Recording Chart 3 ..................................................... 35

4. Food Production ....................................................................................................... 36

4.1. General Guidelines ............................................................................................... 36 4.2. Questions on Cook-Chill ....................................................................................... 37 4.3. Convection Heat ................................................................................................... 37 4.4. Gastronome Pan Sizes: What Does It Mean ....................................................... 38 4.5. Cook/Chill Guidelines: Cooking Instructions ........................................................ 39 4.6. Recipe: Breakfast Items: Egg Recipes ................................................................. 40 4.7. Thermometer Testing and Recalibration Instructions .......................................... 41 4.8. Food Service Audit................................................................................................ 42


5. Panning and Loading Guidelines ........................................................................... 44

5.1. General Guidelines ............................................................................................... 44 5.1.1. Samples of Forms to Be Used .................................................................. 45

5.2. Panning Guidelines ............................................................................................... 54 5.2.1. Planning the Panning Process ................................................................. 54 5.2.2. General Panning Guidelines ..................................................................... 55 5.2.3. Panning Guidelines for Bulk Retherm ...................................................... 56

5.3. Loading Guidelines ............................................................................................... 62 5.3.1. Loading Diagrams ..................................................................................... 63

A. Loading the Oven Example I ................................................................ 64 B. Loading the Oven – Example II ............................................................ 65

6. Cart Operating Procedures: Multigen III Double Refrigeration ........................... 66

6.1Pre-retherm Procedures .......................................................................................... 66 6 .1.1 Pan Loading Procedure in the Module (Rack) ......................................... 66 6 .1.2 Diet Changes ............................................................................................ 66 6 .1.3 Transferring the Module to the Multigen with the Dolly Option ................ 67 6 .1.4 Setting Up the Cart for Service: Safety Recommendations ..................... 67

6.2 Control Panel Operation: Multigen III ..................................................................... 68 6.2.1 Control Panel: Multigen III ........................................................................ 68 6.2.2 Control Panel Instruction: Multigen III ...................................................... 68 6.2.3 The Function Menu ‘F’ .............................................................................. 71

6.3 Post-retherm: Temperature Testing of Products .................................................... 71 6.4Temperature Boosting Procedures - Multigen III ..................................................... 72 6.5 Meal Service Procedure .......................................................................................... 72

6.5.1 Getting Ready for Service......................................................................... 72 6.5.2 Transporting the Retherm Cart ................................................................. 73 6.5.3 Service ...................................................................................................... 73 6.5.4 After Service Procedures .......................................................................... 74

6.6 Cleaning the Retherm Cart ..................................................................................... 74 6.7 Cleaning Schedule .................................................................................................. 75 6.8 Towing Procedure ................................................................................................... 76

7. Training Materials - Multigen III Double Refrigeration ......................................... 78

7.1 Training Materials - Multigen III .............................................................................. 78 7.1.1 Cart Operation Summary ............................................................................. 79

Manual Start .............................................................................................. 80

Automatic Start ......................................................................................... 81 7.1.2 Cart Operation Posting Materials ................................................................ 82

Load/Start with Automatic Timer .............................................................. 83

Manual Start … If You Are Late ................................................................ 84

Ready for Service ..................................................................................... 85

After Service.............................................................................................. 86 7.1.3 Detailed Training: Pre-retherm .................................................................... 87

Panning ..................................................................................................... 88

Loading ..................................................................................................... 89


Transferring the Module to the Cart with Dolly Option ............................. 90

Connecting the Cart to the Power Supply ................................................ 91 7.1.4 Detailed Training: Post-Retherm .............................................................. 92

Temperature Testing of Products ............................................................. 93

Temperature Boosting .............................................................................. 94 7.1.5 Preparing the Cart for Service ..................................................................... 95

Getting the Cart Ready ............................................................................. 96

Transporting the Cart for Delivery ............................................................ 97

Serving Meals from the Cart ..................................................................... 98 7.1.6 Post Meal Service ........................................................................................ 99

After Service............................................................................................ 100

Sanitation for the Retherm Cart .............................................................. 101

Towing Safety - DO................................................................................. 102

Towing Safety - DO NOT ........................................................................ 103 7.2 Training Records ................................................................................................... 104

Training Review/Schedule .............................................................................. 105

Supervisory Staff Training Log ........................................................................ 106

Dietary Staff in Service Training Log .............................................................. 107

Meal Service Procedures - Training Log ........................................................ 108

Notes ............................................................................................................... 109 8. Programming Procedures - Multigen III Double Refrigeration .......................... 110

8.1 Touch Pad Control Panel: Display ..................................................................... 110 8.2 Touch Pad Control Panel: Functions ................................................................. 111 8.3 Programming Instructions ................................................................................... 112 8.4 Automatic Timer Programming Table "Actual Settings" ................................... 116 8.5 Programming Table "Actual Settings" ............................................................... 117 8.6 Procedure Following an RESET Error Code ..................................................... 121

9. Troubleshooting ...................................................................................................... 122

9.1 Equipment Problems: Quick reference ............................................................ 122 9.2 Temperature Troubleshooting Guide For Food Service .................................. 123

A) Cold Food: Not Cold Enough (Multigen II with refrigeration) .................... 123 B) Hot Food: Not Hot Enough ........................................................................ 124 C) Hot Food: Too Hot ..................................................................................... 124

9.3 Programming Troubleshooting Guide .............................................................. 125 9.4 Emergency procedures Bulk Retherm Cart ..................................................... 129

A) Temporary Power Failure ........................................................................... 129 B) Major Power Failure: Emergency Power Activated ................................... 129


10. Maintenance ............................................................................................................ 130

10.1 Service Training and Sign-Over Document .................................................. 130 10.2 Implementation Equipment List/Serial Numbers - Bulk Retherm ................ 131 10.3 Maintenance Log Book ................................................................................. 132 10.4 Preventative Maintenance ........................................................................... 134 10.5 Warranty and Service ................................................................................... 134 10.6 Preventative Maintenance Check List .......................................................... 136 10.7 Maintenance Reports .................................................................................... 137

11. Reports ................................................................................................................. 141

11.1 Installation Report ......................................................................................... 142 11.2 Site Visit Reports .......................................................................................... 143

12. Operation and Technical Manual .......................................................................... 141 13. Burlodge Correspondence ...........................................................................................


FORMS Page No.

M001v1 Jan-01 Retherm/Meal Delivery and Pick-up Schedule ...................................... 26

M002v2 Jan-08 Retherm/Loading Schedule .................................................................... 27

M003v1 Jan-01 Bulk Retherm Cycle Times ..................................................................... 28

M004v1 Jan-01 Food Temperature Recording Chart 1 ................................................... 33



M007v1 Jan-01 Food Audit - Before and After Service ................................................... 43

M008v2 Jan-08 Meal Tally Sheet ..................................................................................... 46

M009v1 Jan-01 Hot Tally Sheet for Production and Cart Loading .................................. 47

M010v1 Jan-01 Tempering and Pull Out Sheet ............................................................... 49

M011v1 Jan-01 Tempering Schedule .............................................................................. 51

M012v1 Jan-01 Daily Panning Schedule ......................................................................... 52

M013v1 Jan-01 Training Review/Schedule .................................................................... 105

M014v1 Jan-01 Supervisory Staff Training Log ............................................................. 106

M015v1 Jan-01 Dietary Staff In-Service Training Log ................................................... 107

M016v1 Jan-01 Meal Service Procedures - Training Log .............................................. 108

M019V3 Jan-08 Multigen III with Refrigeration Programming Table ............................. 117

M022v2 Jan-08 Service Training and Sign-over Document .......................................... 129

M023v2 Jan-08 Implementation Equipment List/Serial Numbers - Bulk Retherm ........ 131

M024v1 Jan-01 Maintenance Log Book ......................................................................... 132

M025v2 Jan-08 Preventative Maintenance Check List .................................................. 136

Date of Issue January - 08 7

Introduction

Installation and Start-up Schedule

Pre Start-up Planning Activities

Food Production

Plating and Tray Assembly Guideline

Cart Operating Procedures

Training Materials/Training Records

Programming Procedures

Troubleshooting

Maintenance

Reports

User Manual

Burlodge Correspondence


1. INTRODUCTION

1.1 Introduction

Thank you for purchasing your new Burlodge Bulk System from the Burlodge Multigen Series: Multigen III. For ease of communication we may use the word Bulk Retherm Cart when referring to any of these retherm carts in a general context. This manual is provided to you as part of the comprehensive support package Burlodge includes with every piece of rethermalization or temperature boosting and maintenance equipment it sells. It does not replace our representatives' involvement with you but merely enhances it. Our goal is to help you in the planning and the execution of your start-up, including the training of all staff involved. The purpose of the manual is not to tell you, as the operator, how to run your business. This manual was designed as an aid to guide you in some of the basic cook-chill operational techniques so that you can apply the equipment to your particular application in the most suitable and efficient way possible. We have also included technical information to maximize the life of your equipment. The Burlodge Multigen Series was designed to provide you with options and flexibility at virtually every stage of your operating process. The equipment works for YOU! The operation of the carts and the food preparation and panning techniques necessary are relatively simple, requiring little, if any modification to the procedures you may already be using. Likewise, meal service may need some changes to accommodate the requirements of the system. You will note that the sections on panning and production are relatively brief and generic in their scope. The manual includes various forms for recording staff training as well as operational activities such as timing or temperature monitoring. These forms are provided as a guide and convenience to you, the user. You may of course prefer to use documentation that is designed by you for your specific application. If you should choose to use the forms provided in this manual we would be happy to provide you with these documents in an electronic format. We are sure that by following the guidelines in this guide, the Operations and Technical Manual, you will have many years of use from your equipment. During that time you will be able to provide your “customers” with the quality and temperature of meals that you strive to produce every day and that they, and legislative organizations, demand.


North American Offices

1.2 Help! Who to call?

USA OFFICE:

Burlodge USA, Inc.

3760 Industrial Drive

Winston Salem, NC 27105

Toll Free: (877) RETHERM

Telephone: (776) 336-1010

Fax: (776) 336-1090

E-mail: [email protected]

World Wide Web www.burlodgeusa.com

CANADA OFFICE

Burlodge Canada

10 Edvac Drive

Brampton, Ontario L6S 5P2

Canada

Toll Free: 1-888-609-5552. Press 2

Phone: 905-790-1881

Fax: 905-790-1883

E-mail: [email protected]

World Wide Web: www.burlodgeca.com


1.3 Acknowledgement of

Purchase Order Include estimated delivery date and copy of order

1.4 Equipment Installation 1.4.1 Cart placement drawing 1.4.2 Electrical supply requirement 1.4.3 Cart receiving and installation guideline

1.4.1 Cart placement drawing - Place a copy at the end of this chapter.

1.4.2 Electrical Supply Requirement

The following information details the type and rating of the electrical supply that is required for the Bulk Retherm Cart. It is the responsibility of the client facility to provide correctly rated and safely installed supply in accordance with local building regulations, National and local Electrical Codes. We require that the "female" electrical receptacle, detailed below, be provided, either as a "drop down" cord set with retractor, or as a flush or surface mounted wall receptacle.

Note: Burlodge recommends the drop-down cord for added flexibility and ease of operation.

120/208 volt, 3-phase, 4-pole, 5-wire (neutral and ground), rated for 20 amps The NEMA Receptacle is L21-20R receptacle

The measured supply voltage under load must be a minimum of 208 V, phase to phase. Wall receptacles or "drop down" cords must be installed by a qualified electrician and be correctly connected to Ground. Ensure that the receptacle or "drop down" cord is long enough and is located so that the Cart cannot damage it, yet remains easily accessible to the operator without stressing the cable.

The Multigen III models require two receptacles per cart. The Multigen III with Refrigeration has two on left end of the cart (when facing the oven doors).


1.4.3 Cart Receiving and Installation Guideline

1. Check transportation routes and access for any obstructions that may cause damage to the cart.

2. Check access doorways and corridors to ensure there is sufficient space for the Cart to pass

through without danger of either the building fabric or Cart being damaged.

3. Check that elevators that are to be used for transportation of the Cart have sufficiently wide entrances to enable the Cart to be loaded and unloaded without damage being caused to either the elevator or Cart.

4. Installation position for wall mounted receptacles:

Height from Floor (2 Receptacles/cart) 36" Spacing Receptacles Between Carts 63” minimum (Assumes end to end positioning parallel to wall)

5. Ensure that the floor surface is flat and even.

6. Multigen III models require two receptacles per cart. When facing the oven doors, the

receptacles are on the left end (side) panel.

7. For positioning of carts other than above please consult your Burlodge Representative.

63" 63"

36" 36"


SECTION 2

INSTALLATION AND START-UP SCHEDULE 2.1 Implementation Time Table 2.1.1 Physical Changes/Equipment

Item Task to be completed Responsibility of: Completion Date

1 Finalize equipment and small ware orders Facility/Burlodge Wk 1

2 Confirm electrical and physical requirements: retherm and/or at service

Facility/Burlodge Wk 5

3 Determine location of electrical hook-ups:

for retherm and/or at service point Facility/Burlodge Wk 6

4 Confirm local service agent or complete

service agreement contract between Facility/Burlodge


5 Verify electrical hook-ups Facility/Burlodge Wk 11

6 Receive equipment into facility Facility/Burlodge Wk 14

7 Verify operation of equipment Burlodge Wk 14

8 Service training for engineering staff Burlodge Wk 14

9 System Goes Live Facility/Burlodge Wk 15


2.1.2 Operational Changes/Training


1 Finalize menu for bulk retherm system Facility/Burlodge Wk 6

2 Start to do tallies for forecasting Facility Wk 6

3 Complete staff work schedules Facility/Burlodge Wk 6

4 Complete temperatures and HACCP procedures


5 Determine transport times and service

schedules for each service Facility Wk 8

6 Computer systems “on-line” for ordering,

diet information, tally Facility Wk 9

7 Address Diet Office issues and policies Facility Wk 10

8 Complete interim menu for transition period

Facility Wk 10

9 Complete interim procedures for start-up Facility Burlodge Wk 12

10 Review panning/retherm/service procedures with staff. Trial the Service process and adjust staffing equipment.


11 Review/finalize all implementation plans,

work schedules and transportation procedures


12 Begin in-service training Facility/Burlodge Wk 14

13 Complete in-service training Facility/Burlodge Wk 14

14 Complete tallies and set-up forecasting estimates for panning.

Facility Wk 14

15 Finalize date and meal period for “go-live” Facility/Burlodge Wk 14



2.1.3 Human Resources Plan


1 Determine long range staffing requirements

Facility Wk 1 minus 4

2 Advise staff affected by reorganization

changes Facility Wk 1

minus 4

3 Review work schedules with staff/unions Facility Wk 1 minus 4

4 “Key” personnel to visit existing

installations Facility/Burlodge Wk 2

5 Set up training schedules for food service

and other staff Facility/Burlodge Wk 4

6 Set up orientation sessions as needed Facility Wk 8

7 Post new daily schedules in advance of “go live”

Facility Wk 13


2.1.4 Public Relations


1 Establish marketing/educational programs for – Food Service staff, other facility staff, community

Facility Wk 2

2 Execute marketing/educational programs Facility Wk 4 - 15 3 Review start-up procedures with Nursing,

Food Services and other affected departments

Facility Wk 6 - 12



2.2 "Go Live" Schedule - Last 2 Weeks

Date Time &

Location Task / Training

Responsibility of:

Week 14 Commence in-service training – cart set-up, service, controls, cart operation, panning, cleaning.

Burlodge

Week 14 Equipment checked by Burlodge

technical staff. Burlodge

Week 14 Automatic Timers set - Hospital to

provide “service time” (wk. 8) Burlodge

Week 14 Unpacking/washing of new service

wares Facility Staff

Week 14 Wash Burlodge equipment/label carts Facility Staff Week 14 Training sessions completed Burlodge Week 15 (Evening prior to start-up day)

Remove old equipment from kitchen. Complete panning for next 2 meals. Set up service cart

Facility Staff and Burlodge Team

Week 15 (start-up day)

Serve 1st Meal

Continued coaching on panning, set-up, transportation, service and cleaning Pan for the next meal according to schedule Troubleshoot, monitor temperatures and food quality Review days activities and plan amendments as necessary

Facility Staff and Burlodge Team

Week 15 to Week 16

As start-up day Facility Staff and Burlodge Team


SECTION 3

PRE START-UP PLANNING ACTIVITIES The following material is included to assist you in the pre planning start-up activities.

A “Pre-Start-up Planning Worksheet” to walk you through some of the decisions that need to be made regarding operational activities.

A “Retherm/Cart Delivery and pick-up schedule”- to use once you have established the service time with nursing.

A “Retherm/Loading Schedule”- to be used with the worksheets.

“Unit Retherm Cycle Times”- to be posted at the time of start-up with the retherm unit. Remember that Burlodge representatives are always available to help you in the planning stages. He/she will also call on you to review the "Implementation Check List” to ensure that the planning is on schedule.

An “Implementation Check List” to help you review the planning at a glance. We have also included some other implementation forms and samples that may be useful to you.

A sample agenda for a "Nursing Information Session".

A sample public relations poster to announce the new system (to the hospital).

Food Temperature Record (3 charts).

Production Volume Forecasting.

Date of Issue January - 08 Page 17

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3.1 Planning Operational Activities

3.1.1 Planning Worksheet (FormT001v2 Jan-08)

Dates:

Start-up date for Bulk Service: First Meal served: Start-up date for Cook-Chill Production:

Equipment Ordering:

Carts: How many/what sizes? Type Accessories: Service Cart Dollies/Extra Complement Transfer Modules/Extra Complement Rack Covers Carts for Soiled Trays

P.O. issued on: Delivery scheduled for:

Ancillary: Pans: stainless/disposable Sizes: Lids for pans/aluminum foil (heavy duty) Type of dishes: China ? Melamine? Size of entrée plate Re-usable versus disposable for beverage, soup, dessert, bread plate Use of Entrée cover/dome? Ovenproof containers for small portions Holding or storage of cold items


Production Equipment


Other



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Meal Service: Vision

Questions to ask and get an answer BEFORE the start-up date:

1. Type of Service:

Dining Room Service: Waitress service?

Tray service: With menu without menu Tray assembly at Service point: With menu? Staffing: Dietary and/or Nursing

Choice given Location of Service points/electrical available

Note: It is important that all players are kept informed throughout the whole process. 2. Service:

Number of serving per pan x number of pans = number of residents per retherm cart Complete the above for every meal for the whole cycle.

Decide the type of panning/service pans to use: ½ s, 1/3 s, ¼ s

Service cart? What will it hold?

Bulk Retherm What will it hold on the shelves / Heated Top Plate

Coffee/tea/hot water service? Type of carafe?

Dessert/poured drink: bulk or individual?

Bread, rolls: pre-wrapped?

Sandwich: in bulk? On plates?

Silverware: Pre-wrapped?

Kosher meals/Vegetarian/Isolation trays

Panning Schedule

Plan the panning schedule, the staffing required and the availability of the tally prior to the meal and/or the forecasting. 1. Breakfast:

2. Lunch:

3. Dinner:


Panning Schedule

Transportation of clean/soiled dishes

Tray service vs. item service

Diet: Menu Diet sheet Cardex

Dining Room: Table pre-set with??

Corridor Service: Location of outlet(s) (2 per cart) Spacing around cart(s)

Special Requests

2. Make a drawing of the Carts Set-up. Check with Burlodge before posting.

Breakfast Meal Service set-up:

Retherm Cart Service Cart Before service: During service: Before service: During service: Left and right oven Left and right oven

Lunch Meal Service set-up

Retherm Cart Service Cart

Before service: During service: Before service: During service: Left and right oven Left and right oven

Dinner Meal Service set-up

Retherm Cart Service Cart Before service: During service: Before service: During service: Left and right oven Left and right oven


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Determine the placement of ALL the equipment

1. Determine the placement of the retherm equipment and accessories in the kitchen/retherm room(s). *Before loading the retherm cart with Hot & Cold Food

*Before setting up the ancillary for the retherm cart and/or the Service cart

*During retherm

*After service, when the carts return to the kitchen:

Where to unload?

What is being discarded? Where?

Where to place remaining leftover items?

Where to clean? Use dolly to remove racks?

2. Panning: How? *Individual racks for each unit? Use transfer modules? Label?

*Pan individual items for each unit? Pan one item for all the units?

*Extra items for last minute changes: where?

*Marking of each pan: What product? Number of portions?

*Pre plated entrée for pureed? Minced?

*Location of racks between meals?

*How/who will do the cleaning and rotation of the racks?

3. Determine the location of the dollies/transfer module when not in use: 4. Determine the loading of the "HOT" and the "COLD" items. *where

*who

*when

5. After Service: Soiled Tray Pick-up, waiting to be stripped


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Drawing of Retherm and Service Cart set-up:


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Determine the Timing for:

Panning, Loading, Retherm Cycles, Transportation, Trays Service and Pick-up. First, determine, with Nursing, the Service schedule for each ward.

"Retherm/Cart Delivery and Pick-up Schedule": use form M002V1.

Fill in Requested Service time for each unit.

Determine the time needed for the cart to reach the ward – Transport Time.

From that, fill in the time you want the retherm to be ready. Second, determine the Retherm/Loading Schedule

Use Form M003v1: transfer the "Service Time" and the "End of Cycle Time" for each meal. With this form you can tentatively schedule the loading times for the left and right oven. Based on an average retherm cycle of 45 minutes for Breakfast and 55 minutes for Lunch and Dinner, fill in the time for the retherm start time.

Later we will use the Form "Unit Retherm Cycle Times".

Note: Check with your Service Representative to finalize the lengths of cycles for your site. Third, determine the schedule for Loading HOT and COLD Food

Continue Form M003v1: complete Loading section for Hot and Cold Section.

If your retherm cart has refrigeration, the timing for loading could be more flexible. Allow at least 30 minutes between loading time of the Cold Section and the retherm start-up time.

If no refrigeration on the Hot Side, do not load more than 15 minutes prior to retherm start-up time.

Fourth, determine Pick-up Schedule

Allow time for patients to eat or be fed.

From this information, you will be able to plan the timing for the dish room.

Determine the time required for each panning session

Determine the time required for panning, labeling and delivery of panned items Breakfast: # of portion # of pans # of racks Lunch: # of portion # of pans # of racks Dinner: # of portion # of pans # of racks Determine the sequence:


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Meal Service

1. Before Retherm: Who? When?

*Plug in the retherm cart. *Turn it "ON". *Load the HOT Food. *Load the COLD Food. *Start Retherm cycle, if not using the Auto start. 2. After Retherm: Who? When?

*End of cycle. *Take and record temperatures. *Start a Boost cycle, if needed.

3. Meal Service

*Who assembles and delivers the meals? *Time allocated for each ward? *Number of staff serving? *Time allocated between wards, if staff serve in more than one unit (elevator).

4. Tray pick-up *Who picks-up soiled trays/dishes?

*Does Nursing help? Training needed?

Tallies/Forecasting/Diet Changes

1. Plan the Process: Forecast

Panning

Tallies

Loading

Service

Diet Changes/New admissions/Late trays.

2. Forecasting: Set up a system for Tallies/Forecast.

3. Work with Nutrition Services to assure a smooth transition.

4. Plan extra food for diet changes/new admission -additional broth, cream soup, gelatin, etc

5. Plan for food requests during meal service: need for extra, where, how?

6. Other diet change related issues:


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Cleaning:

1. Plan the organization of the dish room and the pot wash area.

2. Plan for each new piece of ancillary: How will it get washed? E.g.: Coffee carafes

3. Purchase appropriate and correct number of baskets.

4. Plan for the flow of extra equipment and the extra complements of pans.

5. Determine when and where the dollies will be cleaned.

6. Determine the procedure and the frequency of the Bulk Cart cleaning: daily and deep.

7. Plan to remove any abrasive scrubbing products from the department to maintain the state of the new dishes

Pre Start-up Staffing:

Plan to schedule EXTRA staff for the following: Function Time required When Staff member 1. Unpack dishes/pans/lids 2. Wash trays 3. Wash covers 4. Wash main entrée dishes 5. Wash other new dishes 6. Wash transfer modules and dollies 7. Wash Bulk Retherm Carts 8. Wash other new equipment: service carts/racks Note: *Plan about 15 minutes per Retherm Cart for a good cleaning: inside and out.

*Transfer module: clean every shelf, top and bottom, including the slides. Plan for about 5 minutes per module and dolly


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Training and Information Sessions:

1. Determine WHO needs training and any special information that you want the Burlodge team to include in the training. Dietary aides: ~1 hr to 1 1/2 hours Porters: ~1 hr Nursing: ~15 min if information only Menu clerk(s) Dietitian(s) Food Service Management: *Plan one person from management to attend every session with staff. *Plan a one-hour session as a group, before start-up.

*Plan another one-hour session for key management, for programming training, before Start-up. Maintenance: 2 hrs

2. In planning the staff training schedule, with your Burlodge Representative, plan for: 8 to 12 people per session A quiet location, with enough room for ►the retherm cart

►dolly and transfer module (option)

►service cart

►ancillary

A tray sample with the dishes to be used. A fully set-up service cart. An electrical outlet in the room (120V).


FO

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3.1.2 Retherm/Meal Delivery and Pick up Schedule (Form M001v1 Jan-01)

Breakfast

Nursing unit Start End Service Pick-up

Lunch


Dinner



FORM

3.1.3 Retherm/Loading Schedule (Form M002v2 Jan-08)

Retherm Schedule

Unit

Module Breakfast Cycle 1 Service

Time Lunch Cycle 2 Service

Time Dinner Cycle 3 Service

Time Start End Start End Start End

Loading Time LEFT OVEN Side/COLD Side

Unit

Module Breakfast

Lunch

Dinner

Left Right Left Right Left Right


FORM

3.1.4 Bulk Retherm Cycle Times (Form M003v1 Jan-01)

AUTOMATIC RETHERM TIMES

UNIT:

Loading Start End of cycle

Breakfast

Lunch

Dinner


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3.2 Implementation Checklist: Bulk Retherm Cart

Hospital Name:

Burlodge Contact:

Telephone: Fax:

Equipment Ordering/Receiving

Purchase Order Issued:

Targeted Go-Live Date Communicated: Staff: Burlodge:

Operations

Review timing:

Panning Loading Service

Review Temperature Monitoring:

Refrigeration HACCP Oven/Heated Top Plate/Gantry

Reviewed:

Pans sizes/number Tray Setups

Service Setup Service Equipment

Staffing positions Staffing outline for each position

Training Needs Nursing Engineering Production/Panning Aides

Dates

Content

Location

Training Materials

Public Relations Needs:

Press Conference Give-away Meal Presentations

Displays Information Bulletins First Meal Cards

Menu Review:

Dates for trial of questionable items:

Hot Beverage Service Meal tickets – Tallies - Forecasting

Obtain service times for each unit.

Disposable products:

Rack covers Tray mats Isolation procedures

Procedures:

Information to be posted

Service call procedures


Start-up:

Delivery Date and Schedule confirmed:

Equipment:

Received Counted Signed off (for quantity)

Breakage

Recorded Signed off

Ancillary

Assembled Cleaned Washed

First Meal

Food extras (card) Information slip Tray mats

Times for units programmed on carts

Equipment tested:

Retherm cycle Refrigeration Timers

Beepers Fans

Standard program – recorded

Left Oven Multigen III

Right Oven (Multigen III)

Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3

Oven Temp

Total Time

Grat.Temp

Grat. Time

Service/Maintenance Cycle Oven Temperature Cycle Time

Service Agreement Reviewed:

Nutrition Engineering

Service Training:

Completed Sign off Form


SA

MP

LE

3.3 Forms and Samples

3.3.1 Sample Nursing Information Session Agenda

Nursing Information Session

Agenda

1. Who, what, and why?

Who is Burlodge Manufacturer of the new Meal Delivery System

What is the new "System" A combination of Bulk Rethermalization and Service close to the resident

Why are we changing -To improve the quality of service -To give more choice at point of service -Equipment needed replacing -Partnership with another facility

What should you expect -Moist, hot food: gently heated, in a convection oven -Appetizing and "home smell"

2. "How does it work"?

How the "Multigen" works -Food is rethermed, then taken to point of service -Light and Hot top keep food hot during service

How do we deliver the food -Patients are asked to make a choice -Tray is taken to the room or table

How do we pick-up the trays -Extra rack will be taken to the unit

3. Questions and answers


3.3.2 Sample "Public Relation"

Poster

is pleased to announce

the installation of the new

Bulk Meal System

from Burlodge USA, Inc.

IMPLEMENTATION BEGINS DECEMBER 2012

What? A new “More like Home” system for Meal Delivery

Why? To improve presentation, quality and food temperature of

resident meals

When? Beginning December, 2012


FO

RM

3.3.3 Food Temperature Recording Chart 1 (Form M004v2 Jan-08)

Day 1 - Cart #1 Month of

Week 1 Week 2 Week 3 Week 4

Temp before

Temp after

Temp before

Temp after

Temp before

Temp after

Temp before

Temp after

Meal / Menu

Breakfast

Left Oven: Cereal

Entrée

Right Oven: Cereal

Entrée

Lunch

Left Oven: Soup

Entrée

Right Oven: Soup

Entrée

Dinner

Left Oven: Soup

Entrée

Right Oven: Soup

Entrée

Note:

Take temperatures with the same probe.

Take temperatures in Fahrenheit /Celsius.

Standard to achieve - Hot Temperatures:


FORM


Item Cart #1 Cart #2 Cart #3 Cart #4 Cart #5 Before After Before After Before After Before After Before After

Left

Soup Meat

Potatoes

Right Soup

Meat Potatoes

Left Soup

Meat Potatoes

Right

Soup Meat

Potatoes

Left

Soup Meat

Potatoes

Right Soup Meat

Potatoes


FORM


FOOD TEMPERATURE RECORD

DATE FOOD ITEM MEAL TEMP PRIOR

RETHERM TEMP AFTER

RETHERM UNIT AREA


SECTION 4

FOOD PRODUCTION

4.1 General Guidelines

This manual will not provide guidance to the operator in terms of requirements related to food production. Advice relating to food production is customized to individual client’s specific needs.

It is our experience that numerous methods of production and procurement are being utilized throughout the industry today. That together with regional preferences means that each individual installation and application is unique.

Although some general criteria can be applied to production methodology and recipe formulation, we believe it is preferable to provide specific and customized advice to our clients. Consequently, our installation and start-up program makes allowance for our experienced production personnel to spend time with our client’s food production personnel, to customize production and recipe guidelines.

Food being prepared for the “Bulk Service” process in readiness for rethermalization may be produced in some of the following ways:

In house production using conventional cooking and blast chilling techniques.

In house production using conventional cooking and blast freezing techniques (products are later thawed in preparation for panning).

In house production using tank and kettle systems for both cooking and chilling in sealed casings.

Outsourced manufactured products from on institutional commissary using of the above Techniques.

Outsourced manufactured products from and food manufacturer using any of the above techniques or Techniques associated with factory production and recipe formulation.

Any combination of any of the above.

In this chapter we have included some basic information on Cook-Chill and Convection Cooking and the type of pans used. We also added some guidelines for Cook-Chill production.

Some food items that require low cooking temperature can be prepared directly in the Bulk Retherm Cart. We have included those recipes as an example of what can be done only.

Since Thermometers are widely used in Food Production, we have provided some instructions as to how to test and recalibrate your thermometers.

Finally, we have included a sample of a Food Service Audit form that can be useful in keeping a record of the different activities.


4.2 Questions on Cook Chill 1. What is Bag Chilling?

Soup, sauces and stews are poured into bags then Cryovac sealed closed. The bags are place into a water bath that contains and maintains a block of ice called an Ice Bank. The bags are agitated by a water pump - allowing for even cooling throughout the bags. This is an excellent way to chill liquid products.

2. What is Blast chilling? Food items are placed onto a rack and placed into a cabinet called a Blast Chiller. When the door is closed high-velocity fans circulate cold air. This will chill products down in the recommended times.

3. How many products will fit into a Stainless Steel Pan before Blast Chilling? One 12”X20”X2 ½” pan will hold 12lbs or 6qts of liquid. When placing product in pans it must never exceed 2 inches deep in order to achieve proper and safe temperatures in the allotted time.

4. Where is the food placed after chilling? Food items that have been chilled in the recommended time are placed into a holding Fridge.

Air temperature in the fridge should be 38 – 40 Fahrenheit (3 - 4 Celsius).

4.3 Convection Heat: 1. What is Convection Heat?

It is the production of dry hot air distributed by means of a motor – driven fan, at high velocity.

2. Why hot forced air (Convection) heat instead of a static retherm oven?

The oven reaches the required retherm temperature in less time.

Heating time is reduced and food can be rethermed at lower temperatures.

A total meal can be rethermed at once and all of the food will be ready at the same time.

For the same quantity of food this method saves energy.

Hot forced air distributes the heat evenly, it produces consistent results and the quality of the final dish is enhanced.

Plus

Optimized loading: all the different dishes can be rethermed together without mixing aroma or taste.

With the automatic timer, food can be rethermed without the necessity of handling food or continuously checking progress.


4.4 Gastronome pans sizes: what does it mean


Gu

id

el

in

es

4.5 Cook/Chill Guidelines: Cooking Instructions

PRODUCTS COOKING GUIDELINES

Grilled or fried fish Cook slightly on grill or in combi-oven.

Chops, escallops, steaks

Fry quickly on grill; cooking to be finished in combi or steam oven

Roast beef or lamb Cook in combi oven up to 50%; use piece of meat of no more than 5 lbs. (2.5 Kg).

Poultry or veal Cook in combi oven to 165 F (74°C) core temperature; use piece of meat of no more than 5 lbs. (2.5 Kg).

Swiss steak, stroganoff, beef bourguignon, etc.

Fry meat quickly in high-sided frying pan or in combi-oven; cook slightly in sauce; DO NOT overcook.

"Cube dish" preparation

Cubes to be 1/2" to 3/4" maximum thickness.

Panned dish 1 1/2" (50mm) maximum thickness (chilling will be done more rapidly and rethermalization will be more efficient).

Plain pasta To be cooked "al dente" and then chilled; refresh before service.

Pasta with sauce, macaroni and cheese

To be cooked "al dente" and then chilled; sauce to be slightly thick and chilled; combine sauce and pasta when cold.

Toast Use double thickness ("Texas Style") slices for better results; store in cold room in an airtight container; to be prepared 24 hours in advance only.

Sauces: white, brown or cheese

To be thinner than usual; consistency to be the same hot or cold.

Poached or fried eggs Use large eggs; cook up to 80%; add 1 teaspoon of water on eggs to ensure moisture for retherm if using a small dish.

Scrambled eggs and omelets

Cook eggs creamy; a bit of béchamel can be added; cook in combi or steam oven.

Frozen vegetables Most frozen vegetables can be rethermed from frozen state or thawed and directly rethermed. For some geriatric population, also vegetables can be blanched in a combi or steamed in an oven first, then chilled.

Fresh vegetables Normal cooking; preferably in combi or steam oven.

Hot cereals Cook with 40% less cereal; once chilled it will return to normal consistency.

French Fries Can be rethermed from frozen if you use fries ready to be cooked in an oven; otherwise fry them before retherm.

Mashed potatoes Use fresh or dried potatoes; must be creamy when cold; add more milk or water to preparation; instant mix can also be used.

Rice Make sure it is moist. Keep well sealed to avoid evaporation.


4.6 Recipe: Breakfast Items: Egg Recipes Scrambled Eggs - made from Fresh Eggs:

30 fresh eggs

1 quart milk 1. Mix eggs in stainless steel bowl. 2. Spray a 4” deep ½ pan (square) with vegetable spray. 3. Pour egg mixture into the pan - cover tightly. 4. Place pan in the Bulk Retherm oven.

5. Turn breakfast cycle “on” 266F/130C for 27 minutes. 6. At the end of cycle stir mixture and place back in Bulk Retherm oven for another

27 minutes.

7. At the end of second cycle mix well. Serve. Scrambled Eggs - made from Liquid Eggs:

1 quart liquid eggs

2 pints of milk 1. Mix liquid egg and milk in stainless steel bowl. 2. Spray a 4” deep ½ pan (square) with vegetable spray. 3. Pour egg mixture into the pan - cover tightly. 4. Place pan in Bulk Retherm oven.

5. Turn breakfast cycle “on” 266F/130C for 27 minutes. 6. At the end of cycle stir Mixture and place back in Bulk Retherm oven for another 27

minutes.

7. At the end of second cycle mix well. Serve. Poached Eggs:

15 fresh eggs

1 quart cold water 1. Spray a shallow ½ pan (square) with vegetable spray. 2. Crack eggs into a bowl being careful not to break any yolks 3. Transfer eggs slowly into square pan. 4. Add water and cover tightly.

5. Place into Bulk Retherm oven for ONE breakfast cycle 266F/130C for 27 minutes. 6. At end of cycle, place on hot top. Serve.


4.7 Thermometer testing and Recalibration Instructions Taking food temperature is an integral part of the rethermalization process. As a result, the thermometers we use must be accurate at all times. Therefore it is critical to test them from time to time. Depending of the type of thermometer that you use, the procedure for calibration will vary. However, the test for accuracy is basically the same. We have included a simple method to do so.

Testing for Accuracy:

1. Fill a large glass with finely crushed ice, add clean tap water to fill the glass and stir well. Immerse the thermometer stem or probe in a minimum of 2 inches (5 cm) in mixture, touching neither the sides nor the bottom of the glass

2. Check the reading on the

thermometer: it should be 32F

(0C). 3. Recalibrate the thermometer if

necessary.

Recalibration:

A. Bimetallic thermometer

1. Immerse thermometer in the ice mixture, as in the test

2. Without removing stem from the glass, hold adjusting nut under head with suitable tool and turn

head so pointer reads 32F (0C). Allow a minimum of 30 seconds before adjusting.

B. Thermocouple thermometer

1. Immerse thermometer in the ice mixture, as in the test for accuracy. 2. Recalibrate according to the manufacturer.

C. Burlodge Thermometer

1. Immerse thermometer in the ice mixture, as in the test for accuracy. 2. If required, request maintenance to recalibrate.


4.8. Food Service Audit

The key to the success of a cook/chill/bulk retherm operation is to produce and serve warm, appetizing meals, in sufficient amount and without excessive leftover. With the following Food Audit - Before and After Service, we will have a record of:

Length of Service

Temperature before and after Service

Amount of Left-over or Shortage

General comments


FORM

Food Audit - Before and After Service (Form M007v1 Jan-01) Length of Service Temperatures Comments

Items Number

Of Patients Time Start

Time Finished

Before Service

Boost Yes/No

After Service

Leftovers How Much

Appearance, texture, too much food, not enough, hot or cold, etc…

BREAKFAST

Oatmeal

Cr. Wheat

Other

Other

LUNCH

Soup

Puree Soup

Hot Entrée

Alternative

Gravy

Puree Entrée

Other

Other

SUPPER

Hot Entrée

Alternative

Starch

Vegetable

Puree Entrée

Other

Other

Please Note: The Hot products should be 165°F (74°C) to ensure proper and safe temperatures.


SECTION 5

PANNING & LOADING GUIDELINES 5.1 General Information The Burlodge Rethermalization System uses forced air convection as a heating medium to

safely rethermalize chilled meals from 3C/37°F to 74C/165°F in approximately 50 minutes. Adherence to correct temperatures is important from a food safety viewpoint, and for the end quality of the meal which will be presented to the patient / resident.

NOTE: The temperature of the cold food going into the retherm system (approx. 3C/37°F) is important for the quality and the appearance of the final product. In a Bulk Retherm System, two steps are extremely important.

Proper panning procedures

Correct loading procedures

In the following pages we present some material that will help you in planning the process leading to the Rethermalization and the Service of appetizing meals to your clients. We have included some guidelines, based on our experience with the equipment and the experiences of our previous and present users. The material that we propose can be customized to individual clients needs. Your Burlodge representative and/our Culinary adviser will further help you in the implementation process.

The material includes the following:

A sample of a tally sheet that can be used for planning the daily requirement or for panning and loading purposes. This tally sheet can be split in half (or copied) and used for loading pans in the Bulk Retherm Cart.

An example and a blank Form that summarizes the different tally sheets to be used in the Panning Centre.

A Form that can be used for planning the daily panning requirement. An example and two different blank Forms to be used for Tempering and Pull-out

schedule Some general guidelines for Panning, followed by more specific guidelines on different

types of food and an example of a meal by meal panning procedure. A general oven loading guideline followed by specific diagrams for the different types of

Bulk Retherm Carts being used. A diagram for loading the cold food items the Multigen III Retherm Cart.

These forms and guidelines are provided as a tool for your convenience. If you choose to use any of the forms we will be happy to provide you with them in an electronic format.


5. 1. 1 Sample of Forms

- Tally

- Panning

- Tempering and Pull-Out


Page 46

FO

RM

F

OR

M

Meal tally sheet- per unit (FormM008v2 Jan-08)

Date: ______________ Floor/Unit: ______________ Day: _______________

Left Oven Right Oven

Soup 1: Soup 1:

Soup 2: Soup 2:

Main Entrée 1: Main Entrée 1:

Main Entrée 2: Main Entrée 2:

Minced Entrée 1: Minced Entrée 1:

Minced Entrée 2: Minced Entrée 2:

Starch 1: Starch 1:

Starch 2: Starch 2:

Vegetable1: Vegetable1:

Vegetable 2: Vegetable 2:

Puree Meal: Puree Meal:

Special: Special:


FORM

Day -

Product/

Floor

TOTAL 0 0 0 0 0 0 0 0 0 0 0 0 0

Main Entrée: Half size pan = 12 - 15 Portions

Mashed Potato: Half size pan = 15 Portions

Date-Meal-

Hot Tally Sheet for Production and Cart Loading (FORM M 009v1 Jan-01)


FORM

Day - Monday Date- Sept.4, 2000

GR. Lemon Fish Mashed White Baby Puree Poached Minced Puree Sliced Broth Kosher Kosher

Floors Chick Sand Potato Rice Carrot Dinner Salmon Meat Fish Meat Dinner Soup

6K 20 15 1 35 35 2

7B 23 9 12 16 3

5B 27 11 14 15

5D/5K 18 18 1 20

8B 25 13 12 20 5

4B 27 10 17 22 3

3K/ICU 20 7 12 20 3 5 3

9L 20 6 20 20 1 8 1 2

7L 12 10 12 20 4 10 1 2

10S 15 15 4 16 2 7

8S/CCU 22 14 18 21 2 9 1 3 1 1

6D 16 5 19 14 5

9B 22 15 7 20 1

10D 14 15 15 3

8L 20 1 23 20 1 9 1

3B 31 18 21 30

9S 22 25 22 8 2 1

5L/6L 15 15 15 10 4 10 1 1

4K/4L/DR 15 14 8 20 5 7 1

7S/MICU 8 4 10 10 3 1 2

10L/CSICU

11L 16 13 7 17 4 7

9D 15 12 5 13 1 1 2 5 1 1

TOTAL 423 15 211 312 416 21 96 11 1 0 34 2 2

Half size pan = 12 - 15 Portions Half size pan = 15 Portions

Half size pan = 15 Portions Quarter size pan = 3 - 5 Portions

Hot Tally Sheet for Production and Cart Loading

Main:

Mashed Potato:

Vegetables:

Small Portions:

Meal- Dinner


FORM

Tempering and Pull Out Sheet (3-day THAW) (Form M010v1 Jan-01) Tempering Day __________ Tempering for ___________ Date ___________

Location Product Supplier Pack Size Amount to Pull

Breakfast

Lunch

Dinner


EXAMPLES

Tempering and Pull Out Sheet – (3-Days THAW) Tempering Day 1

Temper Thurs (Day 4)

Location Product Supplier Pack Size Amount to Pull

Breakfast

Refrigerator Cream of Wheat Belisle 2 kg bag 6 bags

Freeze Scrambled Egg Country Queen 5 lb. bag 6 bags

Storeroom Rice Krispies Cold Room 72/cs 30

Dairy Fridge Medium Lite Chse. Ptn. Dairy Fridge 100/cs 30

Freezer Carrot Pineapple Muffin Pail Pail

Lunch Freezer Turkey Rice Soup Marsan 2 kg bag 11 bags

Freezer Broccoli & Cheese. Quiche Kirkwood Individual 80

Freezer French Green Beans Omstead 2 kg 3

Walk in fridge Sliced Deli Beef Sure Slice 1 kg bag 5 bags

Walk in fridge Potato Lite Salad Country Queen Pail 1 ½

Storeroom Rice & Raisin Pudding Deans 100 oz tin 3

Storeroom Pears 100 oz tin 3 tins

Freezer Minced Beef Loaf Marsan Chub 1 chub

Freezer Pureed Beef Marsan Chub 1 chub

Freezer Pureed Green Beans Marsan Chub 1 chub

Freezer Beef Gravy Nestles 1.8 kg bag 1 bag

Dinner Freezer Cream of Mushroom Nestles 1.8 kg bag 12 bags

Freezer Sliced Pork Nestles Foil container 2 foil containers

Escalloped Apple Nestle Foil container 1 foil container

Freezer Mixed Oriental Veg. Omstead 2 kg bag 3 bags

Freezer Steamed Rice Marsan 2 kg bag 1 case

Freezer Chicken Thighs Otter Valley Case 2 cases

Storeroom Barbeque Sauce Kraft 4L 1

Freezer Whipped Potato Marsan 2 kg bag 5 bags


FORM Week ___________ Day________

Tempering Schedule (Form M011v1 Jan-01)

Item Brand Supplier Code Case Spec

Portions/Unit Amount to Pull For Wk/Day/Meal

Special-preparation-instructions


FORM

Daily Panning Schedule (Form M012v2 –Oct 07) Day _________

PRODUCT PORTION

SIZE

SERVING/UNIT

TOTAL #

PORTION

PAN

SIZE

TOTAL # PANS OR

CONTAINERS

WARD SPECIFIC NUMBER OF PANS

1/2 1/3 1/4 1/6 1/2 1/3 1/4 1/6 1/2 1/3 1/4 1/6 1/2 1/3 1/4 1/6 1/2 1/3 1/4 1/6


5.2 Panning Guidelines 5.2.1 Planning the Panning Process

1. The food temperature during panning should not exceed 5C (41°F). Panning should be done in a cold room or refrigerator to meet this requirement.

2. Use shallow pans; no more than 2” deep except for soup and cereal, in which case 4” deep pans can be used. The product in the pan should be no more than 2” deep.

3. Be consistent with portion sizes and use portion control.

4. Use smaller size pans (½, 1/3, ¼ in size), and replenish more often during the meal service - see section 4, p.3 on what gastronome pans mean and how to use them.

5. Establish the number of portions per pan per item. This will ensure that a certain size pan can only accommodate a certain number of portions, regardless of what the number of portions that is required. This is necessary for the food to reach desired temperature at the end of the retherm time.

PAN SIZE # PORTIONS

Full size 20-25

Half size (½) 12-15

Third size (1/3) 9-11

Quarter size (¼) 6-9

6. Wax paper, if used, should be waxed on both sides and be marked “for microwave use”.

7. Plastic wrap can be used to cover hot liquids. Look for the label “for microwave use” to assure that the plastic wrap can withstand high heat.

8. Use of “Heavy Duty Aluminum Foil” is recommended to prevent perforation during handling and to hold moisture in during the retherm process. If stainless steel lids are used, corners should be straight and the lid should be flat (no indent on centre).

9. All pans should be labeled, with a marker on the foil (taking care not to puncture the foil) or with a stick-on label.

10. In general all food should be tempered to a temperature above 0C (32°F). However, some products such as fish, individual meals can be rethermed from a frozen state. Tests should be done to assure that the final temperatures are acceptable.

11. In Section 4, we have included recipes for “cooking” some food items in the retherm cart. It should be noted again that proper handling procedures must be respected during those processes.


5.2.2 General Panning Guidelines

Spray the pans with a Pure Vegetable Cooking Spray, such as Pam.

Spread the food evenly in the pan: make it “level”, with no “peaks”.

Do not let the food touch the lid. Make a tent with the foil or foil cover for the casseroles.

Cover the food tightly; make sure that air will not come in contact with the food to dry it out. Use aluminum foil (shiny side down) and/or stainless steal covers. If you use stainless steel lid covers, make sure the corners are straight, not bent.

Fold aluminum foil tightly under the sides of the pans so it does not catch on the racks when the pans are placed in the oven.

Sliced meats should be shingled to maintain moisture. Add liquid to pan.

Some products (such as French fries and macaroni and cheese) may not require lids during the retherm process. Do some tests to check the products and the acceptance for your population.

Final Recommendations:

Maintain the cold chain and observe the crucial time/temperature guidelines.

Ensure that the food is properly covered, as suggested.


5.2.3 Panning Guidelines for Bulk Retherm: Starch Mashed Potatoes - Shredded,

Frozen (Ex: Ore Ida).

For one bag: Use half size pan. Spread one bag into pan. Add 6 cups of cold water: no need to mix. Cover with plastic wrap and a lid or foil. After retherm, mix well.

Boiled Red Potatoes

Bag must be fully tempered. Spread potatoes out evenly. Cover well.

Seasoned Wedges

Spread frozen wedges evenly in pan. Cover with lid (can leave uncovered to crisp the wedges).

Baby Roast Potatoes

Spread potatoes evenly in pan. Cover with lid (can leave uncovered to crisp the potato).

Potatoes Puffs

Spread frozen puffs evenly in pan. Cover with lid (can leave uncovered to crisp the potato puffs).

Mashed Potatoes- Frozen

Temper bag fully. Spread potatoes evenly. Cover well.

Boiled Potatoes

Temper bag fully. Spread potatoes evenly. Cover well.

Seasoned Fries

Spread frozen fries evenly in pan. Cover with lid (can leave uncovered to crisp the fries if larger fries).

Scallop Potatoes

Precooked item: Leave in foil pan for retherm (can leave a corner undone to lightly brown)

Scallop Potatoes

Dried sliced Potatoes: Split 1 box of Trio into two half-size pans. Divide liquid into both pans, making sure to just cover all potatoes .Mix well. Cover with lid.

Rice

Temper, if frozen. Check for moisture: if dry, add water. Mix well. Cover well.

Noodles

Temper, if frozen. Check for moisture; if dry, add water. Mix well. Cover well.


Panning Guidelines for Bulk Retherm: Vegetables

Carrot coins

Temper fully. 1 bag = Two -½ size pans. Cover with plastic wrap and a lid or foil.

Peas

From frozen. I bag = 1-½ size pan + 1- 1/3 size pan Cover with plastic wrap and a lid or foil.

Green Beans / Wax beans


Mixed Vegetables


Brussels Sprouts

Temper fully. 1 bag = 2 -½ size pans. Cover with plastic wrap and a lid or foil.

Broccoli Cuts


Mashed Turnip/ Parsnip

Temper fully. I bag = 1-½ size pan + 1- 1/3 size pan Cover with plastic wrap and a lid or foil. Mashed after retherm

Diced Squash / Turnip


Cream Corn (canned)

Pour I can into pan. Cover with plastic wrap and a lid or foil.

Corn Temper fully. I bag = 1-½ size pan + 1- 1/3 size pan Cover with plastic wrap and a lid or foil.

Cauliflower

Temper one day. I bag = 1-½ size pan + 1- 1/3 size pan Cover with plastic wrap and a lid or foil.

Canned Beets

Drain half the juice from the beets. Pour rest of juice and beets into a ½ size pan. Cover with plastic wrap and a lid or foil.

Puree Vegetables (bulk)

Temper fully. Cover with plastic wrap and a lid or foil.

Puree Vegetables: shaped portions

Temper slightly, product should maintain its shape. Lay each portion flat. Cover with plastic wrap and a lid or foil.


Panning Guidelines for Bulk Retherm: Breakfast Items

Oatmeal

Temper fully if frozen Use 4” deep pans. 1 bag = 2 –1/3 size pans. Liquid should only be 2” deep to allow proper retherm and prevent spillage. If too thick: add 1 cup water per ½ bag.

Note: Cereal will thicken in the

retherm process.

Cover with plastic wrap and a lid or foil.

Cream of Wheat

Temper fully if frozen Use 4” deep pans. 1 bag = 2 –1/3 size pans. Liquid should only be 2” deep to allow proper retherm and prevent burns. Add water if too thick.

Note: Cereal will thicken in the retherm process.

Cover with plastic wrap and a lid or foil.

Scrambled Eggs

Use 2- 1/3 size shallow pans. Divide 1 bag into the two pans. Place wax paper directly on top of the eggs.

Cover with foil.

Toast

Line the bottom of a ¼ size pan with wax paper. Place 6 slices of toast into each pan. Cover with wax paper then foil.

Note: Retherm for the last 25 minutes of the breakfast cycle, if possible. The cart door will need to be opened and closed as quickly as possible.

Boiled Eggs French toasts

From frozen. Place in pan, overlapping layers. Cover with lid or foil.

Pancakes

From frozen. Place in pan, overlapping layers. Cover with lid or foil.

Muffins

Keep frozen. Place in pan, one layer deep. Cover with a lid or foil if the product is drier and/or if a crust is not wanted.


Panning Guidelines for Bulk Retherm: Soup and Lunch Items

Broth Type Soup

Pour soup into 4" deep- 1/3 size pans. Liquid should be only 2” deep to prevent spillage and burns and to allow good retherm. Stir well before covering. Cover tightly with plastic wrap and foil.

Cream Type Soup

Pour soup into 4" deep - 1/3 size pans. Liquid should be only 2” deep to prevent spillage and burns and to allow good retherm. Stir well before covering. Cover tightly with plastic wrap and foil.

General Comments re: Canned Soup

If liquid is required to thin or strain the soup, use water instead of milk. The addition of milk will increase the chance of the soup curdling

Chicken Pot Pie – Ready-made

Use a ¼ size pan. Take 4 large serving spoons from the casserole dish and place into a ¼ pan. Place 4 pieces of pastry on top of chicken mixture. Cover tightly with saran and foil. Smooth remaining chicken mixture, with the pastry on top. Tent the foil lid in the centre and secure tightly.

Tuna Noodle Casserole- Ready-made

Use a ¼ size pan. Take 3 large serving spoons from the casserole and place into the ¼ pan. Spread mixture flat. Cover tightly with wax paper and foil.

Gently spread remaining tuna noodle casserole smooth – keeping crumb coating on top.

Tent the foil lid in the centre and secure tightly.

Lasagna

Tent the foil lid in the center so the cheese doesn’t stick to the top.

Macaroni and Beef

Tent the foil lid in the centre and secure tightly.

Grilled Cheese Sandwich

Use 1/3 size pan. Place wax paper in bottom of pan. Shingle 6 grilled cheese sandwiches in the pan. Cover with wax paper then foil. Product will crisp up after retherm if foil is rolled back.


Panning Guidelines for Bulk Retherm: Dinner Meal - Example I

Baked Chicken/Sauce

Use ½ size pan. Place chicken in pan. Place wax paper on top. Seal with foil.

Ham

Use 1/3 size pan. Shingle sliced ham (10-12 portions) in the pan. Add 1-cup of liquid. Place wax paper on top. Seal tightly with foil.

Meatloaf

Use 1/3 size pan. Shingle meat loaf (8-10 portions) in the pan. Add 1-cup of liquid. Place wax paper on top. Seal tightly with foil.

Chicken Cacciatore

Use ½ size pan. Place chicken in pan. Place wax paper on top. Seal tightly with foil. Creole Sauce – Spray ¼ size pan. Pour sauce. Cover with plastic wrap and foil.

Mashed Potatoes

Use 1/3 size pan. Massage bag to mix fluid into potatoes. Divide 1 bag into 2 pans. Place wax paper directly on top of potatoes. Seal tightly with foil.

Scalloped Potatoes

Tent the lid in the centre so the potatoes do not stick to the top.

Mashed Potatoes


Mashed Potatoes


Mixed Vegetables

Divide 1 bag into 2- 1/3 size pans. Cover with wax paper and foil.

Peas and Carrots


Green Beans


Peas


Baby meat, baby vegetable, Gravy

Portion in ind. heatproof dishes. Place in s/s pan. Cover with foil.


Portion in ind. heatproof dishes. Place in s/s pan. Cover with foil





PUREE Use white china dish. Add frozen puree. Cover with plastic wrap & foil. Place in s/s pan.

PUREE

Use white china dish. Add frozen puree. Cover with plastic wrap & foil. Place in s/s pan



Frozen purees- best sliced when frozen and panned, therefore will not stick to knife as it does when thawed.

OR Put 1-2 Chubb’s in pan and press down and cover with wax paper


Panning Guidelines for Bulk Retherm: Dinner Meal - Example II

Roast Beef

Use 1/3 size pan. Shingle sliced beef (10-12 portions) in the pan. Add 1-cups of liquid. Place wax paper directly on top Seal tightly with foil.

Roast Pork

Use 1/3 size pan. Shingle sliced pork (10-12 portions) in the pan. Add 1-cups of liquid. Place wax paper directly on top. Seal tightly with foil.

Roast Turkey

Use 1/3 size pan. Shingle sliced turkey (10-12 portions) in the pan. Add 1-cup of liquid. Place wax paper directly on top. Seal tightly with foil.

General Comments

Gravy for all Products

Use 2- ¼ size pans with Pam. Divide 1 package into 2 pans. Tightly cover with plastic wrap and foil.

Mashed Potatoes


Mashed Potatoes


Mashed Potatoes


Dressing


Carrots


Green Beans


Squash

Divide 1 bag into 2- 1/3 size pans. Stir ½ oz. thickener to soak up liquid. Cover with wax paper and foil.







Puree. Use white china dish.

Add frozen puree. Cover with plastic wrap & foil. Place in s/s pan

Puree. Use white china dish. Add

frozen puree. Cover with plastic wrap & foil. Place in s/s pan.

Puree. Use white china dish. Add

frozen puree. Cover with plastic wrap & foil. Place in s/s pan.

General Guidelines: -Label all panned items with black sharpie on foil. Be careful not to puncture the foil. -The bottom shelves are ideal for small amounts of cream soup. -Tightly fold foil under so that it does not catch on the racks as the pans are placed in the oven. Note: Foil should be shiny side down. Product should not be below 0ºC (32°F) prior to retherm cycle. Products at a temperature of 2°-3ºC (36°-38°F) will retherm best. Pans filled too full will not retherm to desired temperature. Foil should be a heavier weight. Wax paper should be waxed on both sides and “microwavable”. Plastic wrap must be “microwavable". Wax paper will allow some moisture loss where as tightly sealed foil and plastic wrap will prevent it.


5.3 LOADING GUIDELINES

Ovens

If the Multigen III does not have refrigeration, load the Oven sections no more than 15 minutes before the scheduled retherm starting time. Check that all of the items needed for the meal are available. Check against the menu (including the Diets) and the Tally and/or Panning sheets. The pans should have a label or a mark identifying the contents. If in doubt, remove the cover and check. Make sure to re-seal properly. If it is not possible, use a new aluminum sheet to re-cover. Remember to re-label. Check the seal on all the pans

Stainless steel covers should be flush on all of edges of the pan Aluminum foil should not be punctured or ripped Aluminum foil wrapping should be pressed tight against the edges, so it won’t come apart when

loading.

Load the Retherm Ovens, following the suggested chart. The 4" deep pans, with no more than 2" of liquid in them, are normally placed at the top, with the first shelf removed to make room for the deeper pans. A full pan may be needed to catch drips. Individual and small portions are usually placed at the bottom. Each shelf can hold:

One full pan (gastronome) or Two – ½ size pans or Tree- 1/3 size pans

When loading two ½ size pans on one shelf (or 1- ½ size and 1- 1/3 size pans), the first pan can

go lengthwise. The second pan can be placed side way across the shelf. This method will facilitate the removal of the back pan. When loading the oven cavity, make sure the aluminum foil. Does not rip or tear. If it does rip, replace the foil. For this reason, we recommend the use of Heavy Duty Aluminum foil. Compare with the menu. Pay attention to avoid putting cold items on the oven side.


5.3.1. LOADING DIAGRAMS

Following are some examples of loading diagrams to help you plan the loading of pans into your Bulk Retherm Cart.

A. Loading for Oven Use - Multigen III - Example I

- Example II


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A. LOADING FOR LEFT OVEN USE - EXAMPLE I

Multigen III Note: Breakfast Items are in Italics

OVEN

Top Shelf MAIN ENTREES

2nd Shelf STARCHES (potatoes, rice)

3rd Shelf Gravy & Sauces

Oatmeal & Cr. Wheat

4th Shelf SPECIALS (minced & pureed) Hard Cooked Eggs

5th Shelf VEGETABLES (carrots, peas) Scrambled Eggs

6th Shelf Additional Items

7th Shelf SOUPS Need to remove above shelf if using 4” deep pans


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A. LOADING FOR OVEN USE - EXAMPLE II

Multigen III

The fourth shelf is for special items such as: hot desserts, and small portions,

small servings of minced or pureed foods.

The second shelf from the top is for the starches: French fries, mashed potatoes,

home fries, potato wedges and hash browns.

The top shelf is used for the main entrée.

Remember to follow standard portion sizes.

Gravies and sauces can go on the third shelf.

It is important to use plastic wrap and aluminum foil as this will contain the liquid

better than a lid or tinfoil. 4” deep pans can be used with 2” of liquids.

The fifth shelf is for special items such as: hot desserts, and small portions, small

servings of minced or pureed foods.

The sixth shelf is for vegetables: carrots, green beans, mixed vegetables, etc.

The bottom shelf is used for any additional items. This shelf can be used for soup in

a 4” deep pan. You will need to remove the 6th

shelf.


SECTION 6 CART OPERATING PROCEDURES: MULTIGEN III 105 DOUBLE

REFRIGERATION

6.1 Pre-retherm Procedures 6.1.1 Pan loading procedure in the module (rack)

A. With the “Dolly” option: Multigen III Double Refrigeration Apply the brakes on the dolly. The transfer modules (racks) should be on the dolly.

Check that the back of the transfer module (with the X) is opposite to the release pedal.

Load the pans onto the shelves, according to the procedure in Section 5.

Food for both sides can be done at the same time, if both transfer modules are be on the

dolly. It is important that the temperature of the food is kept below 5C (41°F) during the process.

Release the brakes on the dolly and place in the refrigerator if done ahead of time. Label the rack, using the tally or other labeling system.

Make sure that:

If there is food to be served cold, it is kept to the oven section that will not be operated for that meal period.

Every pan is tightly covered, except for the ones that should not be. B. Directly in the Retherm cart Apply the brakes on the retherm cart. Load the pans onto the shelves, according to the procedure in Section 5 Close the doors firmly. Make sure that refrigeration is “on”.

6.1.2 Diet changes:

If additional items need to be added to the ovens, it can be done any time before the retherm cycle starts. If the cycle has started, it is best to reheat the item in a microwave just prior to service.

The tallies should be cushioned enough to meet most of the late changes.


6.1.3 Transferring the module to the Multigen with the dolly option:

Brakes must be applied to the Multigen cart prior to transfer.

Open the door(s) fully.

Caution: the transfer module can only be loaded on the right-hand side of the Multigen. Look for the docking bracket in the middle of the Multigen, at the bottom.

Push the dolly by the handles, coming from the left of the Multigen. Align the pins of the dolly with the docking bracket. Push firmly into position.

Facing the cavity of the Multigen, check that the transfer modules are in line with the chamber. Repeat the previous procedure until it lines up.

Apply the brakes on the dolly casters.

Press the foot pedal down to release the transfer module from the dolly and push the transfer module a few inches past the pin holding the transfer module

Take an ergonomic position – bending at the knee, arms at 90° angle, and hands located on each side of the transfer module.

Gently push the transfer module into the Multigen Chamber.

Repeat the operation for the other module.

Release the brakes on the dolly - Never use your hands! Slowly pull the dolly away from the

Multigen.

Close the Multigen door(s) FIRMLY, pushing in the middle of the door, close to the handle. Do not hold the handle when closing the door.

6.1.4. Setting up the cart for service: safety recommendations

Once the cart is loaded, staff may want to set up the top of the cart in preparation for service. 1. The Hot Top/Light function, when selected (by pressing the hot top/light button or programmed will turn “on” at the end of the cycle or when the oven temperatures have been satisfied. It is extremely important to respect the following: o Place only heat resistant dishes and trays on the Hot Top: no Styrofoam, no regular plastic

or plastic wrap. o Do not put any cold food on the Hot Top at any time! o Leave at least 8” clearance under the gantry, all the way across the top. o Use aluminum foil or stainless steel covers to avoid drying out. 2. If transporting the cart to a service location do not overload the top and make sure that all of the items are secure before moving it.


6.2. Control Panel Operation: Multigen III Double Refrigeration

6.2.1. Control Panel: Multigen III Double Refrigeration

The Multigen III with Double Refrigeration has one control panel as shown below.

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1 2 3 4 5 Key

1. Power On/Power Off Touch Pad 2. Function Pad 3. Halogen lamps and heated hot top touch pad 4. Oven selection touch pad 5. Start/Stop touch pad for cycles 1, 2, 3 and boost cycle 6. Hot top temperature 7. Display: shows the two temperatures either hot or cold


6.2.2. Control Panel Instruction: Multigen III Double Refrigeration

Control Panel Display Window Oven Selection Touch Pad

On/Off Button Function Button Hot Top & Light Cycle Buttons

Manual Start – Left Oven

Push the "On/Off" button to start the unit if display is blue and ‘OFF’ appears in the display window

Press the touch pads to select the desired option:

Hot Top & Light

Press the oven selection touch pad once for the left oven (L icon flashing)

Select rethermalization cycle required #1 for Breakfast #2 for Lunch #3 for Dinner

Press oven selection touch pad to confirm

Only the left oven will show timer and temperature.

Manual Start –Right Oven

Push the "On/Off" button to start the unit if display is blue and ‘OFF’ appears in the display window

Press the touch pads to select the desired option:

Hot Top & Light

Press the oven selection touch pad twice for the right oven (R icon flashing)

Select rethermalization cycle required #1 for Breakfast #2 for Lunch #3 for Dinner

Press manual touch pad to confirm

Only the right oven will show timer and temperature.

Starting Both Ovens to finish at the same time

Press oven selection touch pad once. Left side oven icon will flash. Select desired cycle.

Right oven icon will flash. Select desired cycle (within 10 seconds)

The oven timer with the shorter cycle will flash indicating that the start has been delayed and will start at a time to allow both ovens to finish at the same time.

Starting Both Ovens Together

Press oven selection touch pad once. When the left oven icon flashes, press desired cycle within 10 seconds.

The right oven icon will flash. When the right oven icon stops flashing (10 seconds), press desired oven cycle.

Display will show both right and left oven icons, timers and temperatures. The center of the display will indicate which cycles have been selected.


To Start an oven cycle when one oven is in use

Press the oven selection touch pad for the desired oven – once for the left oven; twice for the right oven

The desired oven icon flashed, select the desired cycle within 10 seconds

To stop a cycle while another oven is in a cycle

Press oven selection touch pad for desired oven – once for the left oven twice for the right oven.

Press the desired cycle you wish to stop.

Press the oven selection touch pad once. The selected cycle should show 0 minutes on the timer

Automatic Start

Display panel will read ‘Stand-By’. Current time will be in the lower left and the wake up time will be in the lower right side of the display panel.

Push the "On" button to start the unit if ‘Stand-By’ does not appear.

Check the present time by touching the ‘F’ button five times to display the current date and time.

Check the next time the cycle is to start –appears in the lower left of the display panel – cycle and start time. If the next start time is not correct, follow instructions for a manual start

When the retherm cycle is in operation the display window show the time remaining and temperature for each oven.

Counting Down Time Counting Down Time in Minutes Left Oven in Minutes in Right Oven

At the end of the cycle the oven will automatically turn off and the beeper will sound – at this point the screen for the ovens selected will display and flash “00”. The Gantry light will come "On" automatically.

To cancel the beeper and the flashing “00” for the appropriate oven, press the cycle touch pad indicated on the display panel.

The Hot Top/Light will now remain "On" retherm cycle in a manual. Remember:

The Multigen operates on a 120/208 vac. 20-amp circuit. It is important to note:

The oven section gets precedence during retherm (draws 15 amp.) The Hot Top/Light work together as one unit (draw 10 amp.) but will not work if the oven is

calling for heat. The refrigeration (draws 4.2 amp.) will work independently or with the Hot Top/Light, but only

if the oven is not asking for Heat (20 amp - 20%).

Right Oven Temperature

Left Oven Temperature


6.2.3. The Function Menu “F”

To access the ‘function menu’ press the ‘F’ pad. 1. Press once: If the temperature probe has been connected, the temperature will appear

on the left side of the screen and the menu for recording temperatures will appear on the right side of the screen. If no probe has been connected, three dashes will appear on the screen. 2. Press twice: The wastage menu appears (available on firmware version 0.30+) 3. Press three times: the Maintaining Service cycle settings are displayed. Pressing cycle button #3 at this time will start the Maintenance or Service Cycle for both ovens if the temperature is above 158◦F/70◦C. 4. Press four times: The settings for the cleaning cycle are displayed. Pressing cycle

button #3 at this time will start the Cleaning/Wash Cycle. 5. Press five times: The current time and date settings will appear.

6.3 Post-retherm: Temperature Testing of Products 1. After the rethermalization/heating cycle has finished, allow enough time for the oven fans to stop circulating. This will take only a few moments. DO NOT TURN THE CART OFF OR DISCONNECT IT FROM THE POWER SUPPLY AT THIS POINT.

2. If you are opening the door immediately after a cycle has finished you will need to be cautious. Initially, open the door slightly. This will allow the hot air inside the oven section to be exhausted before you open the door fully.

Caution! Wait a few seconds, stand back, and then open the door slowly. 3. When you open the cart door, the inner face of the door will be HOT – use caution!! Pull the pan to be tested toward you and remove it, using hand protection as needed. Close the door. 4. Using either the optional food probe provided with the cart or other probe you can now test the temperature of the products.

Note: Handle the probe gently especially at the wire junctions. 5. If using the optional food probe, connect it to the cart via the white socket adjacent to the control panel. 6. Make sure that the probe is sanitized in between and before every use by using an antiseptic wipe. 7. Insert the probe tip into the centre of the food product. Be sure not to touch the bottom of the pan, as this may give you a false reading.

Note: Repeated sharp flexing of the probe will break the thermocouple leads. To prolong lead life, avoid sharp bends and over-stretching of the leads, especially near the connector body. 8. If you are using the optional Burlodge food probe the product temperature will be displayed on the cart's control screen in the left hand window. Select which category of product that will be recorded. Use the #1 and #2 to high light the category. 9. Record the temperatures of the products on the appropriate documentation. Temperatures may also be recorded by pressing touch pad #3 or by pressing the black button at the end of the probe. Press the black button for less than 2 seconds. 10. Make sure the probe has been washed and sanitized before storing.

Note: Periodically, probes should be checked for calibration.


6.4 Temperature Boosting Procedure- Multigen III Double Refrigeration

1. If the core temperature of the hot food is not at or higher than the site Temperature Standard at the end of the heating cycle, the touch pad #3 can be used to provide additional heat to the oven. The Boost Maintaining Cycle must have been previously programmed. Normally, the length of the Boost Cycle is set at 5 minutes. The boost cycle is for both ovens. If the temperature in on oven is less than 158°F/70°C, the boost cycle will not turn on.

2. Pressing and holding the #3 touch pad for 5 seconds will start the Boost Cycle. The display left will show the programmed time and the temperature for the appropriate oven (s). 3. At the end of the “Boosting Cycle” repeat the temperature testing of products as before. 4. If the food product is at the correct temperature you are now ready to serve. If not you can repeat the “Boosting Cycle” process as many times as is necessary.

6.5. Meal Service Procedure

6.5.1 Getting Ready For Service.

1. The Retherm cart is ready for temperature testing when the rethermalization cycle has finished. The control panel indicates this visually and with an audible “beep”. Proceed with the following only when you are ready.

2. At the end of the oven cycle (s), the “beeper” will sound and display panel will flash ‘0’ for time and the cart will emit an audible ‘beeping’. The Hot Top/Light will be "On".

3. To silence the “beeper”, press the cycle button once that was used for the rethermalization process (#1, #2 or #3).

4. If the control panel is displaying error codes report this immediately to a supervisor and check the troubleshooting sheet in this Guide (Section 9) for recommended action.

5. Caution! Open the door carefully: open about 1", standing back. Wait for 10 seconds, and then open the door fully slowly.

6. Check the temperature of food products before getting ready for service. Follow the instructions in the “Temperature Testing of Products – Post Retherm” section of this guide. Use the "Boost" cycle if needed.

7. When you are satisfied that the temperature of the food is acceptable, the cart is ready for transportation and/ or for service.

8. Ensure that the service utensils are with the cart.

9. Moving the cart to a different location:

Turn off Hot Top /Light if on. Turn the cart “Off”. This is very important for the electrical components! Disconnect both cord before moving the cart. For safety reasons during transport, place all of the food inside the compartments. Ensure that the power cables are secure and that the tray rail and side shelves are

down. Transport the cart following procedure- see following section.


6.5.2 Transporting the Retherm Cart

1. Always push the cart using the “rails” at the plug side of the cart. The swivel castors are

located at this end and this gives maximum maneuverability. 2. Make sure all items on the cart are well secured. 3. Always try to avoid collisions with obstacles, doors, walls and pedestrians. The retherm carts are designed to be easy to maneuver, but it is the operators’ responsibility to ensure that due care and attention is paid during movement. 4. Take care when moving the retherm cart through doorways and elevator doors. Where possible lock elevator doors in the open position when loading on or off the elevator. Secure doors in the open position until the retherm cart is completely clear.

6.5.3 Service

1. On arrival at the service point, position the retherm cart in an appropriate location so as not to obstruct normal corridor traffic. Apply the brakes. Plug the cables for the left and right hand ovens into the designated receptacle. Turn cart on. 2. Press the ‘F’ button three times until the M cycle appears. Press touch pad #3 to activate the service cycle. The Maintenance cycle will only be active if the temperatures in each oven is above 158°F/70°C. 3. Set up the top of the retherm cart ready for service. 4. Stand away from the oven door and partially (about one inch) open the door. Wait until any

steam has escaped. 5. Use additional caution when the door is open: the inner surface will be very hot. 6. Using hand protection and starting at the top grid, remove the products from the oven compartment. 7. Never reach to the back of the oven: pull the grid 1/3 of the way to access the back pans. 8. Only remove the items required for service, i.e. one of each product. Leave single portions in the oven. 9. Place hot pans onto the Heated Top and ensure that they are kept under the gantry to help maintain food temperature. Place in a logical order for service. 10. Open the containers with caution: the products are hot. Open the lid away from you to allow

the steam to escape. Do not uncover the whole pan: roll the foil half way, or if using lids, keep partially on to maintain the heat in the pan. 11. Caution! If the pan has wax paper, remove and discard. The paper could be drawn toward

the gantry element and cause a fire. 12. Do not place any items on top of the Gantry over-shelf. 6.5.4 Ergonomic Best Practice Tip

PPUUSSHH IITT OORR PPUULLLL IITT??

Pushing vs. Pulling Burlodge Meal Delivery Systems

Whenever possible, push the meal delivery system versus pulling it as most people can develop higher push forces by leaning their body weight into the load being moved. Another advantage to pushing is that more neutral body postures are assumed compared to pulling. Pulling often requires a twist in the trunk and, if it is a one-handed pull, high forces at the shoulder. A further advantage of pushing instead of pulling is the absence of concerns about foot or ankle injuries from the cart riding up on the worker during transfers. Last, two-handed pulling does not allow the worker to see where they are going. What is the best technique to push Burlodge equipment? With proper footwear to ensure a good grip with the floor, stand with the legs approximately shoulder-width apart. To get the meal delivery system in motion, begin with the legs staggered


somewhat; one foot slightly forward of the other. Place the hands between waist and chest level. With the castors in proper alignment, use the large muscles of the legs, back and shoulders to get the load moving. Accelerate the load gradually. Keep the upper body upright as much as possible when maneuvering the equipment. If visibility is impeded, alternate angling the upper body to the left and right sides to maintain sight lines. If I have no option but to pull, what is the best technique?

There will be times when you must pull meal delivery systems versus the preferred method of pushing. Some examples include maneuvering the equipment in small spaces, on and off elevators and when moving Burlodge equipment in and out of operating position. Pulling should be kept to a minimum. However, some general tips for safe operation include: i) always use two hands, and ii) if required, have a co-worker act as your set of eyes, giving you verbal instructions on direction as you pull the load.

Any advice recommended by Burlodge Staff (verbal or in writing) pertaining to Ergonomics of equipment and Safe Handling of same is for general informational purposes only. IT IS NOT INTENDED TO REPLACE OR BE CONSIDERED POLICY AKIN TO YOUR FACILITY. These recommendations are made to reduce risks for injury not to cure any injuries. No promise or guarantee to eliminate injury or every risk is made. Burlodge offers Push Pull third party information on its meal delivery systems so that you can determine safe handling procedures applicable to your specific site. Each user site is different in terrain, staff height, and user policy. The preferred method of maneuvering equipment is pushing however, from time to time the operator must pull the equipment and in both cases, your site should stipulate policies around when it is safe to do either method and what precautions to take such as and not limited to: having extra staff to watch for pedestrians when pushing equipment that is too tall to see around or over. If used incorrectly any equipment, including that labeled or marketed as ergonomic, can cause injury. Burlodge makes no guarantee to cure any injury and specifically does not guarantee that no injury can occur from the use of Burlodge products.

6.5.5. After Service Procedures

1. Turn “Off” the service options: Hot Top/Light on the control panel. Turn off any

heating/maintenance cycles that were selected by pressing touch pad #3. 2. Turn the cart “Off”. This is very important for the electrical components! 3. Disconnect the cart from the wall receptacles before moving it. 4. For safety reasons during transport, place all of the food inside the compartments. 5. Ensure that the power cables are secure and that the tray rail and side shelves are

down. 6. Transport the cart following procedure- see above in section 6.5.2.

6.6 Cleaning the Retherm Cart When the meal service is complete the retherm cart needs to be cleaned and made ready for its next meal period. 1. Ensure that the cart is in a safe area that does not obstruct other equipment or block thoroughfares. Engage the cart brakes by depressing the lever on the brake with your foot: Never use your hands!

2. Empty all of the shelves. Put away or dispose of the food. Leave the doors open to cool the compartments.

3. When the cart has cooled enough to clean, remove the empty transfer module to facilitate the cleaning of the compartment.

4. Use hot, mild soapy water to wipe clean the compartment of the Retherm cart. Use a soft, clean cloth then rinse with clean water. NEVER USE ANY ABRASIVE AGENTS. Make sure the interior is thoroughly rinsed and dried to avoid streaks. Make sure to clean the doors and the door gaskets.


5. Clean the transfer module, wiping every shelf. Replace in the compartment.

6. If surfaces are heavily soiled leave them to soak with the cleaning solution for about 15 minutes before rinsing and drying.

Remember - Frequent cleaning of the carts as described above will prevent the build-up of soil and keep the cleaning and sanitation process a manageable and less arduous task.

7. All external panels of the cart can be cleaned with a hot mild soapy water solution and rinsed with clean water. When cleaning the control panel, only use a soft damp cloth!

8. Once all cleaning has been completed, the exterior of the cart can be polished using a food safe stainless steel polish. It is advisable to only use water based polishes to prevent oily residues building up and to avoid the presence of unsightly finger marks.

DO NOT USE STAINLESS STEEL POLISH ON THE INTERIOR SURFACES OF THE CART.

9. Do not use abrasive cleaning materials or pads on any of the cart surfaces.

10. Daily cleaning of the transfer module: Modules and dollies can be spray washed daily using sanitizing solution.

6.7 Cleaning Schedule If the following Cleaning Schedule is adhered to you will be able to maintain the appearance of your carts for many years. Failure to carryout the schedule as described may result in discoloration of the stainless steel and silicon gaskets. Caution! Any over spray of polish or other cleaning products on the floor can cause a serious hazard. Deep cleaning should be scheduled so that each cart is maintained at the correct level of cleanliness. Monthly deep cleaning routines are normally sufficient to maintain the carts condition; however, this may vary from site to site. Removal of the fan protection panels for cleaning should be carried out every 6 months. Only trained personnel with use of the correct hand tools should do this.

Never use abrasive on any surface.

Do not allow quaternary agent to touch the ABS panels, as it may discolor.

Retherm Cart Daily: -Wipe spills after each meal. -Clean outside of the Retherm cart with soap and water.

-Check the gaskets for spillage. -Do not use quaternary agent on A.B.S. panels.

Monthly: -Clean inside all internal surfaces of the Retherm cart using soap and water.

-Rinse and dry. -Clean gaskets.

Twice a year: -By trained personnel only -Remove the fan side panels; clean the floor beneath the fan, around and behind the heating element

Transfer modules & dollies Daily: -Wash with soap and water. Sanitize. Monthly: -Check and wipe bottom rollers.


Cleaning Schedule

COMPONENT

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Interior Compartment X X X Wipe dry after cleaning

Interior surfaces X X X Never use polish

Gaskets X X X

Exterior A.B.S. panels X X Wipe dry after cleaning Do not use quaternary agent!

Exterior stainless steel panel X X Use non abrasive cleaner

Touch pad control panel X X X Use damp cloth only

A.B.S. front panel X X Use damp cloth only

External food probe X X X Use sterile wipes GENTLY

Gantry X X X Do not touch the heat rod

Sneeze guard X X X Do not use abrasive pads

Dolly X Wipe dry after cleaning

Transfer module X Wipe dry after cleaning


6.8 Towing Procedure The Multigen carts can be fitted with a tow bar. The Multigen transfer module dolly can also be fitted with a tow bar. The towing speed should never exceed 7km/4 miles per hour. Procedures for coupling and un-coupling from a towing vehicle will vary dependant upon the tow hitch style used.

Coupling:

Check the Multigen folding tray rails and the lateral shelves are down.

Ensure all doors are closed correctly and the power cable is secure.

Release the brakes on the castors using your foot. Ensure that the floor area is flat and

even.

Align the front of the Multigen dolly to the rear-towing hitch.

Lower and locate the tow arm ring on the towing pin of the tow hitch.

Secure the safety pin on the towing hitch.

If towing more than one unit, align the front of the second unit to the rear tow hitch of the first cart and follow the above procedure.

Never tow more than 2 Multigens or 4 Dollies at a time if using a power driven tugger. Never tow more than 2 Dollies manually. Retherm carts can only be towed using a power driven tugger.

Un-coupling:

If there is more than one unit always start un-coupling from the last unit being towed. Ensure that the floor area is flat and even.

Remove the safety pin.

Press the towing arm down and release it from the towing pin. Allow the towing arm to rise to the upright storage position. Caution! The towing arm is spring-loaded. Take additional care when carrying out this procedure.

When the unit has been detached and is free standing, if it is not to be moved immediately, apply the castor brakes.

If there is more than one unit attached to the towing vehicle repeat the above procedure.


SECTION 7.

Training Materials

Multigen III

Double Refrigeration


7. 1. 1 Cart Operation Summary

Manual Start

Automatic Start


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Manual Start: Multigen III Double Refrigeration

Display Window Oven Selection Touch Pad

On/Off Switches Function Pad Hot Top & Light Cycle Buttons

Start the Rethermalization Cycle: Manually

Load. Close the door(s). Turn cart on using the on/off touch pad. Select touch pad for Hot Top/Light. Press the oven selection touch pad once. Press the following touch pads for desired cycle

Typically: # 1 for breakfast, # 2 for lunch and # 3 for dinner Pressing the Oven Selection Touch Pad twice. Select desired cycle. Press manual touch pad once to confirm.

Getting Ready for Service

To stop the heating cycle (silence the beeper), Press oven selection touch pad once if turning off the left oven and twice if turning off the right oven.

Take temperatures, as per procedure. Note: Be careful when opening the oven door: open slowly about one inch, wait to let out steam, then open fully.

If temperatures are not as required, Boost by pressing and holding the # 3 touch pad. A five minute Boosting cycle will start. Repeat if needed. Boost is active for both ovens only if the temperature is above 158°F/70°C.

Turn cart “OFF”. Unplug and secure the cords to the cart.

Ready to serve at the patient units:

Plug the Left Hand/Right Hand Cable on the Retherm cart into the special wall outlet. Put brakes "ON".

Turn cart “ON”. Start Maintenance cycle by pressing the ‘F’ touch pad three times then press touch pad #3.

‘M’ will appear as the selected cycle. Carefully open the oven doors fully and remove only as much hot food as needed for service. Keep food on the hot top partly covered during the meal service.

After the service, before leaving the patient unit:

For the Hot Top/Light touch pads to turn them “OFF”. Stop the ‘M’ cycle by pressing touch pad #3. Turn cart “OFF”. Unplug from the wall and secure the cord(s) to the cart. Release the brakes with your foot: Never use your hand


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Automatic Start: Multigen III Double Refrigeration

Temperature Display Hot Top Indicator/Temperature

On/Off Touch Pad Function Touch Pad Hot Top/Light Oven Selection Touch Pad Cycle Buttons

Setting Up the Cart for Automatic Start Load as per schedule. Close the doors. Turn cart “ON”. Check that the next cycle will start automatically. Next cycle and start time will appear in the lower

left corner of the display panel. If the "next meal start time" is not the next meal scheduled time, then start manually- see procedure

"Manual Start"

Getting Ready for Service

To stop the heating cycle (silence the beeper), pree the oven selection touch pad once or the left oven and twice for the right oven. Touch the number of the cycle to be stopped when the correct icon is flashing.

Take temperatures, as per procedure. Note: Be careful when opening the oven door: open slowly about one inch, wait to let out steam, then open fully.

If temperatures are not as required, Boost using Touch Pad # 3 as a Boosting cycle: Press and hold touch pad # 3 for 5 seconds: a 5 minute cycle of additional heat will start. Repeat if needed. Boost will only be active if the oven temperature is above 158°F/70°C.

Turn cart “OFF”. Unplug and secure both cords to the cart.

Ready to serve at the patient units:

Plug the Left Hand and Right Hand plugs of the Retherm cart into the special wall outlet. Put brakes "ON"

Turn cart “ON”. Press Hot Top/Light touch pad. Press ‘F’ touch pad three times until Maintenance cycle appears then press touch pad #3. ‘M’ will appear as the cycle selected.

Carefully open the oven door fully and remove only as much hot food as needed for service. Keep food on the hot top partly covered during the meal service.

After the service, before leaving the patient unit:

Press the Hot Top/Light touch pad to turn “OFF”. Press cycle #3 to turn off ‘M’ cycle. Unplug cords from the wall and secure the cords for transport. Release the brakes with your foot. Never use your hand.


7. 1. 2 Cart Operation Posting

Materials

Load/Start with

Automatic Timer

Manual Start - if you are

late

Ready for Service

After Service


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LOAD/START With Automatic Timer

Control Panel Multigen III

ON/OFF SWITCH CYCLE BUTTONS

Load the Cart

Turn “ON” Control Panel: Press the “ON “switch

Check the ACTUAL Time: Press ‘F’ touch pad 5 times

Check the NEXT Cycle Starting Time Cycle Number and Start Time will be in the lower left corner of the

display panel

see “MANUAL START if you are late”

On the display Panel, check to see if the indicator icon over the Light/Hot Top touch pad is “on”: Indicator is in the lower right of

the display panel should be as follows

If not, press the touch pad once.


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MANUAL START…if you are late

Turning the cart “on” passed the scheduled time

Control Panel- Multigen III Double Refrigeration


1. Turn cart on by pressing oven “ON” switch

2. Turn Light/Hot Top On - icon in lower right display

is as follows:

3. Press the Oven Selection Touch Pad – once for the

left oven and twice for the right oven. Select oven

cycle desired

4. Make sure both ovens are turned on.


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READY FOR SERVICE Control Panel- Multigen III Double Refrigeration


1. Ready: the cart beeps and “0” appears in left or right side of the display panel.

2. Press the oven selection touch pad once. Press the cycle number desired for the left oven to turn off the left oven.

3. Touch the oven selection touch pad twice. Press the cycle number desired for the right oven to turn off the right oven.

4. Take food temperatures as per procedure.

Test the thickest items first (main entrée)

If the product is or above, serve.

If under , proceed to Boost:

To BOOST: hold touch pad #3 for 5 seconds: 05 appears plus a beep. The boost symbol appears on the display panel. If once oven is not used for heating and the temperature is

below 158F/70C, the Boost Cycle will not turn on in that oven.

5. At the end of the 5 minutes, repeat step 1, 2 and 3. CAUTION: Handle the food probe gently, especially at the wire junctions.


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AFTER SERVICE Control Panel: Multigen III Double Refrigeration

ON/OFF SWITCH LIGHT/HOT TOP

1. Turn left oven cycle off by pressing the oven selection touch pad once. Press the number of the cycle to turn off the heating.

2. Turn off the right oven by pressing the oven selection touch pad twice. Press the number of the cycle to turn off the heating.

3. Press “On/Off” touch pad to turn the cart off.

4. Press Light/Hot Top touch pad to turn off light and hot top.

5. Turn Power "OFF" using the ‘On/Off touch pad/

6. Remove all of the food from both ovens.

7. Leave Oven Doors open to cool down.

8. Remove the Transfer Racks & clean.

9. Wash Multigen inside and out.

10. Replace the Transfer Racks.

11. Leave ovens empty, close doors


7. 1. 3. Detailed Training:

Pre-retherm


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Panning

Ensure that all the food is tempered, as scheduled

Use shallow pans. For soup and cereal, use 4” deep pans but fill only 2” deep

Spray the pans with Pure Vegetable Cooking Spray

Place only the established number of portions per pan PAN SIZE # PORTIONS

Full size

Half size (½)

Third size (1/3)

Quarter size (¼)

Spread the food evenly in the pan

Ensure food is moist

Cover pans, except the ones that require browning or crisping. Do not let food touch the cover

If using aluminum foil, ensure that it is not perforated. Wrap tightly under the edges of the pans.

If using stainless steel lids, ensure that they fit tightly.

Label the pans as directed


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Loading

Before loading, ensure refrigeration is operating in each section

Apply the brakes to the cart

Ensure that all the food needed is available

Check the seal on all the pans that require a lid

Load - see posted diagram on the door. If only 2 pans on a shelf, place the back one length wise

Do not rip the aluminum foil: replace if it is

Check that only food to be rethermed goes into the ovens.

Close the retherm cart door firmly. Do not use the handle


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Transferring the Module

to the Cart with Dolly Option

Ensure brakes are applied on the Multigen cart

Fully open the doors

Push the Dolly toward the center of the cart to the docking bracket. Push firmly in position

Check for alignment. Lock both brakes on the dolly

Depress the foot pedal and push the transfer module into the chamber

Disengage Dolly brakes with your foot - never use your hands - and pull dolly towards you.

Close the Retherm cart door firmly. Do not use the handle


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Connecting the Cart

to the Power Supply

Check that the doors are correctly closed.

Ensure the power cords are clear of hazards and not being stretched or under stress.

Hold the plug firmly in your hand and align the plug correctly with the receptacle.

Note: ensure that the silver pin on the plug, which has a bend to one side, is aligned

with the hole in the receptacle that has the shape to receive it.

Push the plug to the receptacle and twist clockwise to lock. Remember to plug in both ovens.

Check that the Display Panel is blue. If the display panel is black, no power is available to the cart.


7. 1. 4. Detailed Training:

Post-retherm


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Temperature Testing Of Products

Wait until heating cycle is complete: stop the cycle/beeper

DO NOT turn cart off or disconnect from power

Use CAUTION – open door slightly to let steam out – inside of oven door will be HOT!

Use hand protection to handle HOT pans

Quickly remove pan(s) that are to be tested- test products from both ovens

Close door

Sanitize food probe before use

Insert probe into centre of food: do not over-stretch or bend the cable at the connector.

Write down product and temperatures on form

Sanitize probe between uses and before storage


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Temperature Boosting

Take temperature as per procedure

If Boosting is required, put all of the food item(s) back into the oven(s). Close the door.

Press and Hold touch pad #3 for 5 seconds. o The 5 minutes Boost Cycle will start on the ovens

that have temperatures above 158F/70C.

05 will appear in the count down section of the display panel for the appropriate oven(s).

At the end of the 5-minute Boost cycle the beeper will sound. Press touch pad # 3 to silence the beeper.

Repeat temperature testing

Repeat the above operation until the temperature of the food is satisfactory, according to the site specifications.


7. 1. 5 Preparing the Cart for

Service


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Getting the Cart Ready

Make sure the cycle has finished –

“Beep” sounds

“00” Flashing in right and or left oven window

The Gantry light comes “on”

Silence the beeper

Report Error Codes to a supervisor

Check temperatures according to procedures

Leave the Service Options in the “ON” position:

Light/Hot Top If transporting the retherm cart elsewhere:

Turn the power “off”. Unplug the cart and secure the cords Check carts destination Secure all items on top of the cart.


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Transporting the Cart for Delivery

Before leaving, check that:

everything is secure on the cart

doors are closed

rail and shelves are down

Always push the cart using the “rails” from the Control Panel/Plug end

Take care – Avoid collisions

Pay attention to doorways and elevators

Never leave the cart unattended on an incline – even if the brakes are applied!

Always apply the brakes when the cart is stationary.


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Serving Meals from the Cart

Position cart in a safe place: do not obstruct walkway. Apply the brakes with your foot.

Plug the cart in with both cables. Turn cart on by pressing the “on” touch pad.

Check that the selected (left oven side) options are “on”

Light/Hot Top

Set up the top of the cart for service.

Open door: Use CAUTION

open slightly to let steam out

inside of oven door will be HOT!

Pull out only the pans needed for service.

Place on the Hot Top, under the gantry.

Keep lids partially on to maintain heat.

Serve cold product from the cold side, if any.

Note: If wax paper was used during retherm, remove and discard.


7. 1. 6 Post Meal Service


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After Service

Moving to another location:

Place all the food inside the compartments

Turn off the cart: Press the “off” switch (both ovens)

Disconnect the cart & secure the cord. Put the tray rail and the side shelves down End of Meal Service:

Turn "off" the service options

Light/Hot Top

Turn off the cart: Press the “off” switch

Disconnect the cart & secure the cords. Put the rail

and the side shelves down

Place all the food inside the compartments


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Sanitation

for the Retherm Cart

Follow the cleaning schedule

Clean up any spills as soon as possible

DO NOT USE:

Acidic Abrasives

Corrosive Detergents

Rust Remover

Scouring Pads

Abrasive Sponges


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Towing Safety

DO

Take extra care in areas where there are patients and pedestrians.

When towing, carry out the coupling and uncoupling in areas where the floor is flat.

Remove all unsecured items prior to transportation.

Ensure that the towing arm is fully extended and located correctly.

Reduce speed when negotiating corners and inclines

Follow the manufacturer’s instructions if you are using a motorized tugger.


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Towing Safety

X DO NOT

Tow more than four Dollies at a time with a motorized tugger or two Dollies manually.

Un-couple the Dollies on uneven floors or inclines.

Exceed the speed of 4 miles/7 km per hour when towing.

Tow outside over rough or uneven surfaces including expansion joints.

Leave the tow bar in the extended position when the Dollies are not being towed.

Couple Dollies together with tow bars at other than a right angle to the Dolly.


Section 7. 2.

Training Records

Date of Issue Jan-01 Page 105

FORM

Training Review/Schedule (Form M013v1 Jan-01)

Location Date Area BULK RETHERM CART

TRAINING

Name Panning Loading

Transfer Module To Cart with

Dolly

Connect To

Power

Temp. Testing /

Boost

Starting Sequences:

* Manual * Automatic

Ready for Service/

After Service

Cleaning Towing/

Transport

Troubleshooting /Safety

Parameters

Power Failure


FO

RM

Supervisory Staff Training Log (Form M014v1 Jan-01)

FACILITY: TOPIC: #HOUR: Date Name Facility Position Employee

Int.


FO

RM

Dietary Staff In Service

Training Log (Form M015v1 Jan-01)

FACILITY: TOPIC:

Date Name # Hours Position Employee Int.


FO

RM

Meal Service Procedures

Training Log

(Form M016v1 Jan-01)

UNIT SERVICE and/or NURSING STAFF

Date Name Position Employee

Init. Patient

Area


Notes


SECTION 8

PROGRAMMING PROCEDURES MULTIGEN III DOUBLE REFRIGERATION

We include the following information to help you understand how the programming works prior to the training session with the management staff:

A look at the control panel touch pads

An understanding of the information seen on the panel

A description of each function being programmed - the hidden parameters - the cycle: time, temperature - the automatic timer

An actual data sheet for each program, specific to your facility. (Burlodge to fill out during week 14).

The procedure to follow in case of an RESET Error Code during operation of the Bulk Retherm Cart.

8.1 Touch Pad Control Panel: Display The Multigen III, Double Refrigeration has two control panels as shown in the following Picture. The left hand control panel will control the heated top plate and the gantry lights, as well as the heating and refrigeration in the left hand oven. The right hand control panel will control only the heating and refrigeration of the right hand oven.

9 10 11

8 5 6 7 1 2 3 (4)

Key 1. Start/Stop Touch Pad for retherm cycle 1. 2. Start/Stop Touch Pad for retherm cycle 2. 3. Start/Stop Touch Pad for retherm cycle 3. 4. Start/Stop Touch Pad for Boost/Maintaining cycle (press and hold for 5 seconds). 5. On/Off Touch Pad for Refrigeration. 6. ‘F’ Function touch pad used for temperature taking, waste function, maintenance cycle, wash cycle,

and current time/date. 7. On/Off Touch Pad for Lights/Heated Hot Top and Heated Gantry 8. Power ON/Off Touch Pad. 9. Indicating remaining time and temperature for left oven.

10. Indicates cycle for left and right oven. 11. Indicating remaining time and temperature for right oven.


8.2 Touch Pad Control Panel: Functions

LEFT SIDE OVEN CENTER PANEL RIGHT SIDE OVEN

ON/OFF SWITCHES CYCLE BUTTONS Control Panel

POWER The blue display panel indicates that there is power supplied.

ON/OFF SWITCH Press to turn unit ON or OFF.

LEFT SIDE OVEN Count down timer display and temperature for left oven

RIGHT SIDE OVEN Count down timer display and temperature for right oven

CENTER PANEL Indicates which cycles have been selected

OVEN SELECTION TOUCH PAD - Used to select eight left or right oven

FUNCTION ICON Press once: temperature taking if probe is plugged in Press twice: Waste Function Press three times: Maintenance Cycle when followed by pressing #3

touch pad Press four times: Wash Cycle when followed by pressing #3 touch pad Press five times: Current time and date set in the cart’s settings.

OVEN SELECTION

TOUCH PAD


8.3 Programming Instructions Turn the cart "OFF". Firmly press and hold the # 1 and # 3 touch pads with your right hand. At the same time, with your left hand, press the "ON" touch pad. When the Program screen appears, release touch pads #1 and #3 and press the #2 touch pad. The first icon in screen #1 is flashing indicating you are in program mode. While in programming mode:

Touch right pad # 1 decreases the values of the settings

Touch left pad # 2 increases the values of the settings

Touch right pad # 3 to scroll or advance through the settings- this selection will automatically lead to the next level (unless otherwise directed).

ICONS RANGE FUNCTIONS TO BE SET DESCRIPTION

SCREEN 1

00 to 025°C 032 to 077°F

Refrigeration for Left oven This parameter should be set to ”OFF” If your cart is not equipped with refrigeration.

30 to 80°C 086 to 176°F

Refrigeration for Right oven This parameter should be set to ”OFF”

If your cart is not equipped with refrigeration.

∆ 002 to 005 Differential or hysteresis setting for the refrigeration parameter

The refrigeration temperatures in the cold compartment will be allowed to fluctuate +

2°C3.6F while in the refrigeration mode

SCREEN 2

000 to 001

Heated Top Plate (H.T.P.) Temperature Setting

The Temperature is normally set at 80°C/176°F

█─╨ 000 to 001 Password setting: always set ”N” If set at ‘Y’ the BWise Card must be used to start any cycle (including Boost)

C/F 000 to 001 Temperature display in Celsius or Fahrenheit

Tdisplay in Fahrenheit.

T display in Celsius


Location on Display

RANGE FUNCTIONS TO BE SET DESCRIPTION

Screen 3 - CYCLE 1

Top Left 00 to 180°C 032 to 365°F

Oven set Temperature Temperature that the oven cavity will reach during the first cycle of rethermalization

Top Left 003 to 099 Total cycle time Total number of minutes of the first retherm cycle

Bottom Left Gratination

Temp

Oven set T Minus

1C/2°F

Gratination or ramp down temperature

During the last part of the cycle (ramp down time) the heating element will start if the oven temperature drops below this setting or the temperature will rise if gratination is desired


Time

00 to Total cycle time- 1

Ramp down time The amount of minutes the ramp down time (fan only) or gratination (elements on) is set at the end of the first cycle.

Top Right 00 to 180°C 032 to 365°F


Top Right 003 to 099 Total cycle time Total number of minutes of the first retherm cycle

Bottom Right

Gratination Temp

Oven set T Minus

1C/2°F


During the last part of the cycle (ramp down time) the heating element will start if the oven temperature drops below this setting or the temperature will rise if gratination is desired.

Bottom Right

Gratination Time

00 to Total cycle time -1

Ramp down time The amount of minutes the ramp down time (fan only) is set at the end of the first cycle or the temperature will rise if gratination is desired.

Location on Display


Screen 4 – CYCLE 2

Top Left 00 to 180°C 032 to 365°F

Oven set Temperature Temperature that the oven cavity will reach during the second cycle of rethermalization

Top Left 003 to 099 Total cycle time Total number of minutes of the first retherm cycle


Temp

Oven set T Minus

1C/2°F




Time


Ramp down time The amount of minutes the ramp down time (fan only) is set at the end of the second cycle.



Top Right 003 to 099 Total cycle time Total number of minutes of the first retherm cycle

Bottom Right

Gratination Temp

Oven set T Minus

1C/2°F



Bottom Right

Gratination Time


Ramp down time The amount of minutes the ramp down time (fan only) is set at the end of the first cycle.


Location on Display


Screen 5 – CYCLE 3

Top Left 00 to 180°C 032 to 365°F


Top Left 003 to 099 Total cycle time Total number of minutes of the third retherm cycle


Temp

Oven set T Minus

1C/2°F




Time





Top Right 003 to 099 Total cycle time Total number of minutes of the third retherm cycle

Bottom Right

Gratination Temp

Oven set T Minus

1C/2°F



Bottom Right

Gratination Time




Screen 6 – MAINTENANCE OR SERVICE CYCLES/WASH CYCLE

M

00 180C

32 356F Temperature of oven during M Cycle

Unless the oven(s) are above 158F/70C, the M cycle will not turn on

003 099 min. Time allowed for M cycle Select time for M cycle

0 90C

32 194F Temperature of Wash cycle Temperature ranges for wash cycle

00 099 min Time allowed for Wash cycle Select time for wash cycle



Screen 7 – WEEKDAY SETTINGS FOR WAKE UP AND AUTO TIMER

1st Meal of the Day

02:00 – 23:59 Wake Up Time If cart is plugged in, the cart will turn on at selected time to refrigeration

OFF to 03 Cycle Choose which cycle is to start

02:00 to 23:59 Time the oven is to turn on Setting the hour/minute for the rethermalization for selected cycle

2nd Meal of the Day




3rd Meal of the Day




Screen 8 – WEEKEND SETTINGS FOR WAKE AND AUTO TIMER

1ST Meal of the Day




2nd Meal of the Day




3rd Meal of the Day





Screen 9 – ACTUAL TIME AND DATE Year 00 to 99 The current year

Month 01 to 12 The current month

Day 01 to 31 The current day of the month

Day of the Week

01 to07 The day of the week Mon 1 Tue 2 Wed 3 Thu 4 Fri 5 Sat 6 Sun 7

Hour/Minutes 00:00 to 23:59

Current time – Hour/Minutes Every time you change the program you must ensure that you enter the correct time

Screen 10 a – AUTOMATIC TIME CHANGE FOR SUMMER TIME CHANGES Month for hour increase

00 to 12 Spring time change: month The following sequences - are programmed once a year, after the fall time change

Day for hour increase

01 to 31 Spring time change: day

Screen 10b – AUTOMATICE TIME CHANGE FOR WINTER TIME CHANGES Month for hour decrease

00 to 12 Fall time change: month If time changes are not observed in your area, set the dates for 11a and 11b the same.

Day for hour decrease

01 to 31 Fall time change: day


8.4 Programming Tables

“Actual Settings”

Date: __________


FORM

Multigen III Programming Table with Refrigeration (M3 105 Series) Form M019v3 Jan-12

To enter Programming: Turn cart Off. Place fingers on 1 and 3. Press "On" and hold the 2 fingers until Program appears.

Press 2.and the first screen for programming appears. To Program: Use Touch Pad # 3 to advance, # 2 to value, #1 to

value unless otherwise indicated.

Adjustable

Parameters Display

Values Permissible Range

Default Settings

Site Specific Settings

°C °F °C °F

Screen 1 Display

Left Fridge Temperature

000 025 (off) 32 077 (off) 04 39

Right Fridge Temperature.

000 025 (off) 32 077 (off) 07 45

Refrigeration Differential ∆ 002 005 3.6 9.0 02 3.6

Screen 2

Heated Hot Plate (HTP)

50 90 122 194 80 176

Touch Pad Lock █─╨ N Y N

Temperature (°C or °F) °C/°F °C °F °C

Screen 3

Cycle 1 Display

Left Oven Set Temperature Left Top

00 170 32 338 140 284

Total Left Cycle Time 00 099 min. 045

Left Gratination Temp. Left Bottom

00 170 32 338 80 170

Left Gratination Time 0 (off) Total Time Left 002

Right oven Temperature Right Top

00 170 32 338 140 284

Total Right Oven Time 00 099 min 45

Right Gratination Temp Right Bottom

00 170 32 338 80 176

Right Gratination Time 0 (off) Total Time Left 002

Screen 4 Cycle 2 Display


00 170 32 338 140 284



00 170 32 338 80 170



00 170 32 338 140 284



00 170 32 338 80 176


Date: __________


Screen 5

Cycle 3 Display


00 170 32 338 140 284



00 170 32 338 80 170



00 170 32 338 140 284



00 170 32 338 80 170


Screen 6

Boost/Wash Cycles Display

Maintenance Temperature M

00 180 32 356 80 176

Maintenance Time 003 099 min. 030

Cleaning Temperature

0 90 32 194 90 194

Cleaning Time 00 099 min 30

Date: __________


Screen 7

FUNCTIONS

VALUES

Multigen III SITE SPECIFIC SETTINGS

Permissible Range

Default Settings

CART LOCATIONS

Timer Status Serial Numbers

WEEKDAY SETTINGS - (When modifying these values, numbers 1 through 5 will flash.) When setting oven timers, only one oven cycle can be used. If choosing cycles of different lengths, the shorter cycle will ‘hold’ so that both cycles will finish at the same time.

1st Meal of the day

Wake Up

Time

02:00 23:59 OFF

Cycle* OFF 03 OFF

Oven Cycle

Start Time 02:00 23:59 OFF

2nd Meal of the day

Wake Up Time

02:00 23:59 OFF

Cycle*

OFF – 03 OFF

Oven Cycle Start Time

02:00 23:59 OFF

3rd Meal of the day

Wake Up

Time

02:00 23:59 OFF

Cycle OFF- 03 OFF

Oven Cycle

Start Time 02:00 23:59 OFF

WEEKEND SETTINGS (When modifying these values, numbers 6 and 7 will flash.) Screen 8 See note above.

1st Meal of the day

Wake Up

Time

02:00 23:59 OFF

Cycle OFF- 03 OFF

Oven cycle

Start Time 0200 23:59 OFF


3rd Meal of the day

Wake Up Time

02:00 23:59 OFF

Cycle*

OFF - 03 OFF


02:00 23:59 OFF

Screen 9 Actual Date and Time

Settings Ranges Default

Year 06 - 06

Month 1 - 12 05

Day 1 - 31 02 To complete only at time of programming Day of the week (1 = Monday) 1 - 7 00

Hour/Minutes 01:59 – 23:00 00

Press touch pad #2 to proceed to 10a and 10b. Screen 11a: Automatic Change for Summer Time Changes

Settings Ranges Default 2011 2012 2013 2014 2015 2016 2017 2018 2019

Month for hour increase (+) 1 - 12 03 03 03 03 03 03 03 03 03 03

Day for hour increase (+) 1 - 31 30 13 11 10 09 08 13 12 11 10

Screen 11b: Automatic Change for Winter Time Changes Settings Ranges Default 2011 2012 2013 2014 2015 2016 2017 2018 2019

Month for hour decrease (-) 1 - 12 10 11 11 11 11 11 11 11 11 11

Day for hour decrease (-) 1 - 31 26 06 04 03 02 01 06 05 04 03 End of Programming

Press the OFF touch pad to save changes. The cart may be turned back ON and the unit will now function as Programmed.

If necessary, you may use touch pad #2 to return to screen #1.

2nd Meal of the day

Wake Up Time

02:00 23:59 OFF

Cycle*

OFF - 03 OFF


02:00 23:59 OFF


8.5 Procedure following an

RESET Error Code

Multigen III Double Refrigeration


8.5. RESET INSTRUCTIONS – Multigen III

1. When ‘RESET’ appears on the display panel, press touch pad #3. 2. ‘Serial n.’ will appear with three sets of numbers below the word. 3. Press touch pad #3 and the first set of numbers to the left will flash. Insert the correct serial number of the cart. The serial number is located on a rating plate above the right cold door. Each serial number consists of six numbers of which the first may be a ‘0’. 4. Using touch pads #1 to decrease the value of the flashing set or #2 to increase the number to match the first two numbers of the cart’s serial number. Press touch pad #3 to move to the center set of numbers and proceed as above. 5. After inserting the last set of numbers Press touch pad #3 to that the word ‘Serial n.’ is flashing again. Press touch pad #2 to proceed to screen one. 6. Press touch pad #3 once until the single number 1 blinks. This is cycle #1 settings. 7. Press touch pad #2 to proceed to cycle 2, press touch pad #2 to proceed to cycle #3. Press touch pad #3 to navigate through the maintenance and wash parameters. 8. Press touch pad #3 to reach screen 8 in which the 1-5 is flashing – press touch pad #2. 9. Press touch pad #2 so that the 6 - 7 will blink. Press touch pad one more time to reach the time/date screen 10. Press touch pad #3 to ‘enter’ the date/time screen and use Touch pad #1 to decrease the value that is flashing and touch pad #2 to increase the value that is flashing. Press touch pad #3 to confirm each setting. 11. When the date/time icon is flashing, press touch pad #2 to exit the date/time screen. Turn the cart off and then back o to ensure the RESET has cleared. NOTE: Please note that if the correct serial number and the actual date are not inserted the Multigen will fall again in RESET mode at next power on. 1. After programming is completed, it will be necessary to access the hidden menu to change

the daylight savings dates from Europe to North America. 2. To access the hidden menu: with the cart disconnected from power, press touch pad #3 and

the hidden touch pad at the same time then reconnect the cart to the power source. 3. Using touch pad #2, advance through the menu selections until displays shows “Clock

Change”. 4. Press touch pad #3 to access the set up menu in the Clock Change section. 5. Press touch pad #1 or # 2 to select “Clock Change in North America”. 6. Then, press and hold the ON/OFF touch pad and press touch pad #3 to confirm. The preset

dates are now stored in memory. 7. To exit the hidden menu, remove the Pod to break power. 8. Once the Hidden menu is corrected, turn the cart off, press and hold touch pad #1. ‘Events’

will appear on the screen. Press touch pad #2 until ‘Language’ appears on the screen. Press touch pad #3 to select. Press touch pad #2 to choose ‘English’. Press touch pad#3 to confirm. Turn the cart off and changes are saved.


SECTION 9

TROUBLESHOOTING

9.1 Equipment Problems? Quick Reference

1. Check if the green icon (on the control panel) is illuminated.

2. If not, call maintenance to check the main power supply to the plug.

3. If the green icon is illuminated, turn the unit on. If the display panel does not light up, call maintenance to check the internal fuses and safety devices in the cart.

4. If the display panel lights up but shows an error code, follow the "Troubleshooting Guide".

5. If the display panel shows the normal display sequence but the retherm cycle did not start as programmed, check the cycle programming: weekday and weekend.

6. Please check the following guidelines to establish if a claim is covered under the warranty:

The standard Burlodge USA, Inc. Warranty does not cover the following:

Wear parts (castors, brakes, door/frame gaskets, bumpers, lights, etc.).

Fuses (first time). If caused by a warrantable fault, then they are covered with the warranty repair.

Cycle or time program adjustments.

Door/hinge repairs or adjustments.

Cleaning of any kind.

Repair or replacement of any part damaged by abuse, fire or exposure to caustic chemicals and/or inclement weather conditions.

If there is any doubt about a warranty claim please contact your maintenance department prior to calling the Service Agent. If you require further clarification, please do not hesitate to call the Burlodge office and talk to a Technical Representative.

9.2 Temperature Troubleshooting Guide for Food Service A) Cold food: Not cold enough when checking temperature after retherm

Multigen III with Refrigeration Only To resolve the problem it is important to examine the entire “cold process” and determine the single or multiple causes of why the cold temperature is not meeting your set standards. Remember that the final internal temperature of food is always a result of three factors:

The initial temperature.

The medium air temperature surrounding the food.

The length of time the food is subject to that temperature.

1. Check temperature of the cold food throughout the entire process. Identify one food item, such as a sandwich or milk, and check the Tº of that particular item at the following times:

Tº just prior to loading the module in the Multigen.

Tº at the end of the retherm cycle.


2. Identify the time frame for the above:

Time at room temperature before loading into the Multigen.

Time at room temperature during loading into the Multigen.

3. Check the Tº of the cold side of the Multigen, by reading the Display Panel

Tº display, prior to retherm, 15 minutes after the refrigeration is turned “on”. This will indicate if the refrigeration is working as programmed.

Tº display at the end of the retherm cycle. This will indicate how well the refrigeration worked during the cycle.

4. Check the gaskets for a good seal and that they are in place and not damaged.

Frame gaskets: check for damage and the fit in the corners.

5. Check “all” aspects of the refrigeration system:

Does the cart location assure an appropriate intake of cool air? Make sure that the air intake, located under the control panel is not blocked by an object or that

the room air Tº is below 86F (30°C).

Check that the preventative maintenance has been done: Fans, finger guards, condenser, and filters. Check with maintenance.

Remember that that the Multigen cart may be at room temperature (~77F/~25°C) prior to being turned “on”. The beginning cold temperatures of all the components on the cold side will

determine the time it will take for the Multigen ambient air temperature to reach 37F (3C). For example, if trays, dishes and desserts were at room temperature before loading, the time it will

take for the Multigen temperature to drop to 37F/3°C will be longer than if all of the components

were at 37F/3°C.

Ideally, all items should be at 37F/3°C when placed in the Multigen Cold Compartment. The refrigeration should be turned "On" early for the cavity to reach 37°F/3°C when food is loaded.

Note: The compressor does not work when the heat is "On”.

B) Hot food: Not hot enough when checking temperature after retherm

1. Check temperatures of the problem items prior to retherm

Dense food items such as casseroles or meat, if still frozen, will not reach the

set temperature. Make sure they are at least 37F/3°C throughout.

Some food items can be rethermed from frozen. Test first. 2. Check the amount of food in a pan

Check the height of the food: if it is touching the lid, it is too high! Lasagna, square meat pie and shepherds pie are often too high.

Use recommended pan sizes- see Section 5 3. Check all the gaskets for a good seal: if not, hot air will escape.

Frame gaskets: check that they meet in the corners and/or are not damaged. 4. Check the method of temperature taking:

When and how the temperatures are taken.

The type of probes used: slow or fast, and where the sensor is. This is very important. If the food does not touch the sensor, it will not record the correct temperature. For example, non-digital probes will not read the temperature of thin sliced meat, small portions or shallow liquid such as gravy accurately.


5. Ask maintenance to check the following:

The door hinges to make sure the door is tight against the frame.

The door handle, to make sure the door closes tight and all the way.

C) Hot food: Too hot when checking temperature after retherm

1. Check the temperature of the food items prior to retherm

If the temperature of some items is already high when retherm starts, it will end up higher.

2. Check the portion size:

Some food or small portions may need to be “protected” by putting them in a small dish inside a pan.

3. Adjust the programming: reduce temperature first, not the cycle time.


9.3 Programming Troubleshooting Guide Problem Possible Reason Operations Action Maintenance

No blue display

1. Cart unplugged/or breaker tripped. (BPod – press high temperature reset) 2. Pod not nested completely or correctly (BPod only)

1. Cold side is too hot: if door was closed after retherm, allow unit to cool; high limit switch

will reset itself. (Cools to 95F/35C – Novaflex II). If it does not reset, call maintenance. 2. Ensure the pod is nested correctly - not in backwards – and that doors are closed.

1. Check if electric is wired properly. 2. Check breaker in electrical panel 3. Check all internal fuses. 4. Protective device tripped Novaflex II only)

-Cold side (113F/45C)

-Hot side 419F/215C Qualified personnel need to complete checking power at the plug, internal fuses, high temp safety thermostat, refrigeration system high pressure manual safety reset, defective transformer – check for power in and out.

Display on but cycle cannot be turned on.

Display panel is locked Ensure that the display panel has not been ‘locked’. See programming – screen 2.

“SC1” on display panel Temperature above 50F/10ºC – defaults (or as set in SC1) on the

cold side

Do not do anything. The cycle will start once the correct temperature is reached. SC1 will appear on the display panel (rather than the cold temperature) until the SC1 Tset has been reached. -Check that doors are closed tightly. -Ensure doors were not opened for a long period of time. Pod may have been nested to close to the retherm time. -If problem persists, contact Maintenance.

1. Check refrigeration system

“SC2” on display panel

(Alarm beeper is sounding but cycle is not finished) Note: Cart will “shut off” if

Tset. goes above 131F/55C (High limit switch)

Temperature above 59F/15C (or as set) on the cold side 1. Gasket has slipped off the doors 2. Door is not shut 3. Refrigeration problem.

Do not turn the cycle off immediately. 1. Check all gaskets, replace if required. 2. Close door. 3. Check high temperature/restricted air intake 4. Ensure there are no broken dividers or missing gaskets. Remove or replace missing/damaged dividers/gaskets. If there is no apparent cause, or temperature does not decrease after intervention, move the Pod to refrigerated area and hold cold items until another B-Pod cart can be used for retherm.

1. Check refrigeration system. 2. Check that door gaskets are not torn or missing.


Problem Possible Reason Operations Action Maintenance

“L3” in display window where

the oven temperature is normally shown

Set temperature for the oven cavity not achieved by the end of the cycle

1. If food temperature is acceptable, no action required.

2. Check programming for sufficient time to reach temperature settings 3. Check to ensure doors have been closed properly. If doors are closed using the safety strap and not the door latch, air temperature is affected. 4. Doors have been opened for removing or inserting new trays – diet changes – at the critical measurement. 5. Run a cycle with an empty Pod to confirm L3. 6. If problem persists, call service dept.

1. Check power supply 2. Check fuses

Meal has not reheated Cart was loaded or turned on after the programmed start time

1. Start the cycle for the meal by pressing the appropriate cycle button.

RESET on display 1. Electrical disturbance 2. Tampering with control panel 3. CPU unit Faulty

1. SUPERVISORS ONLY – Can occur if there was a major fluctuation in voltage. Follow instructions for RESET (Section 8 in Manual)

2. Press touch pad #3. This will reset the cart into programming mode. 3. Follow Reset Procedure in Ops/Tech manual 4. Request Technical Assistance if problem persists

“OL” in display window

where the oven temperature is normally shown

Oven over heated Running back to back cycles Thermal limit prevents the start of a retherm cycle

1. Allow 15 to 20 minutes for oven to

cool below 140ºF/60C before starting retherm cycle. Open all doors.

Power outage Generator testing 1. Turn the cart on 2. Check whether cycle has restarted in window one 3. Restart the cycle by pressing the cycle button 1, 2 or 3

1. Check power supply. 2. Check electrical breakers


Problem Possible Reason Operations Action Maintenance

“H1” in display Refrigeration probe fault or loose connection Temperature has exceeded the safety limit

of 374/190C.

1. Contact Supervisor – using Events list, determine activity prior to alarm 2. Allow cart to cool prior to testing with an empty Pod

Request Technical Assistance 1. Ensure probe is not loose 2. Refrigerator probe defective

“H2” in display Bottom oven probe fault or loose connection – Minigen I, Multigen II Temperature has exceeded the safety limit

of 374/190C.

1. Contact Supervisor – using Events list, determine activity prior to alarm 2. Allow cart to cool prior to testing with an empty cart.

Request Technical Assistance 1. Ensure probe is not loose 2. Bottom oven probe defective

“H3” in display Top oven probe fault or loose connection Temperature has exceeded the safety limit

of 419/215C.

1. Contact Supervisor - using Events list, determine activity prior to alarm 2. Allow cart to cool prior to testing with an empty Pod (BPod only)

Request Technical Assistance 1. Ensure probe is not loose 2. Top oven probe defective.

“H5” in display – Multigen

Series only Hot top probe fault or loose connection Temperature has exceeded the safety limit

of 419/215C.

1. Contact Supervisor - using Events list, determine activity prior to alarm 2. Shut off hot top if it is on and remove all pans if any from the hot top. Allow top to cool to room temperature. If alarm does not clear, request Technical Assistance.

Request Technical Assistance 1. Ensure probe is not loose 2. Hot top probe defective.

Water on the floor or in the base of the unit

1. Clogged drain line 2. Multigen series – cold wall refrigeration needs to defrost and wiped out after every meal.

1. Clear obstruction – DO NOT use sharp objects 2. Allow adequate time for defrosting of Multigen carts. 3. More than a few hours of operation in the cooling mode can cause excessive frost/condensation. Contact Burlodge Technical Support for further assistance/advice.

Burlodge equipment is designed to only operate the cold sides for a few hours.

Foul odor coming from the unit

1. Condensate pan not cleaned 1. Include cleaning of condensate pan(s) in PM checklist

1. Locate and clean condensate drain pan/heater. Disconnect from power supply before proceeding. Refer to Burlodge Technical Manual for instructions for your model

Light will not come on. Multigen Series only.

Light will operate only in the refrigeration or M cycle (Multigen Series only)

NOTE: This Trouble Shooting Guide is intended as a Quick Reference to resolve common errors/problems. Contact Burlodge Technical

Support for further information if your problem/issue is not solved by this guide. 10/10 – SB/JO


9.4 EMERGENCY PROCEDURES BULK RETHERM CART

A. Temporary Power Failure

1. ANY power failure will shut the Bulk Retherm Cart “Off”. If the Cart is on Emergency power or

when power is restored, the cart will return to the state that it was in prior to power loss. The programming will not be lost. 2. If the power failure occurs during a retherm cycle and the oven temperature is above

158F/70C, the cycle will continue from where it was interrupted. If the temperature is below 158F/70C, the cycle will have to be re-started manually by pressing the appropriate cycle touch pad: #1 or #2, or #3. See instructions for manual start in Section 6.

B. Major Power Failure: Emergency Power Activated

1. Locate the Bulk Retherm Cart power outlet with the red labels: these plugs are connected to the Emergency power source.

2. Only a few carts can be rethermed at one time. Ensure that the units that need to be delivered first to the wards are rethermed first. 3. The retherm will have to be activated manually: for example, press #1 for Breakfast, #2 for Lunch and #3 for Dinner.

4. Back-to-Back rethermalization will need to be completed for the remaining carts.


FO

RM

SECTION 10

MAINTENANCE

10.1 Service training and sign-over document (Form M022v1 Jan-01)

The following items have been completed as part of the service training for: Facility Name

Maintenance Staff Names: (please sign)

Date(s) of training:

Spare Part Inventory Verified:

Spare Parts Location:

Manuals Received and Reviewed:

Preventive Maintenance Requirements Reviewed:

Service Call Procedures and Policies Reviewed re: outside normal working hours, warranty vs. non-warranty work, nuisance calls, neglect or misuse of the equipment

Equipment Operation and Programming Reviewed:


FO

RM

10.2 Implementation Equipment List/Serial Numbers Bulk Retherm(Form M023v2 Jan-08)

Start-up Date: Job No.: ___________________

Installation Team:

Manufacturer Information Start-up Information

Series Model Date Serial n. Site

location Desiccate Removed

Plug Wiring

Checked

Voltage* - minimum 208 volt

L1-L2 L1-L3 L2-L3

Firmware Version: Door Key #:

Display Default Setting Site Specific Settings

C F

Left Oven Fridge Temp.

02 37

Right Oven Fridge Temp

07 45

Fridge Differential ∆ 02 3.6

HTP

80 176

Touch Pad Lock (SmartCard) █─╨ N

Temperature C/F C

Multigen III

Left Oven

Parameters Cycle 1 Cycle 2 Cycle 3

Oven set temperature

Total cycle time

Gratination Temperature

Gratination Time

Right Oven

Oven set temperature Cycle 1 Cycle 2 Cycle 3

Total cycle time

Gratination Temperature

Gratination Time

Date of Issue January - 08 An ISO 14001 Certified Company Page 133

10.3 Maintenance Log Book (Form M024v1 Jan-01)

Please record all maintenance and repair information whether conducted by in-house staff or outside company, then fax to Burlodge at (336) 776 - 1090.

Burlodge Identification Hospital Identification

Model type Identification #

Model # Floor

Serial #

Manufacturing Date

Cart Size

DATE DESCRIPTION


10.4 Preventive Maintenance All Burlodge equipment must be regularly inspected and maintained in order to ensure long trouble free service (and not void the warranty). Preventive maintenance requires approximately two (2) hours per cart per year. Every Six Months - Please refer to form F006v1 for details

10.5 Warranty and Service

Warranty Duration:

The standard warranty on Burlodge equipment is one year from date of original installation. The warranty coverage is full 100% parts and labor. Heating elements are warranted for five years and compressors one year from the date of original installation.

What is covered under warranty:

Any failure that is the result of defects in materials or workmanship occurring within the applicable duration of the warranty period.

What is not covered under warranty:

i. Any incidental or consequential damages that may result from the failure or malfunction of the Burlodge product. ii. Any failure that results from an accident, user abuse, neglect or failure to operate the product in accordance with the instructions provided in the User Manual(s) supplied with the product, or damage resulting from improper servicing by a non-authorized Service Agent. iii. Normal adjustments, which are outlined in the User Manual(s), and elsewhere, provided with the product. iv. Any component(s) or accessories not sold, manufactured or installed by Burlodge or its Authorized Service Agent. v. Pre-delivery set-up or assembly of the unit(s). vi. This warranty does not apply to accessories, normal maintenance or adjustment(s) of the product set forth in the Users Manual(s).

Responsibilities of the Warrantor

A. Repair or replace components which have failed, and which qualify under the warranty terms and conditions as detailed above, within the duration of the applicable warranty period at no cost to the User. B. Ensure that the Authorized Service Agent is reimbursed for parts and labor costs incurred due to performance of a warranty repair in accordance with established warranty policies and procedures.


Responsibilities of the User

A. Use reasonable care in the cleaning, maintenance, and operation of the unit(s) as outlined in the User Manual(s) and during in-service training. B. Immediately contact Burlodge or an Authorized Service Agent if a failure occurs.

When warrantor will perform

Repair of warranty defects will be scheduled as soon as possible after Burlodge or its Authorized Service Agent receives the original service call. The repairs will be made, whenever possible, at the place of business of the equipment owner, during normal daytime business hours. Any warranty work requests by the equipment owner outside normal Monday to Friday business hours will be at their expense for any premium rates incurred for such hours worked.

Determination of warranty repairs

Burlodge or its Authorized Service Agent will determine, at the time of the service call, the validity of the warranty repair. If the repair is deemed not to be covered under warranty, the equipment owner must make arrangements with the Authorized Service Agent for the method and terms of payment for such time and materials as may be required to complete the repair.

SERVICE AND WARRANTY WORK MAY ONLY BE DONE BY

BURLODGE AUTHORIZED SERVICE AGENTS.


FORM

10.6 Preventive Maintenance Check List Form M025v2 Jan-08

Minigen/Multigen Cart

- Check and clean condenser coil, shroud, fans and filter - Check and clean the compressor-cooling fan and finger guard

- Check heating element motor(s); tighten fan set screws

- Check all internal probes, clean if necessary

- Check main power receptacle and mounting hardware

- Check and tighten all screws, bolts and hinges

- Check and adjust upper and lower door bushings, latches and hold open clips

- Check and replace, if necessary, all door and frame gaskets

- Check and clean castors and brakes

- Visually inspect electronic components

- Check proper operation of all functions, cycles, buzzer and current time settings

- Check gantry: lights, heating rods, fans

Minigen/Multigen Dolly/Rack

- Check for broken welds, repair as required

- Check and repair or replace bent or damaged tow bars and springs

- Check operation of foot pedal release return spring

- Check and clean castors and brakes

- Check rack, bottom nylon rollers, tray slides

Note: Some parts, such as refrigeration and dolly are optional and may not be supplied with your equipment.

SITE NAME: ________________________ DATE: ________________________ Technician _____________________ MODEL: ________________________ SERIAL NO. ______________________

Date of Issue January – 08 Page 137

10.7 Maintenance Reports

Date of Issue: 17/04/07 –R1 An ISO 14001 Certified Company Page 138

SECTION 11

Reports

11.1 Installation Report


11.2 Site Visit Reports


SITE VISIT REPORT (Form T022V1Jan-00)

Copies: file

Date

Account Name

Account Location

Account Number

Person Contacted

ITEMS REVIEWED ACTION

1. Equipment/Dishware

Recommendation

2. Temperature/Product Results

Recommendation

3. Training/Procedures

Recommendation

Comments

SIGNATURE

POSITION


OPERATION and

TECHNICAL MANUAL

MULTIGEN III 105 Series


1. Table of Contents

HEADING PAGE

1. TABEL OF CONTENTS 142

2. INTRODUCTION 144

3. TECHNICAL DATA SHEET 144

4. PRODUCT IDENTIFICATION 146

5. TROLLEY IDENTIFICATION 146

6. STANDARDS AND CERTIFICATION 147

7. PACKAGING, HANDLING, FORWARDING AND TRANSPORT 147

8. TROLLEY DESCRIPTION 148

9. SAFE MODE 149

10. CORRECT USE 149

11. WORKING ENVIRONMENT 149

12. TROLLEY DISPOSAL 149

13. GENERAL SAFETY PRECAUTIONS 150

14. CONNECTING TO THE POWER SUPPLY 150

15. CONTROL PANEL 151

16. DISPLAY 152

17. STARTING/STOPPING THE L AND R OVEN MANUALLY. 153

18. THE FUNCTION MENU “F” 157

19. PROGRAMMING 158

20. PROGRAMMING THE OVEN CYCLES AND AUTOMATIC STARTS. 159

21. USER’S RECOGNITION (USE OF BCARDWISE CARD) 165

22. PROGRAMMING THE OVEN CYCLES AND AUTOMATIC STARTS (USE OF BCARDWISE CARD) 166

23. PROGRAMMING A NEW MACHINE AND FROM A ‘RESET’ 167

24. DETACHABLE EXTERNAL FOOD PROBE 167

25. WASTAGE 168

26. DATALOGGER (EVENT LOGGER) 168

27. DOWNLOADING THE EVENTS LIST ON THE BCARDWISE+ CARD 170

28. DOWNLOADING THE TROLLEY SETUP ON THE BCARDWISE CARD 170

29. CHANGING THE EVENTS LIST LANGUAGE 171

30. MONITORING THE SIGNAL COMMUNICATION (BWISE OPTION) 171

31. SPECIAL FEATURES 172

32. SAFETY FEATURES 173

33. OPERATING INSTRUCTIONS 173

34. STARTING A REGENERATION CYCLE 174

35. OPERATING INSTRUCTIONS FOOD SERVICE 175

36. POST SERVICE PROCEDURE 175

37. COOK FREEZE : COOK CHILL - FLOW CHART 176

38. HOT LINE - FLOW CHART 177

39. DAILY CLEANING PROCEDURES 177

40. CLEANING SCHEDULE 178

Formatted: Bullets and Numbering


41. POWER WASHING MULTIGEN III 178

42. CLEANING BY HAND MULTIGEN III 178

43. THE CLEANING CYCLE 179

44. ERROR CODES 180

45. FAULT FINDING 181

46. TOWING ATTACHMENT 181

47. TOWING PROCEDURE FOR THE MULTIGEN III 182

48. TOWING PROCEDURE FOR THE MULTIGEN DOLLIES 182

49. TOWING SAFETY MULTIGEN III 183

50. TOWING SAFETY MULTIGEN DOLLY 183

51. MAINTENANCE 184

52. REGULAR MAINTENANCE 185

53. REGULAR MAINTENANCE CONTINUED. 186

54. TECHNICAL ASSISTANCE AFTER SALES SERVICE 186

55. PREVENTATIVE MAINTENANCE 186

56. WARRANTY AND SERVICE CALLS 187

57. SPARE PARTS 188

58. WARRANTY 189

59. DIMENSIONS 191

60. INSTALLATION CANADA/USA 192

61. MULTIGEN SERIES 105 SEQUENCE OF EVENTS/GENERAL UNDERSTANDING 192

62. ELECTRICAL SPECIFICATION 194

63. ELECTRICAL SCHEMATIC 195


2. INTRODUCTION

In choosing the Burlodge Multigen III trolley you have the most advanced, purpose designed unit of its kind available today. With careful use and regular maintenance your unit will give you many years of trouble free service. This manual is an integral part of the safety of your trolley and a guide for all operators and maintenance staff. It contains important information on the operation and maintenance of your Burlodge trolley. Ensure all personnel read this manual carefully, are fully conversant with its contents and receive any additional training that may be required to enable them to operate and maintain the trolley in a safe and correct manner. Pay particular attention to the safety information included in the text. Keep this manual in a safe place where it is accessible to all personnel at all times. This manual is a guide only and will be supplemented by on-site training designed for your individual requirements. It is important to note that the program settings in this manual are purely an example and will vary to the actual settings for your trolley and site. When you receive your trolley, it will be programmed to the standard default factory settings but will be re-programmed to suit your specific conditions. Please Note: Before installing or using your Burlodge trolley, a licensed electrician needs to ensure that it will be connected to an appropriate power supply. The voltage and frequency must correspond with the data plate. Refer to the instructions given in the “Installation” section. It is important to use the trolley only in the way that is described in this manual. Burlodge will not be responsible for any damage that may result through incorrect use or failure to follow the instructions in this manual. This manual relates to all trolleys in the Multigen III series. The following abbreviations are used in this manual to identify each individual model and options:

Options: The following symbols are used in this manual to highlight important text:

Read carefully highlights text that is important to safety

Electrical Caution Required !

Caution Required Correct action or procedure × Prohibited action or procedure

3. MULTIGEN SERIES 105 TECHNICAL DATA SHEET General Specifications:

Electric Specifications: 2 each - 115/208/3/60 20 Amp or 2 each 20 amp 115 volt

Either cord can be used noting that only as many elements for the heating will be engaged as the number of phases

in the cord. IE: 3 Phase for reheating of food, single phase for holding of hot food.

Cords: USA only 2 M0A.704 - 120 Volt 20 amp single phase - NEMA # L5-20

2 M0A.707 - 120/208 Volt 20 amp 3-phase - NEMA # L21-20

Cord: Canada: 2 Cords and plugs - NEMA # L21-20,115/208/3/60, optional 115 volt adapter cord

Weight: Empty - 600 Pounds/272kg

Note: All pans of food can exceed 100 Pounds


Refrigeration System: Refrigerant: - R 134A, 12.35oz/350 grams, air cooled; 70F/21C ambient & 33F/0.5C on both sides witha clean

condenser - 2-4/140 psi

Fuses: F1, 2 & 3 - 20 amp time delay; BUSA P # BLBLX21.08

Fuse: F4 – 20amp GRB or fast acting; BUSA P # X21.196 Fuse: F5 - 500 ma glass 5x20 mm; BUSA P # BLX21.654

Fuse: F6 - 3.15 amp ¼” X 1 ¼” glass; BUSA P# BLX21.717

Heat of Rejection: Condenser is approximately 4390 BTU/Hour Other sources: oven doors, transformers, motors, etc., approx. 900 BTU/Hr.

The BTU ratings for the Multigen III is the maximum amount with both condenser and heating on and the compressor

operating 100% of the time. 5290 BTU/hr is the total of the refrigeration system, radiant heat from the sheet metal surfaces and miscellaneous heat from transformers, motors, etc.

Compressor Man: Danfoss M# SC 12 G Man., P# 104G7250 115 V; BUSA P # BLX26.063

FLA for this application 5.6-6.6 Amps, LRA 45 Amps

Start Relay Man. Part # 117U6020, BUSA P # DF117U602000

Start Capacitor Man P# Part # 117U5023, 240uf +/- 10%, BUSA P # BLX26.095

TEV’s Danfoss TN 2 MOP 55, BUSA P # BLX26.078

Solenoid Coil Danfoss Type 8T120CS coil 0187F682, .22 amps, 14 watt, BUSA P # BLX26.001

Solenoid Bodies Man: Danfoss “TOP” Oven Normally Closed, BUSA P# BLX26.004

“BOTTOM” Refrigeration Normally Open, BUSA P # BLX26.006

High Pressure Manual Reset: 27.5 Bar/398.9 psig, BUSA P# BLX26.140

Electrical:

Magnetic Door Switch N/O, BUSA P # X21.568

Contactor - Main Man: G/E P # CL02A310T, 4 Pole, 120 volt coil - 1 per unit, BUSA P # BLX21.765

Contactor - Heating - 2 per unit, 4-pole 120 volt coil; BUSA P # BLX21.766

Gantry Bulb Man. - 3.31 amps each; BUSA P # BL320.020.091

Elements: There is one bank of three elements in the right oven (5400 watts; BLX21.024) and one bank of three

elements in the left oven (4900 watts; BLX21.592)

Left Elements Amps Ohms Right Elements Amps Ohms

Outer 9.2 13.3 Outer 13.3 9.3

Middle 16.5 7.4 Middle 16.2 7.5

Inner 16.3 7.6 Inner 15.9 7.7

BLX21.930 (Note) 1 per oven section right and left. Each is a bank of 3 individual elements, amps and ohms are approximate values.

Heated Top Plate: 2.4 amps each 2 per unit, 200 watt, 120 VAC; BUSA P # BLX21.237


Transformer Man: JARD 40 VA; BUSA P # BLX21.046

Safety T-Stat Manual Reset: 215C/419F; BUSA P# BLX21.636

Oven Motors: 1.7 amps each, Man: FIR Type 3008 1261, 120 W/120 volts; 3400 RPM; BUSA P# BLX22.078

Run Capacitor: (Oven Motor), Man: DUCATI 20uf @ 330 volt; BUSA P# BLX21.579

Condenser Fan Motor: 115 V; BUSA P# BLX22.066

Temperature Sensing Probes (Thermister) BUSA P # BLX21.804 Ohm’s @ 32F/0 - 1000 +/- 1%

Ohm’s @ 70F/21C - 1100 +/- 1%

Ohm’s @ 280F/138C 1520 +/- 1%

CPU - BUSA P# BLX21.592

Power Board (Slave) - BUSA P#BLX31.027

3.Display Board (Touch Pad) - B USA P# BLX21.490

Rev. January 18, 2012 JO

4. PRODUCT IDENTIFICATION MANUFACTURER BURLODGE SRL ADDRESS Via CÁ BERTONCINA No 43 24068 Seriate (BG) Tel. 0039 035 4524900 Fax 0039 035 302994 TYPE OF DOCUMENT Operating and Maintenance Instructions TYPE Regeneration/Hot Line Multi-Portion Hostess Trolley MODEL Multigen III SERIAL NUMBER YEAR OF MANUFACTURE

5. TROLLEY IDENTIFICATION The data plates shown below are attached to the panel opposite the oven doors of the trolley and contain all the data necessary for the identification of the trolley. Under no circumstances should this plate be removed, as this would invalidate the warranty. It would also no longer be possible to identify the trolley for future technical assistance and correct spare parts. You equipment may display one or two rating panels.

Multigen III

BLM53.700.0108

Date 10.3.2008 Left Side Made in EC

Serial nN° BLC 123456

Supply V: 208Y 3P Hz60 V:120Y 1P Hz60 Clim. Class: N

Amps 16.0 15.0 IP 20

Watts 5500 1800 Gas R134A

Gas Qty (12.35 oz.) 350 g. Pressure: Low 88/High 332 psi

Multigen III

BLM53.700.0108

Date 10.3.2008 Right Side Made in EC

Serial N° BLC 123456


Amps 16.0 15.0

Watts 5500 1800


Left Side Right Side



6. STANDARDS AND CERTIFICATION

Technical Standards Applied

The Multigen III has been designed to the following standards. Low Voltage Directives

EEC 73/23* EEC 93/68* EMC Directives

EEC 89/336* EEC 92/31* Technical Safety Standards

EN 60335-1* EN 60335-2-42* EN 60335-2-49* UL 471** UL 197** Technical EMC Standards

EN 55014-1* EN 55014-2* EN 61000-4-2* EN 61000-4-3* EN 61000-4-4* EN 61000-4-5* EN 61000-4-6* EN 61000-4-11* EN 61000-4-13* Sanitary Standards

ANSI NSF 169** *50 Hertz models ***all models **60 Hertz models

** *

7. PACKAGING, HANDLING, FORWARDING AND TRANSPORT When received, all shipments must be inspected for any damage to the pallets or packaging. Any damage found or any discrepancy in the number of items delivered must be noted on the carrier’s consignment note. This document shows the number of pallets and packages delivered while an itemized description of the goods is listed on the Burlodge packing slip attached to the consignment note. This documentation may vary. If the packaging is not removed while the carrier is present, the terms “Unopened” or/ “Contents Unexamined” or similar should be noted on the consignment note. The goods must be thoroughly checked for any physical signs of damage and any damage found must be reported to Burlodge by fax or telephone within 2 days from date of delivery. A written confirmation must follow within 5 working days together with a photocopy of the accompanying document on which the Model and Serial number of the damaged trolley/goods must be indicated. Unloading and handling in the Shipping/Receiving warehouse is the responsibility of the client. Burlodge is not responsible for any damage that may occur within this area. For unloading and unpacking, proceed as follows: Unloading:

Unloading must be carried out by qualified staff (forklift operator) using a forklift truck with a suitable load-bearing capacity for the weight of the trolley, which is indicated on the packaging. The trolley is packed on a single pallet and may contain other small items inside the trolley.

The following data is indicated on the packaging


Destination

Order no.

Pallet no. Gross weight Sender Contents Unpacking:

Proceed as follows:

Carefully cut the nylon straps

Remove the cardboard box. Cut the nylon straps holding the trolley to the wooden pallet. Remove the wooden slats blocking the castors. Unlock the brakes on the front swivel castorsWith the use of a ramp, carefully wheel the trolley from the pallet paying particular attention to the refrigeration system and the glass gantry (when applicable). At least 2 people may be required to unload the trolley from the pallet. Ensure that protective clothing and eyewear are worn and that the correct tools are used to carry out the above operation. NOTE: The consignee, in compliance with the local laws and regulations, must dispose of packaging material. Cleaning: 7.The trolley should be cleaned prior to being used. Follow the instructions that are given in the “Cleaning Procedure” section. If the trolley is to be stored, it must be repacked and protected by the original packaging.

8. TROLLEY DESCRIPTION

Multigen III rail side view Multigen III side view

For identification purposes the section of the trolley where the control panel is located is referred to as the front of the trolley. This then identifies all right and left-hand components of the trolley.

Key to figures

1 Control Panel 5 Swivel Castor with Brake 9 Card Reader

2 Power Cable/Plug 6 Right side oven door 10 Gantry glass

3 Push Handles 7 Lights 11 Gantry Containers

4 Lower Bumper 8 Left side oven door 12 Guard Rail

4

8

10 7

1

5

6

9

11

2

3



Multigen Guard Rail

9. SAFE MODE

!

It is essential to have the trolley in a safe condition before any cleaning or maintenance takes place. This is referred to in this manual as the SAFE MODE. The trolley is in the SAFE MODE under the following conditions: Fully isolated from any power source.

The cables, if supplied, is correctly secured in the holder.

The oven chamber is at ambient temperature, i.e. below 30 C/86 F.

Brakes are applied on the swivel castors.

Oven side fans are stopped

The heat top plate and gantry parts are at ambient temperature - less than 30°C/85F.

The tray rail is in “down” position

10. CORRECT USE The Multigen III has been designed for the following uses Your Burlodge trolley has been designed for the following uses:

Regeneration of Multi-portion chilled meals from 37F to 167F/3C to 75C

Maintaining of Multi-portion meals above 63C/145F Meal service of hot and cold foods. Holding of cold Multi-portion meals prior to regeneration and service.

It is not recommended that the trolley be used for any other purpose than described above.

11. WORKING ENVIRONMENT In order to guarantee the correct and safe functioning of your Burlodge trolley, it should be used in a clean, dry

environment with temperatures between 3C/37°F and 30C/86°F and with a maximum relative humidity of 65%. Your Burlodge trolley is designed for indoor use only and must be protected from external weather conditions at all times.

12. TROLLEY DISPOSAL It is the responsibility of the user to ensure that local laws and regulations are complied with when dismantling the trolley and disposal of all packaging and freight materials.

! Ensure that all door locking mechanisms are removed before to dispose the trolley.

12


If your trolley is fitted with the Battery Display System option remove the battery and dispose of it correctly, before dismantling the trolley.

! Do not dispose of it into a fire as it may explode. ,

Do not short circuit and neither tamper or damage it.

13. GENERAL SAFETY PRECAUTIONS

WARNING - The trolley must be properly connected to earth through the power supply cables. Always disconnect the trolley from the power supply before attempting to move it. Always hold the plug and not the cable when connecting and disconnecting the trolley. Always clean the optional food probe with a sterile alcohol wipe before and after every use, remove the probe and store it in a secure place.

!

Before starting any cleaning always disconnect the trolley from the power source and wait at least one minute to allow the fans to stop rotating. Refer to the “Safe Mode” section. Secure the trolley by using the brakes on the two swivel castors to prevent the trolley from rolling away. Avoid moving the trolley over uneven door thresholds, steps and irregular flooring to ensure that both the castors and the refrigeration system are not subjected to mechanical damage.

Never pull on the power cable to withdraw the plug.

Do not attempt to use the trolley if the power cable is damaged, worn or frayed. Call our Service Department or your Authorized Service Agent to replace the cable immediately.

Do not let the power cables rest on or touch hot surfaces or hang over sharp edges.

Never open the doors fully at the end of the cycle open the doors slowly to allow excess heat and steam to escape. After a cycle, take care in touching items in the hot side: risk of burns Never place the trolley close to any sources of heat i.e. gas ranges, dishwasher’s etc. Never use sharp instruments on the control panel facia - always use your fingers. WARNING:. It is dangerous for anyone other than a fully trained authorized service agent or other fully trained personnel to perform a service repair. All transport routes should be checked for any obstructions that may damage the trolley or cause a hazard to operating personnel.

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities and/or lack of experience or knowledge, unless they have been given instructions concerning the use of the appliance by a person responsible for their safety.

14. CONNECTING TO THE POWER SUPPLY

Connecting

Proceed as follows:

Ensure that the power supply is switched off before introducing the plugs to the wall receptacle or drop cord.

Allow adequate space around the trolley so that it is safe and accessible

Apply the brakes on the swivel castors.

Ensure that the power cords are clear of any hazards and not being stretched.



Hold the plug firmly in your hand.

The blue display will light

Disconnecting

Proceed as follows:

Ensure that the brakes on the swivel castors are still applied.

Turn off all options selected – including oven cycles, Light/Hot top, etc.

Hold the plug firmly and twist slightly to the left and remove the plug from the wall receptacle or drop cord.

Place the plugs in the holder on the front of the trolley.

The above are given as general guidelines, but may vary depending on the type of plug and socket used. Therefore, it is essential that you follow the instructions given by the manufacturer of the specific type and model of plug and socket used.

!

Always check the power cords before every use. Always hold the plug body and not the power cable to withdraw the plug. Always store the plugs in the plug holders.

Never use the trolley if there are any signs of damage or fraying to the power cord. Never use wet hands and ensure that both the plug and wall sockets are dry. Never disconnect the trolley during a retherm / maintaining cycle. ALWAYS stop the cycle and turn the trolley off before disconnecting from the power supply. Disconnecting during any cycle can possibly cause a flash or spark at the plug. The plug may be damaged and there is a risk of electrical shock.

15. CONTROL PANEL

Touch Pad Controls aAnd Display

The Multigen has the control panel shown in the following Figure

7 6

1 2 3 4 5




Control Panel 1. Power On/Power Off pad 2. Function pad 3. Halogen lamps & Heated top plate pad 4. Oven Selection Switch 5. Start/Stop touch pads for cycles 1, 2, 3 and boost cycle 6. Hot top temperature 7. Display: it shows the two temperatures, left and right oven

16. DISPLAY Display when trolley is in “Off” status

Trolley connected to main supply but not operative

Display when trolley is in “Automatic start” or “Stand-by” mode

Trolley connected to main supply but in “Automatic start” mode. This means that the trolley will automatically switch itself ON. Do not carry out service work on the machine when in “Automatic start” mode. Stand-By is only displayed if the trolley has been programmed to do so. Display shows the actual time i.e. 17:29 and when the trolley will switch itself ON i.e. 07:01

Display outside an oven cycle:

Left side indicates the left (oven or oven + fridge – snowflake symbol) chamber temperature Right side indicates the right (over or oven + fridge – snowflake symbol) chamber temperature Horizontal line on right bottom side shows heated top status and temperature . Disabled without waves enabled with waves .

Indicates that the hot top is ON

Indicates that the hot top is Off

Display during both ovens cycle, programs 1 – 2:


Left side: indicates the remaining time to the end of cycle “43”and temperature “22” in left side oven Center side: indicates selected rethermalization programs ( “1” Left oven “2” Right oven) Right side: indicates the remaining time to the end of the cycle is “23” and the temperature is “19” in Right oven

Hot top is on and at 19F.

Display during an oven cycle, single side manual start :

Left side: no time + flashing clock icon (not displayed in this photo) – no oven selected. Center side: indicates selected rethermalization programs, right side (cycle 1) Right side: indicates the remaining time to the cycle end “25” and temperature on right side oven “22”

17. STARTING/STOPPING THE L AND R OVEN MANUALLY

L and R oven selection touch pad

This touch pad allows the L or R ovens to be used independently. It is also possible to:

Start one oven only L or R

Have the two ovens finishing at the same time although the cycle times are different

Have the two ovens starting at the same time

Stopping the cycle of one of the two ovens only

Start one oven only L or R

Manual start of the Left oven

Press the,manual touch pad once: The following will appear on the display.

Select cycle 1 by pressing touch pad #1

Press oven selection touch pad to confirm. The following will appear on the display. The timer symbol of the R oven will flash and no time will be displayed as the R oven as it is not in cycle.



Manual Start of the Right oven

Press the oven selection l touch pad once: The following will appear on the display .

Press the oven selection touch pad again. The following will appear on the display .

Select cycle #1.by pressing the #1 touch pad.

The above will appear on the display. The timer symbol of the L oven will flash (not shown here) and no time will be displayed as the L oven it is nort in cycle. Note : To stop a cycle when only one oven is in a cycle press any cycle 1-2-3 touch pad

Have the two ovens finishing at the same time although the cycle times are different

1.Starting the L and R ovens so that they finish the cycle at the same time

Press the oven selection touch pad once

The following will appear on the display. Press cycle 1 touch pad

The following will appear on the display. The R oven symbol will flash . Press cycle 2 . This must be done within 10 sec.

Note that the short cycle time timer will flash (not shown in this photo) , indicating that the cycle has been delayed, starting to at a time to allow both ovens to finish at the same time



2.Starting the L and R oven together when cycle lengths are NOT the same

For example, to start the L oven on cycle 1 and the R oven on cycle 2:

Press the oven selection touch pad once:

The following will appear on the display. Press cycle 1. This must be done within 10 sec.

Wait until the R oven symbol stops flashing - 10 sec. When the symbol stops flashing press cycle 2.

The above will appear on display indicating that both the L & R ovens are working. The clock will begin to count down indicating that the L and R ovens are in cycle. The right oven will finish before (20 minutes) the left oven as shown on the display.

Manually starting or stopping one oven cycle without interrupting the other oven 1.To manually start the one oven while the other oven is in a cycle OR to manually stop one oven while the other oven is in a cycle.

For example, to start the R oven on cycle 2 while the L oven is in a cycle

Display will appear as follows:





Press the oven selection touch pad once: The following will appear on the display

Press the oven selection touch pad again.

The R oven symbol will flash . Press cycle 2 . This must be done within 10 sec. The following will appear on the display

The left oven will finish in 30 minutes while the right oven will finish in 45 minutes.

2.Stopping one cycle while the other oven is in a cycle For example, stopping cycle 1 and letting cycle 2 continue

Press the oven selection touch pad once: The following will appear on the display

Press cycle 1 touch pad

Press the manual touch pad: The following will appear on the display

The L oven timer will flash and the clock shows 0 while the R oven completes its cycle.



18. THE FUNCTION MENU ‘F’ The Function Pad enables you to view different functions of the program. To access the Function Menu, press touch pad ‘F’.

Press “F” touch pad once: The temperature of the external food probe is displayed (This function is only available when the ovens are off or not in cycle). If the probe is not connected three dashes will be displayed and revert to normal mode after 2 seconds. The start time of the next oven cycle is also shown at the bottom of the display. If this has not been programmed only the probe temperature will appear. See “Detachable external food probe” item for probing. Food probes are ordered separately.

PROBE NOT INSERTED PROBE INSERTED

Press “F” touch pad twice: The Wastage menu appears

Press “F” touch pad three times: The Maintaining cycle settings are displayed By pressing “cycle 3” button icon it is possible to start the Maintaining cycle

Press “F” touch pad four times: The cleaning cycle setting will be displayed By pressing “cycle 3” button icon it is possible to start the cleaning cycle

Press “F” touch pad five times: The actual time and date will be displayed

Note: date is displayed as day/month/year.


19. PROGRAMMING

Special Touch Pad Functions and Displays in Programming Mode.

When in programming mode the touch pads on the control panel take on different functions compared to normal use.

Cycle 1 touch pad reduces the set value of the parameter. Note arrow on touch pad.

Cycle 2 touch pad increases the set value of the parameter. Note arrow on touch pad.

Cycle 3 touch pad confirms the set value of the parameter and advances to the next parameter. Note arrow on touch pad. Access to Programming Mode

Apply the brakes on the castors.

Connect the trolley to the power supply. The blue display will illuminate.

If “OFF” appears proceed to the next step otherwise press the “On” key to put the trolley in Stand by

Simultaneously firmly press cycle 1 and cycles 3 touch pads, press the “On” touch pad and the following display will appear:

Display will show firmware revision and trolley serial number. Press now cycle 2 for set up, oven cycle, auto start timer and option programming. Grouping of Parameter Settings In order to facilitate the entry of the parameters that can be set, they have been divided into different groups, appearing on the display subdivided in “screens”, as shown below:

Screen 1 & 2 = settings for technical functions

Screen 3 = settings for the regeneration Cycle 1



Screen 6 = maintaining and cleaning cycle

Screen 7 & 8 = settings for the automatic start, timer (M-F & S&S)

Screen 9 = actual time and date

Screen 10a & 10b = daylight savings



20. PROGRAMMING THE OVEN CYCLES AND AUTOMATIC START TIMES Simultaneously firmly press cycle 1 and cycles 3 touch pads, and press the “ON” touch pad: the word “Program”, together with firmware version, S/N and an icon appears on window.

Release cycle 1 and 3 and immediately (within 2 seconds) press cycle 2 touch pad: the first program screen will appear. The following table summarizes both the range of values that can be modified and the pre-set default values of firmware M3 . The settings will remain in the memory even if the trolley is disconnected from the power supply. Please note that the default settings may vary depending on the issue date of the Firmware.

Group 0 Screens 1 and 2 parameters:

Screen 1 The first parameter under modification will flash. When the icon or symbol is flashing, press touch pad #1 and #2 to move the value up and down; once the desired value is reached, press touch pad #3 to confirm and to move to the next parameter. After the “differential icon” (∆) setting, the display goes to a second screen (“Screen 2”). ( Refer to next table for allowable ranges )

Screen 2 Repeat the setting procedure until all the parameters intended to be modified have been set to the required value. After “C/F” parameter the display goes automatically to next screen (Screen 3).


Date Of Issue – January – 08 An ISO 14001 Company Page 160

FUNCTIONS Symbol / Icon VALUES

or position Default Individual Allowable

on display Settings Settings range

Syste

m S

ettin

gs

Parameters appearing in Screen 1

C F C F

Fridge in right side Oven temperature. If available*

04 39

000 025 (off) 32 77 (off)

Fridge in left side Oven temperature. If available *

07 45

000 025 (off) 32 77 (off)

Refrigeration Differential ∆ 02 02 002 005 3.6 9.0

Parameters appearing in Screen number 2

Heat top plate

80 176 50 90 122 194

Touch Pad Lock (smartcard)

█─╨

00

N 000 (off) 001 (on)Y

N Y

Temp. (C orF) °C/°F 00

000 (C) 001

(F) C F

* If set to the off position, oven cycle refrigeration set is automatically switched off. However, refrigeration during oven cycle can be reactivated by setting the refrigeration parameter in the oven set screens 6 and 7 (see later).

** The minimum setting of security 1 is the fridge set temperature plus one °C/two F degree

Screens 3, 4 and 5 will look as shown below

Screens 3, 4 and 5 look the same except for the central number (“1”, “2” or “3”) - . This number indicatesing corresponding oven cycles and is associated with 8 parameters. These 8 parameters are, respectively: Oven left set temperature and total time (left oven setting) Oven left gratination time and temperature ; final part of left oven cycle (left oven gratination) Oven right set temperature and total time (right oven settings) Oven right gratination time and temperature; final part of right oven cycle (right oven gratination) Each oven cycle can be subdivided in two phases: Phase 1: During phase 1 oven is running with time and temperatures selectable in the parameters indicated as left (or right) oven settings. Phase 2 The final phase consists of the “gratination” or “ventilation” during which, for the selected time , the oven will heat at a different temperature from that set for the first cycle phase. The two ovens will finish at the same time, however it is possible to differentiate rethermalization processes by selecting a lower time and temperature for one of the two ovens , thatthat can contain less food or food more easy to rethermalize. Once completed the programming for oven cycle 1, move to screens 4 and 5 corresponding to oven cycles 2 and 3.

Right Oven

Settings

Left Oven Settings

Left Oven

Gratination

Right Oven

Gratination Cycle number


The following table summarizes both the range of values that can be modified and the pre-set default values of oven cycle parameters. Screens 3, 4 and 5:

FUNCTIONS Symbol / Icon

VALUES

or position Default Individual Allowable on display Settings Settings range

Display C F C F

Oven

Cycle

Se

ttings

Parameters appearing in Screen number 3 ( “1” in the central window)

Cycle 1

Oven Left Set Temp. Left oven settings

140 284 0 170 °C 32 338

Total Left Cycle Time 45 000 99 min

Left Gratination Temp. Gratination settings

80 176 000 170 32 338

Left Gratination Time 002 000(off) Total Left Time

Oven Right Set Temp. Right oven

settings

140 284 0 170 C 32 338

Total Right Cycle Time

45

000 99 min

Right Gratination Temp.

Gratination

settings

80 176

000 170 32 338

Right Gratination Time 002 000(off) Total Right Time


Cycle 2


140 284 0 170 °C 32 338



80 176 000 170 32 338

Left Gratination Time 002 000(off) Total Left Time


settings

140 284 0 170 C 32 338


45

000 99 min


Gratination

settings

80 176

000 170 32 338



Cycle 3


140 284 0 170 °C 32 338



80 176 000 170 32 338

Left Gratination Time 002 000 (off) Total Left Time


settings

140 284 0 170 C 32 338


45

000 99 min


Gratination

settings

80 176

000 170 32 338



Screen 6 will look as shown below

In screen 6 the user can program the two ancillary cycles “maintaining” and “cleaning”. The Maintaining Cycle is intended to operate during meal service and maintain hot food temperatures still in

the ovens. The Maintenance Cycle will only operate if the oven temperature is above 158F/70C when the Maintenance Cycle is started. The Maintenance Cycle is effective for BOTH ovens. Cleaning cycle is intended to operate with a special detergent container put in the oven chambers. The following table summarizes both the range of values that can be modified and the pre-set default values of the Maintenance and Wash/Cleaning Cycles.

FUNCTIONS Symbol / Icon VALUES

or position Default Individual Allowable on display Settings Settings range

Display C F

Press Cycle 3 Each Time to Continue

Se

tting

s

Parameters appearing in Screen number 6 C F

Cycle Mant.

Temperature

M Maintaining

settings

80 176 0 170 C 32 338

Maintaining Time

30 0 min 99 min

Clean Cycle

Cleaning Temp.

Cleaning settings

90 194 0 90 C 32 194

Cleaning Time 30 0 min 99 min

Screens 7 (Timer settings - Monday through Friday, 1-5) appears as shown below:

Wake up time Cycle number Oven cycle time

Screen 8 will be the settings for Saturday and Sunday.

Within screens 7 and 8 is possible to program three automatic starts by day, including trolley (refrigeration if available) automatic switch on, oven cycle automatic start and options. The automatic timer allows an automatic start for oven cycles 1 -2 – 3 at a preset time without any need for an operator to be present.

Maintaining Cycle

Cleaning Cycle


SCREEN 7 & 8 The following table summarizes both the range of values that can be modified and the pre-set default values of the Timer – Monday through Friday and Saturday and Sunday.

The top row contains the numbers from 1 to 5 or 6 and 7 , thatcorresponding to the days of the week. The other choices are for selecting the cycle and time to start for three meals.


Weekd

ay S

ettin

gs

When these parameters are under modification numbers 1,2,3,4 and 5 will flash

Default settings

Allowable range

1st Meal Of the day

Wake – Up time OFF 02:00 23:59

Cycle number OFF OFF 03

Oven cycle Time OFF 02:00 23:59

2nd Meal Of the day




3rd Meal Of the day





Weeken

d S

ettin

gs

When these parameters are under modification numbers 6 and 7 will flash

1st Meal Of the day

Wake – Up time OFF 02:00 23:59 Cycle number OFF OFF 03


2nd Meal Of the day



3rd Meal Of the day



As an example, to program an automatic start - effective for BOTH ovens only

Trolley switching ON at 07:01 Oven cycle 2 starting at 07:30 Heated top plate switching on only after regeneration cycle (not pictures)

Procedure is the following:

1. with touch pads 1 and 2 select wake up time as 07:01

2. press touchpad 3 to confirm 3. with touch pads 1 and 2 select oven cycle 2




4. with touch pads 1 and 2 select automatic start at 07:30

5. press touchpad 3 to confirm 6. with touch pads 1 and 2 select to have heated top plate on, after regeneration only

8.7. press touch pad 3 to confirm. 9.8. switch off the trolley

Display in “Stand-By” status if automatic start time is set. On left side Display shows current time and on right side next wake-up or automatic start time. Note1: Wake up can be set to off by placing wake up time identical to corresponding automatic start time. Note 2: It is possible to set a wake up time and to leave automatic start set to Stand-By: Trolley will switch on in automatic but regeneration cycle must be started manually. Note 3: Both ovens times and temperatures follow selected cycle number (1, 2 or 3) program parameters. To erase a timer program, go to screen 7, move to the row you want to modify (left side of screen) and set the time to the same value as on the right. ‘OFF’ appears on the display. Use tough pad #3 to confirm and move the cursor to

the right side. Using touch pads #1 or #2, set the cycle number to ‘0’. ‘OFF” appears in the right column. The timer for this meal has been turned off.

Screen 9 will look as shown below: The next screen permitallows tofor programming the actual time and date

Screen 9 : actual date and time

Date

/Tim

e Year 06

Month 08 Day 18

Day of the week 02 Hour:Minutes 00

Default date values may depend of firmware release.

Note: Even if not displayed, it is possible to also set the seconds: When setting the minute, with the minute value flashing, as soon as the user presses the touch pad #3 to confirm the minutes value, the seconds counter will be set to zero.



Screen 10a &10b will look as shown below:

The last two screens allow for program the daylight savings dates. When programming the daylight savings, note that the date entered will correspond to the “Sunday” date; e.g., if the 1 hour shift is expected to happen during the night between 29 and 30 March, date to program is March 30. Note: If no daylight savings times are needed enter the same date in Screen 10a and 10b.

Screen 10a & 10b : Daylight Ssavings

Clo

ck

Month for hour increase (+) 03(*) 01 to 12 Day for hour increase (+) 25(*) 01 to 31 Month for hour decrease (-)

10(*) 01 to 12 Day for hour decrease (-) 29(*) 01 to 31

(*) note: default values may change in case of future firmware upgrades Screens 10a and 10b are the last two screens the user can access during programming. Press touch pad #2 will return the user to screen 1. This means that if some modifications have been forgotten, the user can always proceed through all the programming screens and come back to the beginning. At any time, the user can press touch pad #3 to confirm the last parameter to be changed then turn the cart off to save changes and exit from programming mode.

21. USER’S RECOGNITION (USE OF BCARDWISE CARD)

BCardWise for trolley setup

The BCardWise card avoids the use of the trolley by unauthorized persons. Setting the password parameter on “Y”, the use of the keyboard is allowed by means of a programmed BCardWise only.


Set the password parameter on “Y”; (refer to screen 2 programming)

All the keyboard keypads are locked To unlock the keypad inserts the BCardWise

The display shows user name and code number previously set by operations The trolley will store an event i.e. “ MASTER USER”, recording the hour, minute and card number (in this

example, 001). Now it is possible to use the keyboard

Note: this event occurs only after each power ON and only after the first time the card is inserted. Inserting

more than one time card 001 will be recorded only the first time. But inserting another card with another number will generate another event with the other card number.

22. PROGRAMMING THE OVEN CYCLES AND AUTOMATIC START (USE OF BCARDWISE CARD) This procedure allows the user to program the trolley using the Burlodge BCardWise Card. The user must be provided with a BCardWise Card containing a copy of the correct Multigen program. It is possible to load the program onto the card by reading from another Multigen or by using the programming functions of the BWise software (please see related manual). Press the cycle 2 touch pad and the “ON” touch pad at the same time. The word “Program” and BCardWise icon appear on the display.

Release the touch pads and insert the BCardWise card into the card slot. The following icon appears: Data will be uploaded within few seconds, and the following icon will appear: Remove the card Press the “On/Off” key to exit from programming mode.


23. PROGRAMMING A NEW MACHINE AND FROM A ‘RESET’ ERROR CODE The word “RESET” appears on the display.

Press touch pad number “3” The screen “Serial n” will appear. The words “Serial n” will flash. Press touch pad #number “3” to insert the first 2 digits of the serial number (move up and down with touch pads 1

and 2). In the same way insert the other 4 digits of the serial number. Press 3 again to return to “Serial n” (flashing). Press touch pad 2 to access programming screen 1.

All parameters are now set to default or C. Advance through screen 1 to screen 2 and change C/F setting of

C to F.

Continue to advance to the date/time icon to set current time and date. Please note that if the correct serial number and the actual date are not inserted the trolley will fall again in RESET mode at next power on. When time permits, reprogram cart to custom settings.

24. DETACHABLE EXTERNAL FOOD PROBE The detachable external food probe is connected to the trolley by plugging it into the external white probe socket, located on the front panel next to the touch pads. The probe is used to check the temperature of food products prior to and after regeneration. The temperature read out of the probe will only be displayed when no regeneration cycle is selected. The type and temperature of the food product, together with the time and date, is recorded by pressing the switch on the HIT probe then immediately releasing it or by pressing touch pad “3”. An audible long beep follows immediately to confirm that the data has been recorded. Do not hold the probe switch down for more than two seconds or the display will revert to its normal mode. The user can choose between 4 series (a, b, c and d) of 8 different food items (Soup, Protein, Carbohydrate, Vegetable, Cold Item, Dessert and Others) by pressing touch pads 1 and 2. A total of 32 products can be probed. Correct Use

Ensure that the oven is not in cycle.

Connect the food probe to the external white socket on the trolley.

Remove one product at a time from the oven or cold side and close the door.

Clean the probe with an antiseptic wipe.

Insert the probe into the centre of the food product.

Press the Function key : the following display will appear


The product temperature will be displayed and the first food item will be highlighted. Using touch pads 1 and 2 select the desired food item (i.e. “Protein d”) scrolling down the menu list

Ensure that the maximum temperature has been reached – temperature will stabilize. This may take a few moments for the probe to react. Press and release (within two seconds) the probe’s black knob on the top of the temperature probe or press touch pad 3. An audible LONG beep will follow to confirm that the data has been recorded. The display will indicate the temperature just recorded i.e. 74˚C and the next food item will be highlighted. If only a short beep is heard or no beep occurs the probe button or touch pad 3 must be pressed again. Return the food product to its original compartment and close the door. Clean the probe with an antiseptic wipe. A new wipe should be used for each item tested. Repeat the above procedure for further temperature testing of food products. Make sure the probe has been cleaned before storing.

Do not place the probe or measure temperatures inside either the oven or the cold chamber. Do not attempt to probe frozen products. Do not hold the switch down for more than two seconds. Do not over stretch the cable. Do not use for any other purpose than food temperature testing.

Do not use external food probes with blue plugs because they will indicate the wrong temperature

Use with care. Keep the probe clean. Ensure that the probe is stored safely. This probe is an accurate measuring instrument and must be treated with great care. The sharp tip of the probe can represent a hazard if misused. Remove the probe from the trolley at the end of every meal service and store it away safely. The tip of the probe must be cleaned thoroughly using a sterile wipe before and after every use. This feature can only be used with a Burlodge probe. Caution: The probe is not designed to be inserted into frozen products.

25. WASTAGE The Wastage Function allows the user to notify the kitchen how many portions, at the end of each meal, are wasted. To specify the number of portions, the user has to enter, on the trolley keypad, the corresponding number. Correct use: Ensure that the oven is not under cycle. Press twice the “F” key: The display shows the following screen.


Using keys 1 and 2, select the menu item which you wish to notify a wastage of

Press key 3 to confirm Using keys 1 and 2, select the number of portions wasted Press key 3 to confirm Proceed selecting the following item Finally, press several times the “F” key until the display returns to its initial screen.

Here is an example of wastage of 3 portions of proteins and of 4 portions of carbohydrates

26. DATA LOGGER (EVENT LOGGER) The Data Logger allows all events to be recorded. Events can be shown on the display or can be transmitted or downloaded using the BCardWise+. Reading events on the trolley display Keep the cycle “1” touch pad depressed and press the “ON” touch pad. The word “Events” will appear on the display. Press the cycle “3” touch pad to confirm. The latest event will appear (see picture below). In the display shown above, the following applies: “450” is the progressive event number. “RDoor closed” is the event description. “12:19” is the time at which the event occurred. “201°F” and “208°F” are the left oven and right oven temperatures. To scroll the events list press touch pad “2” (up) and touch pad “1” (down). To exit the events list press the “F” key.


27. DOWNLOADING THE EVENTS LIST ON THE BCARDWISE+ CARD Keep the cycle 1 touch pad depressed and press the “ON” touch pad. The word “Events”, together with a book icon, will appear on the display.

Press the touch pad #2 to scroll to Datalog. The BCardWise+ card icon will appear. (Note the “+” sign on the card icon.)

Insert the card and wait a few seconds. A new icon will appear prompting the user to remove the card.

Data has been correctly downloaded onto BCardWise+ card.

28. DOWNLOADING THE TROLLEY SETUP ON THE BCARDWISE CARD This feature will allow the user to copy the setup from the trolley onto the BCardWise card. Keep the touch pad #1 depressed and press the “ON” touch pad. The “Events” will appear on the display.

Press touch pad #2 twice to scroll to the third topic on the menu. “Program”, together with an icon prompting the user to insert the BCardWise card, will appear. (Note that this card icon does not have a “+” sign.)

Insert the card and wait a few seconds. A new icon will appear prompting the user to remove the card. Remove the card. Data has been correctly downloaded onto the BCardWise card.


29. CHANGING THE EVENTS LIST LANGUAGE The events list and other text strings can be examined in different languages. The user can choose between Italian, English, French, Deutch and Dutch using the following procedure: Keep touch pad #1 depressed and press the “ON” touch pad. “Events”, will appear on the display.

Press the cycle “2” touch pad three times to scroll to the fourth topic on the menu. The current language will appear on the display.

Press the cycle “3” touch pad. The word will flash. Select the required language using touch pads “1” and “2”. Press touch pad “3” to confirm the new language.

30. MONITORING THE SIGNAL COMMUNICATION (BWISE OPTION) This function allows the user to check that the trolley is online with BWise being reached by a data signal emitted by the computer where BWise is installed. Keep touch pad #1 depressed and press the “ON” touch pad. “Events” will appear on the display

Press the cycle “2” touch pad four times to access the last topic on the menu. “Line”, together with a computer icon, will appear on the display.

If the trolley is receiving a signal the word “In” will appear next to the computer icon. When the trolley recognizes slave address and sends out the answer the word “Out” will appear. If nothing appears the trolley is not receiving communications. Refer to the installation procedures in the BWise technical manual for details.




31. SPECIAL FEATURES

Battery Display System This option allows the control panel to be switched on for a period of 20 seconds without the unit being connected to a power source. All the displays will function normally and permit the use of the external food probe for temperature product testing. The control panel will automatically be switched off after 20 seconds. This function can be repeated as many times as required. If the trolley is turned off immediately after the oven cycle and transported to the ward; during the transportation time and before of the service hot and cold temperatures will be recorded every 5 minutes and for a maximum time of 1 hours. After this time battery system is disabled. If the trolley is connected or disconnected from power supply the battery system works for an hour more.

Memorizsed Power Supply Failure

Various start-up procedures and oven cycle settings are kept in memory. In the case of a power failure, the cycle will restart automatically as soon as the mains supply will return. The same applies when the trolley is in in case that the trolley is inrefrigeration mode. The cycle will continue from where it was interrupted. During the interrupted cycle or power failure, if the temperature of the oven goes below 70ºC/ (158ºF) the oven cycle time is reset and a new cycle will need to be started manually. If the trolley is in Stand-By (blue display indicating “OFF” or “Stand-by”), when the mains comes back the machine will return in stand by mode (again blue display indicating “OFF” or “Stand-By”).

Audible Warning

Quick intermittent beeps denote the alarm status. A slow intermittent beep denotes normal status i.e. end of a cycle.

Memory Back Up

The default settings remain in the memory even if the microprocessor batteries are discharged. Refer to the Programming Data Table that summarizes both the permissible ranges of the values that can be modified and the pre-set default values. The battery has an expected life of approximately four years and it is recommended that it be replaced after this period. Contact the Burlodge Technical Department.

Boost Cycle

This option allows the user to start an additional, 5-minute-long oven cycle to boost food temperatures when this

results below 75°C/158F. To start a boosting cycle, the user needs to keep touchpad “3” depressed for 5 seconds. During boost cycle refrigeration, heated top plate and lights will behave as during a standard regeneration cycle. Boost

cycle will start only in the oven section having a temperature higher than 70°C/158F. If following a boosting cycle

start, the temperature in one of the two sections is below 70°C/158F, it means that in that section no regeneration cycle occurred and consequently no boosting cycle is needed.

Maintaining Cycle (“keep hot” cycle)

This option allows the user to start an ancillary oven cycle, which keeps food hot inside the oven cavity during a meal service. To start a maintaining cycle, the user has to press the “F” key until the “M” letter appears, together with time and temperature settings, then press the key “enter” or “3”. Boost cycle will start only in the oven section having

temperature higher than 70°C/158F .

If following a maintaining cycle start, the temperature of one of the two sections is below 70°C/158F, it means that in that section the regeneration cycle did not occur and consequently a maintaining cycle is not necessary.

Cleaning Cycle

This option allows for a special cleaning cycle. To start this cycle, press the F key until the icon shown in the here above picture appears then press the key “3”. The cycle will start in both oven sections. It is thus absolutely necessary that both oven doors remain closed. During this cycle, fridge, heated top plate and lights remain off.


32. SAFETY FEATURES Your Burlodge trolley includes the following built-in safety features: Active Safety Features:

High limit temperature thermostats (manual reset) Door micro switch Thermally protected motors. Castors with brakes. Auto shut down for oven probe failure. Microprocessor based software. Error codes. Passive Safety Features:

Fixed fan guards. All-round rubber bumpers to absorb impacts.

33. OPERATING INSTRUCTIONS

Connection to the Power Supply Proceed as follows: Apply the brakes on the castors at the front of the trolley (always use your feet and never your hands). Ensure both power supplies are turned off. Holding the plug firmly in your hand, align and insert the plug into the wall socket. Allow adequate space around the trolley so that it is safe and accessible. Ensure that the power cords are clear of any hazards and not being stressed. The display will illuminate blue and show “OFF”. This indicates that you have power from the wall receptacle. The refrigeration (if present) will automatically be on.

N.B.: if the trolley power is ON as soon as power is connected it means that it was disconnected from the main power supply before pressing the “On/Off” touch pad. Select the hostess functions that are required:

This function pad controls both the light and hot top as one option.

Heat Top Plate & Lights § Lights and heated can switch ON automatically if they were ON before of the last power OFF. If they are OFF, press the top plate/lamp touch pad once to switch on the top plate & lights. The hot top icon (waves) appears on the display and lights will switch ON. Pressing the hot top /lamp touch pad a second time switches off the top plate and the icon (waves) disappears and lights will switch OFF.

!


34. STARTING A REGENERATION CYCLE

One or two oven regeneration cycles can be started in the following ways:

Manual start, by using the key oven selection touch pad Oven direct start, by pressing one of the keys 1, 2 or 3 Timer start.

As per the programming start by manual selection touch pad, refer to section “Starting the L and R oven

manually”. As per the direct oven start, by using one of the preset programs 1-2-3, press keys 1, 2 or 3. The two ovens

will finish their regeneration at the same time. As per the timer start, follow what specified in the Screen 3, 4 or 5 “Programming the Oven Cycles and

automatic starts” Section.

If during a cycle, an oven door is opened, an “open door” icon appears on the display and buzzer sounds. The

heating elements of the “open door” side are disabled. If both doors are opened, the fans are switched off.

As soon as one of the doors is closed, the ventilation starts again in both sections. Attention! Heating elements start only in the section where the door is closed!

The lights, Heated top plate and Refrigeration will now remain off. When heating elements on left side are off

along the oven cycle the heating top plate is “on”. Take care that after regeneration cycle, items in the oven section are HOT

The display will continuously show the countdown timer together with temperatures of the two compartments. Two minutes prior to the end of the cycle the clock icon will start to flash to inform the user that the cycle is near

completion. At the end of the cycle the oven will automatically switch off, the lights and heated top plate will switch on and the

buzzer will sound. The clock icon and the countdown timer will flash “00” until the cycle has been cancelled. To cancel the cycle and buzzer press the cycle touch pad corresponding to the oven cycle just elapsed. The refrigeration in the cold compartment will now remain on until the “Power OFF” touch pad is pressed. The lights, heated top plate and refrigeration will now remain on until they will be switched off manually or the

entire machine will be switched OFF. Take care: after a regeneration cycle items in the oven section are HOT.

!


Temperature testing post regeneration

Allow adequate time for the oven fans to stop before opening the oven door. Stand away from the oven door and partially open the door until all the steam has escaped. Use additional caution when the oven door is open as the inner face will be very HOT. Using gloves, remove the products from the oven. Never reach into the back of the oven. Instead pull the grid to approximately one third of the way out for ease of

access to the containers at the back of the oven. Place the container on the heated top plate directly above the oven. Connect the food probe to the external white socket on the trolley. Clean the probe with an antiseptic wipe. Insert the probe into the centre of the food product. Take care not to stretch the probe cable. The product temperature will be displayed accompanied by an audible bleep if the product temperature is

above 75C (/167°F). Another audible bleep if the product temperature is less than 10°C/ (50°F). If the food product is at the correct temperature it is ready to serve. Make sure the probe has been cleaned before storing.

35. OPERATING INSTRUCTIONS FOOD SERVICE Wheel the trolley to a suitable area ensuring that doors and passageways are not blocked. Apply the brakes on the trolley. Connect to the power supply and switch the trolley on. Ensure the serving functions have been selected. Allow adequate time for the oven fan to stop before opening the oven door. Stand away from the oven door and partially open it until all the steam has escaped. Use additional caution when the oven door is open as the inner face will be very HOT. Using gloves, remove the products from the oven. Never reach into the back of the oven. Instead pull the grid to approximately one third of the way out for ease of

access to the containers at the back of the oven. Only remove the items required, i.e. one of each product. Remove any lids from the containers. Remember the products are HOT so open the lid away from you to allow

the steam to escape safely from the container. Place all hot food products on the heated top plate and ensure they are kept under the gantry § in order to

maintain temperature. Decant any liquids, i.e. custard, soups and gravy, into flasks or jugs. This will help to reduce spillage. Cold products can either be served directly from the cold compartment § or placed on the lateral shelf §.

36. POST SERVICE PROCEDURE Turn cart off – including all oven cycles and options. Disconnect the trolley from the power supply. Place all containers and excess food into the oven compartment for safety during transport. Ensure that the power cables are stored correctly in its holder and the tray rail § is in the down position. Transport the trolley to the designated cleaning area. Ensure that the trolley is completely isolated from the power supply, the plug has been returned to its holder on

the front of the trolley and the trolley is in the SAFE MODE.

Carry out daily cleaning procedure.


37. COOK/FREEZE: COOK/CHILL – FLOW CHART

SELECT SERVICE OPTION

PRE-HEAT

PRESS ON PAD

SELECT CYCLE

STOP CYCLE

CONNECT TO POWER

SERVE

LOAD OVEN

COOK

COOK

CHILL

FREEZE

Date of Issue January - 08An ISO 14001 Certified Company Page

177

38. HOT LINE – FLOW CHART

39. DAILY CLEANING PROCEDURES Move the trolley to a safe area before cleaning. Ensure the trolley is in the SAFE MODE before commencing cleaning. Remove all grids from the transfer modules. Remove the transfer modules from both compartments. Using a hot soapy solution, wipe both compartments then rinse with water. You must ensure that no

soapy substances are left in the trolley as these may taint the next food products. Leave heavily soiled surfaces to soak for about fifteen minutes for ease of cleaning. Clean the heated top plate with hot soapy water, rinse and dry. The heated top plate should then be

cleaned with a sanitizer as this surface may come into direct contact with food products. Clean the sneeze screen with a soft cloth using a suitable hard surface cleaner. Never use abrasive

pads or abrasive cleaners as these will damage the surface of the sneeze guard.

PRE-HEAT

BOOST (If needed)

PRESS ON TOUCH PAD

LOAD OVENS

SELECT SERVICE OPTION

STOP CYCLE

CONNECT TO POWER

SERVE

Date of Issue January - 08 An ISO 14001 Certified company Page 178

All exterior stainless steel panels can be cleaned with hot soapy water then rinsed with clean water. Clean the control panel with a damp cloth only. Polish the exterior of the trolley with food safe stainless steel polish.

40. CLEANING SCHEDULE Cleaning Schedule after Every Meal Service

COMPONENT

HA

ND

WA

SH

SA

NIT

IZE

DIS

HW

AS

H

JE

TW

AS

H

PO

LIS

H NOTES

Oven Compartments × × × Wipe dry after cleaning

Interior Surfaces × × × Never use polish

Silicon Gaskets × × × Wipe dry after cleaning

Exterior A.B.S Panels × × Wipe dry after cleaning

Exterior St. Steel Panels

× × Use non abrasive surface cleaner

Touch pad Controls × × × Use slightly damp cloth only

Front Panel × × Use slightly damp cloth only

External Food Probe × × × Use sterile wipes

Grids × × Do not use abrasive cleaning pads

Dolly × Wipe dry after cleaning

Transfer module × Wipe dry after cleaning

Failure to carry out daily cleaning may lead to discoloration of the stainless steel and silicon gaskets. Caution! Any over spray of polish or other cleaning products on the floor can cause a serious hazard. Deep cleaning should be scheduled so that the trolley is maintained at the correct level of cleanliness. Under normal conditions, deep cleaning should be carried out at monthly intervals. This may be varied to suit site conditions. Remove the fan protection panels every six months for cleaning. For safety reasons only trained staff should remove these panels, using the correct hand tools. Caution! Do not use any abrasive or caustic products for cleaning. Use of these products will permanently damage the components and surfaces of the trolley.

41. POWER WASHING - MULTIGEN III

Under no circumstances should the MULTIGEN III be subject to any form of power washing

42. CLEANING BY HAND – MULTIGEN III

Use two containers: one containing water plus detergent and one containing clean warm water with an added sanitizer (hard water should be avoided wherever possible), with separate soft lint free cloths. Each cloth should be rinsed and wrung in its appropriate container. Clean with a cloth using the water with the added detergent, wringing the cloth so that all the water is removed, then rinse with the clean cloth, using clean warm water in conjunction with a sanitizing agent and dry. If there is any spillage of water into the electrical components (e.g. the power supply plug) under no circumstances should the trolley be used until it is completely dry and an authorized electrician has checked and passed it safe to use. Burlodge, or its authorized service agents, are permitted to carry out any repairs


during the period of warranty. Failure to comply with this requirement may invalidate the warranty of the trolley.

43. THE CLEANING CYCLE

Press function pad three times: The cleaning cycle setting will be displayed By pressing “cycle 3” button icon it is possible to start the cleaning cycle

Put a pan in the ovens containing ½ liter/2 cups water and mild detergent.

Close the ovens door and start the cleaning cycle lasting 30 - 45 minutes at 90°C/194F. At the end of the cycle, disconnect the trolley from the mains and wait until the ovens side reaches a safety temperature.

Open the ovens door and remove the pan. Use a great care as it can still contain some hot water. Wear gloves and remove the deposits from the walls with a cloth. Rinse the walls with warm water.

!



44. ERROR CODES The operator is informed of any abnormalities by a series of error messages that appear on the displays in code form. If the abnormality prevents the use of the trolley, it is accompanied by an audible alarm. The error codes are fully explained together with the possible causes and the suggested corrective action in the following table.

CODE EXPLANATION POSSIBLE CAUSE

Display is illuminated but, when trying to operate the trolley via control panel, nothing happens.

Password parameter set to “Y”

ACTION Use the BSmartWise card to unlock the control panel

H1 Auto shut down of all functions. Right oven Probe failure or loose connection.

ACTION Request Technical Assistance

H1 Auto shut down of all functions. Right Oven Temperature has exceeded the safety limit of

190C/ / 374F.

ACTION Request Technical Assistance.

H3 Auto shut down of all functions. Left Oven probe failure or loose connection.


H3 Auto shut down of all functions. Left Oven temperature has exceeded the safety limit of

190C / 374F.


L2 & L3 Oven set temperature has not been achieved during the cycle.

Program set incorrectly.

ACTION Refer to the PROGRAMMING section to reprogram the trolley to the correct Settings. If problem continues, contact Technical Support

RESET Auto shut down trolley in safe mode. Electrical disturbances through power supply.

ACTION Press touch pad 3: this will reset the Trolley and will enter in programming mode (see section “Programming a New Machine and From a ‘Reset’)

RESET Auto shut down trolley in safe mode. CPU unit Faulty


? BCardWise data not recognized

BCardWise is empty or contains programming data of a different trolley.

ACTION Reprogram the BCardWise with BWise software using a Multigen parameter list.


45. FAULT FINDING The two tables below are a guide for authorized technical personnel. Fault finding should only be carried out by a competent electrician. Table one refers to checks that should be made before placing any service calls.

TABLE ONE

PROBLEM EXPLANATION POSSIBLE CAUSE

No blue DISPLAY No power to the trolley. Power supply failure.

ACTION Check power supply to wall plugs.


ACTION Check connections in the plugs.


ACTION Check power supply cables for any damage and continuity.

Table two refers to checks that can only be carried out by Authorized technical personnel during the period of warranty.

TABLE TWO

PROBLEM EXPLANATION POSSIBLE CAUSE

No blue DISPLAY No power to the trolley. Line fuse blown (left side).

ACTION Find and rectify cause for the failure, then replace the line fuse.

No blue DISPLAY

No supply from the transformer.

Transformer safety fuse blown (left side).

ACTION Find and rectify cause for the failure, then replace transformer safety fuse.

No blue DISPLAY Internal oven high limit thermostat tripped.

Temperature in the oven chamber (left, right or both) has exceeded 215°C/419°F.

ACTION Find and rectify cause of oven temperature, then reset the oven high limit thermostat

No blue DISPLAY Internal motor safety switch has tripped.

Motor overheat (left, right or both)

ACTION Find and rectify cause for the failure. The thermostat will automatically reset when the temperature of the motor cools down

46. TOWING ATTACHMENT The Multigen III can be fitted with a tow bar. The towing attachment has been designed and constructed to be used in conjunction with a towing hitch towing up to a maximum of two Multigen III’s at a time at a maximum speed of 4km/2.5 miles per hour. The Multigen III transfer module dolly can also be fitted with a tow bar. The towing attachment has been designed and constructed to be used in conjunction with a towing hitch pin towing up to a maximum of four Multigen dollies at a time, at a maximum speed of 4km / 2,.5 miles per hour.


47. TOWING PROCEDURE FOR THE MULTIGEN III

!

Coupling

Check the folding tray rail is in the down position and all other items, including the lateral shelf, have been removed from the trolley.

Ensure all doors are closed correctly and the power cable is stored. Check that all items not secured are removed from the Multigen III. Ensure the floor is flat and even. Release the brakes on the castors. Align the front of the Multigen III with the rear of the towing hitch. Lower and locate the tow arm ring onto the towing pin of the towing hitch. Secure the safety pin on the towing hitch. If towing two Multigen III’s, align the front of the second Multigen with the rear of the first Multigen. Push the second Multigen and connect the tow arm ring to the rear-towing pin of the first Multigen. Do not forget to use the safety pin.

Uncoupling

Ensure the floor is flat and even. Remove the safety pin. Press down the foot pedal on the first Multigen III and roll the second Multigen backwards. Press down the pedal on the tow arm section of the second Multigen and push the bar safely back

underneath the Multigen until the arm locks into place. Repeat this operation for the first Multigen III to uncouple it from the towing hitch (this part of the

operation may vary slightly depending on the towing attachment fitted to the towing hitch). Apply the brakes before leaving the Multigen.

48. TOWING PROCEDURE FOR THE MULTIGEN DOLLIES

!

Coupling

Check that the locking pin has secured the transfer module to the dolly and fit the cover over the module. Release the brakes on the castors. Align the front of the dolly to the rear of the towing hitch. Raise the towing arm sideways to the upright position then pull the arm forward until it is slightly below the

horizontal position and place the tow arm ring onto the towing pin of the towing hitch. Never tow more than four Dollies at a time. If towing more than one Dolly align the front of the second Dolly and follow the above procedure. Uncoupling

If there is more than one dolly always commence from the last dolly being towed. Ensure the floor is flat and even. Press down the towing arm and release it from the towing pin. Raise the arm to the upright position then

lower the arm sideways to its storage position. Caution! The towing arm is spring loaded so take additional care when carrying out this procedure. Apply the brakes before leaving the Dolly. Repeat the above operation until there is only one dolly left. Uncouple this last dolly from the towing hitch

(this part of the operation may vary slightly depending on the towing attachment fitted to the towing hitch).


49. TOWING SAFETY - MULTIGEN III

DO ENSURE

Extra care is taken in areas where there are patients and pedestrians. The floor is flat and even. All doors are closed. All unsecured items have been removed from the Multigen III prior to transportation. The cables are stored in the correct position and cannot be snagged during transportation. That the towing arm is fully extended and located correctly. The safety pin has been inserted. Reduce speed when negotiating corners and inclines.

DO NOT

Towing more than two Multigen III’s at one time. Uncouple the Multigen or the Dollies on uneven floors or inclines. Exceed the speed of 4km/2.5 miles per hour. Tow Multigen outside or over rough or uneven surfaces including expansion joints.

50. TOWING SAFETY - MULTIGEN DOLLY

DO ENSURE

Extra care is taken in areas where there are patients and pedestrians. The floor is flat and even. All unsecured items have been removed prior to transportation. That the towing arm is fully extended and located correctly. Reduce speed when negotiating corners and inclines. The safety pin has been inserted.

DO NOT

Tow more than four Dollies at one time. Uncouple the Dollies on uneven floors or inclines. Exceed the speed of 4km/2.5 miles per hour. Tow outside or over rough or uneven surfaces including expansion joints.






51. MAINTENANCE

Safety Precautions and Preparing For Maintenance

A maintenance program to maintain the trolley in optimal condition is clearly defined in four different categories. Daily cleaning (refer to Daily Cleaning Procedure and Cleaning By Hand sections) Periodic cleaning (refer to Daily Cleaning Procedure and Cleaning By Hand sections) User maintenance (refer to Interim Maintenance section) Maintenance schedule to manufacturer’s recommendations. Contact Burlodge Technical Department for

specialized training. Checks to be carried out before every use

EQUIPMENT VISUAL OPERATIONAL NOTES

Power Supply Plugs Do not use if there are any signs of damage

Power Supply Cables

Do not use if there are any signs of damage

External Probe Do not use if there are any signs of damage

Touch pad Controls Do not use if there are any signs of damage

Light Report any defect for immediate repair

Heated Top Plate Report any defect for immediate repair

Door Latches Report any defect for immediate repair

Refrigeration Unit Report any defect for immediate repair

Tow Unit Do not use if there are any signs of damage

Castors Do not use if there are any signs of damage

Doors Do not use if there are any signs of damage

Tray rail Do not use if there are any signs of damage

The trolley operator should carry out the checks referred to in the above table.

SERVICING All servicing must be performed by Burlodge authorized agents. It must be to the manufacturer’s specification and at the required intervals. Some of the functions are optional and may not be available or operational on your trolley. In this case the relative functions and touch pads are disabled.



52. REGULAR MAINTENANCE The maintenance checks listed in the table below should be carried out as an interim service between the full six monthly services. It is also valid as quarterly checks in the first twelve months of use. At the end of this period a full service is required to the manufacturer’s specification.

Multigen III

COMPONENT

VIS

UA

L

OP

ER

AT

ION

AL

NOTES

Power Supply Plugs Check the plug for damage to the pins or strain relief and that all screws are tight.

Power Supply Cables

Check for any damage, abrasion, cuts, or fraying which could compromise the insulation and the integrity of the power supply cable.

Cable Entry Connector/s

Check the cable gland nut is tight and the power supply cable is firmly gripped in the connector.

External Probe Check the cord is firmly inserted and secured and the probe tip is not damaged.

ABS Front Panel

Check all the retaining screws are in place and not loose. Check the panel has not been damaged and is held firmly against the seal.

Touch pad Controls Check the membrane is not damaged. Ensure all the displays, LED’s and touch pads function correctly.

Door Latches

Check the latch for correct operation, loosen the setscrew on the striker plate to adjust the cone, tighten the screw after any adjustment.

Doors Check that they close correctly against the silicon gaskets.

Door Hinges Check for excessive wear in the bushings or in the up and down movement of the door.

Tray rail (Optional) Check the hinges are not damaged and that the rail locks in the open position correctly.

Lateral shelf (Optional)

Check the support bar screws are tight and that it locates correctly on the end of the trolley.

Towing Unit Pole End (Optional)

Check the spring to ensure it holds the pole at the correct tension so that it does not drop down and it springs back instantly when pushed down. The spring must be replaced annually

Towing Unit Female End (Optional)

Check the retaining nuts are tight and that the safety pin is still attached.

Castors

Ensure the brakes function correctly and the wheels are free and not damaged. Check that the retaining nuts are tight and not entangled with mop strings or other materials.

Nylon rollers for transfer module

Clean the rollers.

Docking System Check that both units align and dock correctly and that the locating pins are not damaged.

If any faults are found they should be reported immediately and the trolley should be not be used until the fault has been rectified.


53. REGULAR MAINTENANCE - CONTINUED

Multigen III Transfer Module and Dolly

COMPONENT V

ISU

AL

O

PE

RA

TIO

NA

L

NOTES

Towing Unit Pole End (Optional)

Check the spring to ensure it holds the pole at the correct tension so that it does not drop down and it springs back instantly when pushed down The spring must be replaced annually.

Towing Pin (Optional) Check the pin to make sure it is not damaged.

Castors

Ensure the brakes function correctly and the wheels are free and not damaged. Check that the retaining nuts are tight and not entangled with mop strings or other materials.

Transfer Module locking pin Check to make sure the pin locates and locks the transfer module into place correctly

Locking Arm for the docking system.

Check to make sure it is not damaged and that it locates and locks correctly into the Multigen docking plate. Check tension of the spring.

Docking Arm and Pedal Check to make sure it is not damaged and that it locates and locks correctly into the Multigen docking plate.

Docking Pin

Check the pin to make sure it is not damaged and that it locates correctly into the Multigen docking plate.

Transfer Module

Clean the bottom nylon rollers and lubricate with food grade silicone spray. Ensure the module is not damaged.

Transfer Module Check all support guides.

54. TECHNICAL ASSISTANCE AFTER SALES SERVICE Technical Assistance

Burlodge offers a wide range of service contracts. Standard, Comprehensive and Fully Comprehensive contracts are available along with the option of having your in-house staff trained to act as Burlodge Service Agents. For further information and for specialized contracts contact our Service Department. The Burlodge support team is unrivalled in its experience in the field. The Burlodge Technical Service has been designed to ensure our customers experience the minimum delay possible when a fault or problem is encountered. This brings you the benefit of after sales support from a strong technical network. Burlodge is well aware that down time must be minimized. Our Authorizsed Service Agents are in your locality to provide comprehensive, quick service.

55. PREVENTATIVE MAINTENANCE All equipment must be serviced at six monthly intervals. Correct preventative maintenance is essential to ensure the reliable and safe operation of the trolley and the longest economical life of the equipment. Only competent and fully trained personnel may carry out servicing to the manufacturer’s specifications.

Burlodge offers a wide range of service contracts covering this equipment provided such equipment is operated and maintained in accordance with the manufacturer’s recommendations. You will have the peace of mind that comes with having a fully trained service force able to support this product wherever it is located, through preventive maintenance contracts and after sales service. For further information and for specialized contracts, please contact the Burlodge Technical Department.


Suggested Preventative Maintenance is as follows:

Minigen/Multigen Cart

- Check and clean condenser coil, shroud, fans and filter - Check and clean the compressor-cooling fan and finger guard - Check heating element motor(s); tighten fan set screws - Check all internal probes, clean if necessary - Check main power receptacle and mounting hardware - Check and tighten all screws, bolts and hinges - Check and adjust upper and lower door bushings, latches and hold open clips - Check and replace, if necessary, all door and frame gaskets - Check and clean castors and brakes - Visually inspect electronic components - Check proper operation of all functions, cycles, buzzer and current time settings - Check gantry: lights, heating rods, fans

Minigen/Multigen Dolly/Rack

- Check for broken welds, repair as required - Check and repair or replace bent or damaged tow bars and springs - Check operation of foot pedal release return spring - Check and clean castors and brakes - Check rack, bottom nylon rollers, tray slides

Note: Some parts, such as refrigeration and dolly are optional and may not be supplied with your equipment.

56. WARRANTY AND SERVICE CALLS Before you contact the Burlodge Service Department or authorized service agent please make sure that a competent electrician has carried out the following checks:

Check the power supply. Check the power cables, plugs and internal fuses. Check for any visual damage.

Under no circumstances remove or interfere with any part of the Multigen III even if it is disconnected from the power supply. If the trolley still does not operate, contact your local service agent or the Burlodge Service Department. Please ensure that you give the following information when placing a call with the Service Department. (Refer to the rating plate at the rear of the trolley.) Your equipment may or may not have two rating panels.

Multigen III

BLM53.700.0108




Amps 16.0 15.0 IP 20



Multigen III

BLM53.700.0108




Amps 16.0 15.0

Watts 5500 1800


Left Oven Right Oven



The Series name (i.e. Multigen III) Model code Date of manufacture Serial number The location of the equipment A detailed description of the problem Your name, department, position and phone number Caution: Any electrical testing by untrained personnel is extremely hazardous and may cause permanent damage to the onboard electronics if not carried out correctly.

57. SPARE PARTS

Use only original Burlodge spare parts. They are an exact replacement. Use of other spare parts may compromise the safety and performance of the trolley. Burlodge, or its authorized service agents, must carry out any repairs during the period of warranty. Failure to comply with these requirements may invalidate the warranty and all certifications of the trolley. How to Order Spare Parts

Multigen III

BLM53.700.0108




Amps 16.0 15.0 IP 20



Multigen III

BLM53.700.0108




Amps 16.0 15.0

Watts 5500 1800


Left oven Right Oven Your cart may or may not have two rating panels. The spare parts table is divided into different categories to assist you in identifying the parts you may require. This table also highlights the parts that we recommend you keep in your stock. Refer to the diagrams in the “Spare Parts” section to initially identify the component. When ordering spare parts or requesting technical assistance refer to the data plate to identify the trolley. This information is essential in order to correctly identify the parts required for the trolley.

Please supply the following information: The Series name (i.e., Multigen III etc.) Model code Date of manufacture Serial number Part number Description of part

Quantity required Your name, department, position and

phone number Delivery address Invoicing address Purchase Order number


58. WARRANTY Standard Warranty

The standard warranty is one year parts and labor or as per contract. All equipment (except china, trays and consumable components) is covered against faulty material or workmanship. In the unlikely event of any valid failures, Burlodge or its authorized agents will repair the trolley free of any charges. The following will not be covered by the warranty and may invalidate it. Damage during unloading or storage. Incorrect installation. Neglect or misuse of the equipment. Use of the trolley other than described in this manual. Fire, water or frost damage. Using parts not supplied by Burlodge/authorized service agent. Service carried out by service companies not authorized by Burlodge. False calls. Voltage fluctuations exceeding the nominal voltage +/- range guaranteed by the local energy supplier not

more than +/- 10%. Power failures. Damaged power cord or plug. Re-programming after commissioning and after initial training.

Only authorized persons may carry out repairs during the warranty period or in compliance with the Burlodge contract. Should the Customer fail to comply with these requirements, both the initial warranty period and all certification of the trolley will automatically become invalid. This manual is provided to assist you to resolve some of the problems you may incur. Please make sure that you refer to this manual before placing a service call as we reserve the right to charge for any calls that could have been resolved by reading this manual.


TROUBLE SHOOTING FLOW CHART

Cart not operating correctly, i.e. not hot/cold enough

Dietary Manager confirms: -All settings are correct -Runs empty cart to test -Pod doors are properly closed

-Unit OK or

NO display with Pod in proper position

Pod positioned correctly: -Doors not open -Pod not in backwards -Manager attempts resetting high temperature safety B-Pod

Dietary Manager calls Inside Maintenance to: -check power -Fuses -High Temperature Reset

Unit OK or

Dietary Manager contact Burlodge USA, Inc.: WS Office – 336-337-1010, ext. 205, M – F 8:30 to 5:00 Eastern time. Have ready: -Model and serial number of the cart -Location or room number for cart -Nature of the problem and what has been checked -Contact information for two people at location A BUSA representative will place a call with the warranty agent and follow the call through until resolved. Warranty Agent (internal or external) will report resolution or status to contact person at facility.

Cart not operating correctly or not operating at all.


59. DIMENSIONS

Multigen III with guard rail


60. INSTALLATION CANADAANADA/USA The plug and cord on the trolley will be of a type and rating that meet the required electrical voltage and current requirements of the trolley. The measured supply voltage must be within 10% of the rating plate. Check the rating plate on each piece of equipment for further details. If the power supply available does not suit the electrical requirements of the trolley, contact our Service Department or an Authorized Service Agent. Check that the wall plug or cord set has been installed by a qualified electrician and is correctly connected to Earth. Ensure the power supply is compatible to that which is stated on the rating plate. Ideally the trolley should be connected to a interlocked switched socket incorporating both earth fault device and over current protection. Ensure the plug or cord set is located so that the trolley cannot damage it, yet remains easily accessible to the operator without stressing the power cable. The electrical installation must conform to the National and local Electrical Codes.

The transportation route and access should be checked for any obstructions that may cause damage to the trolley. Plug Connections Multigen II 208v 60Hz 3P+N+G

NOTE. If your trolley is supplied without a plug on the power supply cable or the plug must be replaced, ensure that the plug is an exact NEMA replacement (L21-20P) and that it corresponds with the trolley data plate. The conductors must be connected to conform to the table below.

Three Phase, Neutral and Earth PLUG SUPPLY Phase X : Orange Phase Y : Black Phase Z : Red Neutral N : White Earth G: Green Caution ! : The trolley has two power supply cords or flanged inlet . Connect each plug / flanged inlet to a receptacle that is connected to an individual circuit

61. MULTIGEN SERIES 105 SEQUENCE OF EVENTS/GENERAL UNDERSTANDING General Understanding:

The Multigen series 105 precedes the Series 103. The quickest way to identify the 105 Series is the display

screen which is a blue color when illuminated LCD. The 103 Series display is red colored LED’s Mounted either

on the over head Gantry or on the Inlet Power side panel.

There are 4 different models in the Multigen 105 Series Minigen I, Minigen II, Multigen II and Multigen III. All have the same basic functions there are just different sizes with different capacities.

Multigen Series Models are all manufactured to the client’s custom requirements. There are a number of

features available for the units that your specific unit may or may not have including but not limited to, over

head gantry/heat lamps, single and or double refrigeration and or oven(s), etc.

The Power Supply- A basic understanding of electricity/electrical trouble shooting is required to understand the different power supplies for the Multigen Series of different units. The power requirement is 208/120 Volts

20 Amps Max breaker and three or single phase 60Hz.

Two different cords can be ordered for the unit which is interchangeable onto the power inlet plug of the unit.

Part Number M0A.707 with Male twist lock Plug NEMA number L21-20. 102/208 Volt 3 Phase, 20 Amp.


Or:

Part Number M0A.704 with a straight blade male plug NEMA Number 5-20

120 Volt 20 Amps.

A look at the unit’s electrical schematic may be helpful in understanding the 2 different power supplies.

All of the components of the unit lights, electrical refrigeration parts, heating elements, etc. are 120 Volts. The unit can be used to reheat/regenerate cold foods to a minimum of 165 F or the holding of Hot foods. If

the unit is to be used to reheat cold foods it must be plugged in with the 208/120 Volt 3Phase cord. This is to

allow power to all 3 of the heating elements that are 102 volts in a parallel circuit utilizing a common neutral leg. This gets the maximum amount of heat to the food in a minimum amount of time, more wattage. After

the cold food has been reheated the power supply cords can then be changed. Now with the 120 Volt cord you can keep the food that has already been heated to a minimum of 145F, using only the one heating

element that now only has power to it.

Why Some Components Work Sometimes and not Other Times:

If you were to add up all of the different electrical component amperages they would be well in excess of the 20 Amp supply. For this reason during the heating cycle the CPU will not allow components such as the lights

to operate. The unit will also give preference to the heating elements during the heating cycle over the refrigeration compressor. However if the oven is at its set temperature and the refrigeration system is calling

for cooling it will allow the compressor to run. If the oven temperature drops and requires the heating

elements to be re engaged the CPU will then turn off the compressor and engage the elements. The CPU is simply managing the power supply and switching components on and off as required by priority.

The Refrigeration System:

The refrigeration within the unit is a conduction system or cold wall. Without a fan it allows the food in the cold section to stay cold longer when the door is opened to serve the patient’s. It is also important to note the

cold section does not have a drain or drain heater to dissipate the condensation. After each meal service it is required to shut the cooling system off and leave the door open so any frost that has built up on the walls to

melt and be wiped up. A conduction cooling system also takes longer with out the use of a fan to move the air to cool the space. It is required to let the refrigeration system rum no less than 40 minutes before loading the

cold food items or the stating of an oven cycle.

Sequence of Operation:

When the unit is connected to the power supply if all of the safeties in the Series circuit are closed the

Transformer receives 120 Volts. It then sends 12 Volts form its secondary side to the CPU. The display screen

will then illuminate and scroll the name Burlodge twice then display off or stand by if a stand by cycle has been programmed.

The CPU will then close the micro relay on the power board CN-9 and energize the coil of the main contactor

sending 120 Volts to the connection point CN-1 on the power board. CN7 will be engaged powering the 2

refrigeration solenoids opening the solenoids for the right or cold side and closing the solenoids for the oven or hot side if equipped. After a time delay of 15 Seconds the relay CN-4 will close and energize the

refrigeration compressor. The compressor will cool the chamber to the set point or if equipped with double refrigeration the CN-7 circuit will de-energize and energize ever time the temperature in the compartment it is cooling drops by 6F. This will continue to happen until both compartments are at their set temperatures.

At the pre-programmed time or started manually the oven will come on. The refrigeration then takes second precedence to the heating. The circuit CN- 2 will close starting the oven motor(s) and the appropriate CN

circuit will close energizing the heating contactor coil(s). The coil(s) will stay engaged until the oven compartment(s) are at set temperature at which time the coil is de- energized. The heating fan(s) will

continuous run thru the entire time of the heating cycle whether the elements are engaged or not. At the


completion of the Heating cycle time the elements and the fans are shut off. If they were preset to be on and

equipped the hot top and gantry lights will come on automatically and the compressor will continue to run as needed.

The CPU is given the temperature of the chambers and hot top by the thermister probes mounted in them.

62. ELECTRICAL SPECIFICATION

USA/ Canada ANADA Multigen III 208V 60Hz 3P+N+G

RÉF. FRIDGE Total Réefrigeration. only

208V 60Hz+N+G AMPS KW AMPS KW

M53.700 no refrigeration 2 x 16 5.5 + 5.5

M53.700 double refrigeration 2 x 16 5.5 + 5.5 6.0 0.6

BLM53.700 No refrigeration 2 x 16 5.5 + 5.5

BLM53.700 Double refrigeration 2 x 16 5.5 + 5.5 2.5 0.5

RÉF. Accessories Consumption

Voltage AMPS KW

120V 60Hz Halogen Lights 5.0 0.6

120V 60Hz Heat top plate 3.5 0.4

Revised USA 20080214 SB Revised USA 20081126 SB Revised USA 20110413 SB Revised USA 20120119 SB\


63. ELECTRICAL SCHEMATIC

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