AeroWhip - Installation Guide

The B&C REFRIGERATION “AEROWHIP” soft serve ice cream machine is designed to be installed into a mobile food vending Van, truck or trailer.  The way the machine is installed will have a significant impact on the ease of operating, cleaning and servicing of the machine and its supporting refrigeration unit.

The following points are intended to act as a guide when a new installation is being planned.

• The optimum height for the machine is determined by two factors, the height of the serving handle, and the access to the top tank for filling and cleaning.
• It is important to remember that an ice cream machine is processing milk products, and will require regular cleaning to keep the ice cream in good condition, and maintain health and safety standards.
• The milk or “mix” is placed in the refrigerated top tank and will be stored there until it is sold or removed for cleaning. The Mix pump is also located in the top tank, and will need to be removed during the cleaning process, so it is important to leave enough room above the top of the machine so sufficient access is available to clean and service the machine.
• Generally the top of the machine should be 1400mm above the floor of the vehicle.  The machine is 710mm high and sits on four vibration rubbers which add a further 30mm.  Therefore the shelf that the machine sits on should be approximately 660mm above the floor.  This may vary depending on the individual operators choice
• The serving handle should be at a working height that allows the operator to see the ice cream flowing into the cone or cup from above, and is comfortable to operate.  Normally the handle will be between your waste and your lower chest, depending on the height of the operator.
• The sides of the machine will require service access on both sides as the electrical systems and temperature measuring equipment are located behind the side covers.  Allow 250mm on each side minimum.
• The rear panel provides access to the dasher motor, tachometer and V belts, so it should also be accessible for service.  
• The bench tops should be stainless steel or a suitable kitchen bench type material, such as polyurethane.  Normally smooth finished are the most serviceable and easy to clean.  White smooth finishes are popular, as is stainless steel.

The AEROWHIP machines are designed to have smooth surfaces that are easy to clean and do not trap milk in gaps or crevices.  Your bench tops and cupboard doors should be similarly designed.

The machine requires a 240volt single phase (10amp) 50Hz power supply.  The supply frequency (50Hz) is very important as low frequency or under voltage events will cause the control system to shut the machine down, and could damage the motors, if prolonged power problems are common.

Most Vehicles are assembled with a dual power supply, with mains power, and an on board generator both capable of providing the power.  Where possible use mains power, via a good quality extension lead, as the power supply will be stable. 

Cycle and voltage meters should be installed so that power quality can be monitored at all times.

Where a generator is installed look for a simple reliable unit with a capacity of at least  8kva  /6.4kw power factor corrected (ice cream machine load only).  Remember to add up all the electrical fixtures you intend to operate when selecting your generator, such as slushy and coffee machines.  A close coupled Diesel Sea Wasp brand or similar unit has been regularly used.

do not use extension leads that are significantly longer than the distance required as long leads can induce voltage drops

Marine generators with water cooled radiators are popular and provide good service.  The Air flow that cools the water cooled radiator should have a fan that is capable of pushing the air past the generator, through the radiator and then out through a safety grill cut into the side of the van.

In a lot of newer installations the operators are choosing to have the generator powered by the same fuel as the vehicle so they can both run on fuel drawn from the same fuel tank.  Remember that the generator will normally require its own battery for starting.  Consideration should be given to how the coolant will be checked and topped up during generator servicing, as the generator generally is located under the serving bench that the AEROWHIP machine is sitting on, as the height of that bench has been determined already.

The refrigeration condensing unit will have a sucking fan (induced draught) which draws cool air from outside the vehicle on the opposite side to the radiator, thereby creating a cross flow of air inside the generator / refrigeration compartment that will ensure the cooling air is drawn in and rejected on a continuous cycle.

It is worth considering which side of the vehicle your customers will be lining up to be served, as the refrigeration air intake should be on that side, and the generators warm air discharge should be on the opposite side, as your customers will not want to stand in front of the warm air outlet.

The refrigeration systems operate on refrigerant R134a and have a critical charge.  Only an experienced refrigeration technician is allowed to service the refrigeration systems under the Australian refrigeration code, and the controlled substances legislation.

The two refrigeration condensing units have been engineered to provide the correct amount of cooling for the freezing barrel, and the top tank, and they operate independently of each other.

The top tank refrigeration unit is located inside the AEROWHIP machine and has been pre-charged with a refrigerant holding charge.  The main freezing system refrigeration unit, is normally located beside the generator in the rear of the vehicle.  The machine will remove heat from the ice cream and reject that heat into the cooling air that is drawn over the air cooled condenser coil attached to the refrigeration machine.  The cooling air needs to be drawn into the vehicle through a hole in the side of the body of the vehcial.  This hole will require a safety grill that stops fingers but not the air flow being drawn into the unit. 

Maintaining the correct serving temperature also effects, the taste and the mouth feel, as the moisture content and fats in the mix, and the ability for the mix to hold the correct amount of air (over run), will be effected by the serving temperature

The air cooled condenser has a face size of 470mm wide x 440mm high, and the hole needs to line up with the face of the heat exchanger.  B&C REFRIGERATION  have designed and manufacture a special refrigeration package for this application, and we strongly recommend that this unit be installed.  If the refrigeration system is too large the compressor will make the mix too cold in the freezing barrel and will affect the consistency of the mix and cause freeze ups in the barrel.  The control system will also make the compressor turn off when the suction pressure falls too low (short cycling).  An undersized machine will not be able to keep up with the cooling capacity of the freezing barrel and the ice cream will be too warm if multiple sales are made in a short time frame, and the product will not hold its shape in the cone or cup.

Maintaining the correct serving temperature also effects, the taste and the mouth feel, as the moisture content and fats in the mix, and the ability for the mix to hold the correct amount of air (over run), will be effected by the serving temperature. 

Consideration should be given to how the components will be serviced or changed over the life of the system, as the refrigeration / generator compartment is often smaller then we would prefer to see. 

The refrigerant charge is variable depending on the installation and amount used will be adjusted when the system is commissioned.  The main refrigeration unit will require a condenser fan cycling control to maintain the correct operating pressure in the system.

For more information about the correct installation of your AEROWHIP machine, please CONTACT US or E-Mail B&C REFRIGERATION.