Packaged Coldroom Service Manual
Contents
1. a REFRIGERATOR Packaged Coldroom lt 1 QUALITY W rat AAA EMERY Dieu ET EHON DRT SERVICE MANUA Environmental Management Policy Disposal Requirements Introduction Control Panel 2 LCD 28 Controller With LCD 16 Display used on All Rooms From E5167380 From Feb06 2to5 High Temperature Room LDU 15 Controller 6 to 7 Low Temperature Room CDC 122 Controller From Dec 04 to Feb 05 Low Temperature Room LCD 15 Controller From Feb 05 Parts Lists Water Cooler System Filling Instruction Environmental Management Policy for Service Manuals and Duets Product Support and Installation Contractors Foster Refrigerator recognises that its activities products and services can have an adverse impact upon the environment The organisation is committed to implementing systems and controls to manage reduce and eliminate its adverse environmental impacts wherever possible and has formulated an Environmental Policy outlining our core aims A copy of the Environmental Policy is available to all contractors and suppliers upon request The organisation is committed to working with suppliers and contractors where their activities have the potential to impact upon the environment To achieve the aims stated in the Environmental Policy we require that all suppliers and contractors operate in compliance with the law and are committed to best practice in environmental management Product Support and Installation contractors are2. 0 _ SM oOo o ee ADR o a CDC 122 T1R2 B Electrical Connections Mod CDC 122 T1R2 B HE 5 3 A 240V ac os 5 1 A 240V ac Ds arsovac PF OE PWR 12V 10 3W Operation Guidelines for Foster controller part number 00 555462 low temperature models FPC2Lup to E5165449 LCD 15 Controller El Initial Start Up Start Up amp self Test Ea The indication is only displayed during the first three seconds following the mains electrical power being applied to the unit During this period the controller performs a self check Once the self check has been completed OFF will be displayed O I Press and hold for three seconds The unit will start and the air temperature will be displayed Check temperature set point Important to note that the ability to increase and decrease the set point is not a function available to the user as the set point is fixed To make adjustments to the set point it is necessary to access the parameter and alter SPL and SPH accordingly Check set point by pressing the button HE3 To increase set point press MESJ r until required temperature is displayed To decrease set point press ji iset until required temperature is displayed Factory Set Temperature Range Freezer 18 C to 21 C Exit from set up occurs after 10 seconds if no button is pressed when F is displayed release On completion of the defrost E will be displayed unt
3. 00 555739 Controller Operation Guidelines LCD 16 Display 00 555740 Initial Start Up Start Up amp self Test e The indication is only displayed during the first three seconds following the mains electrical power being applied to the unit During this period the controller performs a self check Once the self check has been completed OFF will be displayed Press and hold for three seconds The unit will start and the air temperature will be displayed Check temperature set point Important to note that the ability to increase and decrease the set point is not a function available to the user on the freezer rooms as the set point is fixed but limited adjustment is available on the High temperature rooms To make adjustments to the set point it is necessary to access the parameter and alter SPL and SPH accordingly Check set point by pressing the button MESJ To increase set point press MES mr until required temperature is displayed until required temperature is displayed To decrease set point press i set Factory Temperature Set Point Refrigerator 1 C to 4 C Freezer 18 C to 21 C Exit from set up occurs after 10 seconds if no button is pressed 2 Manual Defrost To initiate a manual defrost press and hold EF will be displayed release On completion of the defrost REC will be displayed until the cabinet temperature is achieved and then it will revert to displaying the normal ca
4. 06 15
5. 555621 15451251 15480002 00 555739 00 555740 00 555397 00 555398 00 555462 00 555397 00 555398 15246156 00 555199 00 555200 15243562 15243565 00 555548 00 555637 15714027 01 252076 01 16240094 16240094 01 252938 01 MS34FB R404 LBP fa ee Ring Mount 25W C W Blade E a Ring Mount 25w C W Blade DML 033S 28 BAR PA389 2 250W 240V Cut Out 70 c Cut In 55 c CAJ2464Z SE 230 50 Loblite 7000 00 White a a MX18TB R404 HBP CAJ9510Z 230 50 1 Pe Oa Motor 10w ee ea Ring Mount 25w C W Blade Part Number 00 555675 15422115 00 555567 00 555570 01 252381 01 00 555565 00 555568 00 555388 00 555386 15240025 00 555621 15480002 00 555739 00 555740 00 555397 00 555357 15243562 15243565 00 555548 00 555637 13 ie Heat Exchanger Fan Grid Mount 16W 15470027 oe Heat Exchanger Fan Elco A200 31 5170 00 555622 re Glycol Heat Exchanger Coil 00 555563 Glycol Heat Exchanger Complete Complete Housing with Coil Fan Motor amp Blade Eo ee E Pe Refrigerant 650 Grms R404A Ls Capillary 3 metres 0 064 Pas WPC2L ZF Low Temp System Item Cid Description CS amp Parrt Number Water Cooled Condenser 00 5 55567 Evaporator Coil 00 5 55566 oe Heat Exchanger Fan Grid Mount 16W 15470027 Sn Heat Exchanger Fan Elco A200 31 5170 00 555622 Glycol Heat Exchanger Coil 00 555563 Glycol Heat Exchanger Complete Complete Housing with Coil Fan Motor amp Blade Peed Door Frame Heater pe 01
6. Menu Pressing and releasing activates the information menu From this menu you can display the temperature relating to T1 air probe T2 evaporator probe if fitted and T3 condenser probe if fitted The maximum temperature THI and the minimum temperature TLO the cabinet has achieved since it was last re set The total operating time of the condenser CND since it was last cleaned and the keyboard status LOC The information to be displayed can be selected sequentially by pressing liaset I repeatedly or scrolling or hrr buttons Once selected press HEJ to display the value through the menu using the Exit from the info menu by pressing 0 1 or is automatic after 6 seconds if no buttons are pressed To reset the temperature settings recorded in THI and TLO and the hours counted in CND access the info lieset 0 1 menu press i iz 8 to display the value plus simultaneously for resetting to be completed To check the LOC status scroll through to LOC press jiaset to display status YES to lock keys NO to leave keys accessible NOTE with the keys locked it is not possible to turn the unit off or ON or to check the set point Parameter Setting and Adjustment It is strongly advised that before adjusting any Service Parameters a thorough understanding of the following instructions should be obtained set part and The parameters are accessed by pressing the following keys
7. cancelled by shutting the door Possible Causes Faulty door switch Door left open for more than 5minutes High Pressure Alarm Only applies to machines fitted with a condenser probe HP Will be displayed This alarm relate to the condenser which must be checked and cleaned at regular intervals the frequency being determined by site conditions The alarm will sound but can be silenced by pressing any of the buttons and the unit will continue to operate however it will return after the pre set designated period The unit returning to normal operating temperature will automatically cancel the alarm Possible Causes Condenser fan not working Condenser blocked dirty Condenser obstructed Air Temperature Probe Failure E Will be displayed The alarm will sound but can be silenced by pressing any button There is no further action that can be taken by the user in this instance During this period the unit will continue to operate but have a reduced performance Action Replace Probe Evaporator Temperature Probe Failure Automatic Defrost Cabinets Only B23 Will be displayed The alarm will sound but can be silenced by pressing any button There is no further action that can be taken by the user in this instance During this period the unit will continue to operate satisfactorily but this failure will have an effect on the defrost and therefore efficiency if allowed to continue Action Replace Probe Information
8. in succession keeping them pressed for 5 seconds After this period the first parameter SCL will be displayed Press button to go back Press isset iset to display the value to change it Exit from set up is by pressing O T or is automatic if no buttons are pressed for 30 seconds NOTE When receiving a replacement controller the unit will be set with the default settings Change the settings to those relating to the particular model After changing parameter SCL from 1 to 2 moving through parameters SPL SP FDD IISL and IISP you may find that or will be displayed or indicates that the control setting is out of range To get the parameter back into range for example SPL press kiima to display the value part continue pressing both buttons until the display shows the temperature required then release both buttons Use the same procedure to adjust all of the parameters displaying or LCD 28CS4E B 00 555735 Controller Parameter lists Definition ScL eadout scale 1 C 2 C F inimum setpoint SPh_ Maxi SP yy 7 m aximum setpoint etpoint hermostat hysteresis inimum compressor rest time 0 min run cycle with PF1 Ni lt cSd ompressor Stop delay after door open OS y efrost frequency efrost end temperature J 3 5 dto Maximum defrost durati
9. required to 1 Ensure that wherever possible waste is removed from the client s site where arrangements are in place all waste should be returned to Foster Refrigerator s premises In certain circumstances waste may be disposed of on the clients site if permission is given if the client has arrangements in place for the type of waste 2 If arranging for the disposal of your waste handle store and dispose of it in such a way as to prevent its escape into the environment harm to human health and to ensure the compliance with the environmental law Guidance is available from the Environment Agency on how to comply with the waste management duty of care 3 The following waste must be stored of separately from other wastes as they are hazardous to the environment refrigerants polyurethane foam oils 4 When arranging for disposal of waste ensure a waste transfer note or consignment note is completed as appropriate Ensure that all waste is correctly described on the waste note and include the appropriate six digit code from the European Waste Catalogue Your waste contractor or Foster can provide further information if necessary 5 Ensure that all waste is removed by a registered waste carrier a carrier in possession of a waste management licence or a carrier holding an appropriate exemption Ensure the person receiving the waste at its ultimate destination is in receipt of a waste management licence or valid exemption 6
10. 252938 01 aaa a r a Refrigerant 400 Grms R404A Ee Capillary 3 metres 0 064 Loe 14 Water Cooled Condensing System Filling Instruction Filling the system with water Fill the 5 litre container with clean water Remove the plastic cap from the end of the Water Fill Pipe Insert the funnel in to the end of the Water Fill Pipe Slowly and with care avoiding any spillage poor 2 litres of the water into the tank Plug the mains lead in to the power source and turn the unit ON After a short period the water pump will start to circulate the water round the system Leave the pump to run for a further 2 minutes Switch the unit Off before adding the remaining 3 litres of the water Switch the unit On and leave running for a few minutes to check that the water is circulating correctly Check the water level in of the tank by placing a hand against the front the tank if filled with sufficient water will be warm half way up if not it may be necessary to add more water Refit the plastic cap to the water fill pipe Water outlet A Water fill pipe Remote condenser fan electrical connection Water inlet B Heat Exchanger Detail Water Inlet A Airflow Airflow Water Outlet B Foster Refrigerator Oldmedow Road Kings Lynn Norfolk PE30 4JU Tel 01553 691122 Fax 01553 691447 Website www fosterrefrigerator co uk Email sales foster uk com a Division of ITW UK Ltd FASTFIT SM 02
11. Handle and store refrigerants in such a way as to prevent their emission to atmosphere and ensure they are disposed of safely and in accordance with environmental law 7 Make arrangements to ensure all staff who handle refrigerants do so at a level of competence consistent with the City Guilds 2078 Handling Refrigerants qualification or equivalent qualification 8 Ensure all liquid substances are securely stored to prevent leaks and spill and are not disposed of to storm drains foul drain surface water to soil DISPOSAL REQUIREMENTS If not disposed of properly all refrigerators have components that can be harmful to the environment All old refrigerators must be disposed of by appropriately registered and licensed waste contractors and in accordance with national laws and regulations Introduction Constructed on site from foamed insulated panels provided with profiled edges and heavy duty Fosterloks for positive locking and long term stability The condensing system is incorporated in the front coldroom panel locked into position The temperature controller On Off switch and light switch are located in the hinged front panel Access to the condensing system is by removal of the retaining screws from the right hand side of the hinged panel Control Panel used on High and Low temperature coldrooms from E5167380 Feb 2006 EC eed Temperature Mains ON OFF Interior Light Controller Switch Switch Controller Operation LCD 28CS4E B
12. ature Set Point 03 02 HYS Hysteresis 3 3 CRT Compressor Rest Time minutes 1 1 CDC Compressor Regulation with T1 Fail 7 7 DFR Defrosting Frequency 24 hours 4 4 DTO Defrosting Duration minutes 20 20 DDY Defrost Display Control 1 1 ATL Low Alarm Differential 3 3 ATH High Alarm Differential 5 10 ATD Temperature Alarm Delay minutes 60 90 ACC Condenser Clean Interval 00 00 OAU Auxiliary Output Mode of Operation NON NON BAU Auxiliary Button Mode of Operation NON NON OS1 T1 Offset SIM Display Slowdown LDU 151E BG Electrical Connections Mod LDU 151E HOL DATE T1 25 0 25 0 NTC PWR 230V 10 50 60 Hz 3W Low Temperature Room Control Panel CDC Controller from December 2004 to February 2005 When the unit is switched on the display shows for a period of five seconds during which the controller performs a self check The display then shows the air temperature measured by probe 1 5 6 7 CDC Controller Check Set Point Low point of temperature band Press and hold button 1 CE Increase Set Point s Press and hold button 1 Press button 3 ALT until required temperature is displayed Decrease Set Point gg AS Press button 1 CE Press button 4 w until required temperature is displayed Manual Defrost AIN Press and hold button 2 D Press button 4 w a timed defrost will follow Indicators LED 5 Compressor on 8 LED 6 Evaporator Fan on G8 LED 7 Defrost on D Alarms and Warnin
13. binet temperature Set Unit to Standby Press 071 display shows OFF Standby Indication This indication is displayed while the unit is not operating but with mains power applied to the unit This mode may be used for internal cleaning regimes and short periods when the unit is not required For extended periods of inactivity the mains supply should be isolated Alarm and Warnings High temperature alarm HI Will be displayed The alarm will sound but can be silenced by pressing any of the buttons however it will return after the pre set designated period The unit returning to normal operating temperature will automatically cancel the alarm Possible Causes Evaporator fan not working Restricted airflow through airduct Evaporator iced up Compressor not working Low temperature alarm wl Will be displayed The alarm will sound but can be silenced by pressing any of the buttons and the unit will continue to operate however it will return after the pre set designated period The unit returning to normal operating temperature will automatically cancel the alarm Possible Causes Controller faulty not switching compressor off Compressor secondary relay will not de energise low temperature models Door Open Alarm Only applies to cabinets fitted with door switches DO Will be displayed The alarm will sound but can be silenced by pressing O T The display will continue to display the alarm message until
14. effect on the overall efficiency if allowed to continue Action Replace Probe Parameter Setting and Adjustment It is strongly advised that before adjusting any Service Parameters a thorough understanding of the following instructions should be obtained set mr and The parameters are accessed by pressing the following keys in succession keeping them pressed for 5 seconds After this period the first parameter SCL will be displayed 10 Exit from set up is by pressing NOTE When receiving a replacement controller the unit will be set with the default settings Change the settings to those relating to the particular model After changing parameter SCL from 1 to 2 moving through parameters SPL SP FDD lIISL and IISP you may find that or will be displayed or indicates that the control setting is out of range heset ert To get the parameter back into range for example SPL press to display the value and continue pressing both buttons until the display shows the temperature required then release both buttons Use the same procedure to adjust all of the parameters displaying or Foster Controller part number 00 555462 Parameter list LCD 15C S3E Default Values C 2 C Display Parameter FPC Lt Rooms a m oo oo SCL Readout scale SPL Minimum setpoint Maximum setpoint Setpoint HYS Thermos
15. gs PF1 indicates air probe failure PF2 indicates evaporator probe failure Access to the control parameters is achieved by pressing sequences N yo w CE ALT and holding in the keys for a period of 4 seconds It is possible to scroll through the parameters by pressing e or ALT a m z The value of a selected parameter is checked by pressing and may be altered by pressing at the same aS yo ase time ALT or w Exit from set up occurs after 10 seconds if no key is pressed If an alarm condition is entered the alarm buzzer will sound and ALM will flash on the display The alarm may be acknowledged by pressing any key causing the buzzer to cease and the display will alternate between ALM and air temperature while the alarm condition persists The alarm will re sound every 30 minutes while an alarm condition persists LAE CDC 122 T1 R2BS PARAMETER SETTINGS 15246156 a CDC122T1R2B Fan restart after defrost Fan operation during defrost Refrigeration minimum on time e a _ SPH a ee ee ee 2 3 0 ee 0 ee 5 7 0 o DRE 6 6 DLI Defrost limit temperature 10 o ee ee DRP DIS 5 ee ee DOP A FRS e a ee ee FID 0o ALO Lowalarmthreshold 8B AHI Highalarmthreshold f 2 ADL Temperature alarmdelay 10 AIN Alarminputselecton tt O81 Air probe offset OP OS2 0O __ OS3
16. ht Controller Switch Switch High Temperature Room Control Panel When the controller is switched on a single line appears on the display for 3 seconds to indicate the autotest period After this period the air temperature measured by the T1 probe is displayed LDU 15 Controller Check temperature set point Check set point by pressing the set button To increase set point press set To decrease set point press set Factory Temperature Set Point 1 C Exit from set up occurs after 10 seconds if no button is pressed Alarms and Warnings HI High Temperature Alarm LO Low Temperature Alarm E1 T1 Probe Failure DF Defrosting in Progress CLN Clean Condenser Controller Set Up The parameters are accessed by pressing the following keys in succession set and keeping them pressed for 3 seconds Access to the parameters has been achieved with the first parameter SCL being displayed To pass from one parameter to the next press either the or key To display the value press set To change the value press set to increase or set to decrease Exit from set up by pressing aux or is automatic after 30 seconds if no buttons are pressed Controller Parameters LDU151E BG Controller 00 555357 LDU151E B High Temp SSRA ona eter Default Values Room SCL Readout Scale 1 C 1 C SPL Minimum Temperature Set Point 00 00 SPH Maximum Temperature Set Point 08 08 SP Effective Temper
17. il the cabinet temperature is achieved after which it will revert to displaying the normal cabinet temperature Manual Defrost To initiate a manual defrost press and hold Alarm and Warnings High temperature alarm H Will be displayed The alarm will sound but can be silenced by pressing any of the buttons however it will return after the pre set designated period as set in parameter ATH The unit returning to normal operating temperature will automatically cancel the alarm Possible Causes Evaporator fan not working Restricted airflow through airduct Evaporator iced up Compressor not working Low temperature alarm to Will be displayed The alarm will sound but can be silenced by pressing any of the buttons and the unit will continue to operate however it will return after the pre set designated period as set in parameter ATH The unit returning to normal operating temperature will automatically cancel the alarm Possible Causes Controller faulty not switching compressor off Compressor secondary relay will not de energise Door Open Alarm Only applies to rooms fitted with door switches Po Will be displayed The alarm will sound but can be silenced by pressing any button The display will continue to display the alarm message until cancelled by shutting the door After 1 minute the compressor will stop as set in parameter CSD Possible Causes Faulty door switch Door left open for more
18. on dty Defrost type FAN ELE GAS ELE flag OFF ELE dd drn Drain down time Display control during defrost Fid Fan operation in defrost Evaporator Fan re start F an timed control Low temperature alarm Aht Condenser HP Alarm 0 70 60 Ahm AHTalarmmanagement NON ALR STP NON flag NON Acc Condenser cleaning 0 52 0 hdS Eco gt Heavy Duty sensitivity 1 5 3 flag 3 Z 0 O Maximum setpoint II HSL Setpoint II ISL WHY Ihermostat hysteresis II Defrost frequency Il Z N liFt Fan timed control II NO YES NO flag NO Sb Stand By button function NO YES YES flag NO dS Door switch enabling NO YES NO flag NO NO AUX Output Control Air probe offset vaporator Probe enabling E Evaporator Probe offset Condenser Probe enabling Condenser Probe offset Display slowdown Unit address SCHEMATIC WIRING DIAGRAM E R FOR GUIDANCE ONLY REFRIGERATOR Only Use Genuine Foster Parts Controller Part No 00 555739 Display Part No 00 555740 Air Probe Part No 00 555397 Evap Probe Part No 00 555398 REFER TO SERVICE MANUAL BEFORE ADJUSTING PARAMETERS OR WIRING FOSTER REFRIGERATOR Olmedow Road Kings Lynn Norfolk PE30 4JU Tel 44 0 1553 780300 Email Spares Foster uk com www Fosterrefrigerator uk com 230 VOLTS Detail shows high temperature controller FPC2H Models up to E5167380 Temperature Mains ON OFF Interior Lig
19. ray Temperature Switch Cut Out 70 c Cut In 55 c 00 555621 3 8 Inlet 1 2 Outlet 15480002 Controller LCD28CS4E B From Feb 2006 00 555739 Display LCD 16 00 555740 LCD 16 00 Bulkhead Light Loblite 7000 00 White HP Pressure Switch 28 BAR 00 555386 00 555397 00 555548 Light Bulb 60W BC Pearl 240V R S 00 555637 a 12 Refrigerant 1200 grms R404A Capillary 3 metres 0 064 PC2L ZF Low Temp System Compressor Compressor Condenser Coil Condenser Fan Evaporator Fan Guard Evaporator Coil Evaporator Fan Drier HP Pressure Switch Vap Tray Heater Rod Vap Tray Temperature Switch Hot Gas Valve Solenoid Accumulator Controller Display Air Probe Evaporator Probe Controller Air Probe Evaporator Probe Controller Air Probe Evaporator Probe ON Off Rocker Switch Light Switch Bulkhead Light Light Bulb Pressure Relief Valve Drip Tray Heater Rod Evaporator Klixon Drain Pan Klixon Door Frame Heater Refrigerant Capillary PC2H ZF High Temp System Compressor Compressor Water Cooled Condenser Condenser Fan Evaporator Fan Guard Evaporator Coil Evaporator Fan Drier HP Pressure Switch Vap Tray Heater Rod Vap Tray Temperature Switch Accumulator Controller Display Air Probe Controller Probe ON Off Rocker Switch Light Switch Bulkhead Light Light Bulb Part Number 00 555683 15422412 00 555561 00 555569 01 252381 01 00 555566 00 555568 00 555388 00 555386 15240025 00
20. tat hysteresis CRT CDC CSD gt a wo m Minimum compressor rest time 10 min run cycle with PF 1 Cmpr Stop delay after door open Defrost frequency DLI Defrost end temperature DTO Maximum defrost duration DTY m m Defrost type Drain down time DDY Display control during defrost Fan operation in defrost Evapor Fan re start FTC Fan timed control ATL ATH ATD ADO _ Door alarm delay AHT Condenser HP Alarm AHM CC lt m N Low temperature alarm High temperature alarm Temperature alarm delay AHT alarm management gt Condenser cleaning Eco gt Heavy Duty sensitivity 2nd parameter set management ISL Minimum setpoint Il Maximum setpoint Il Setpoint II Thermostat hysteresis II m oN 5 oo N oo IHY 11 YES YES YES YES E LCD151CSE Electrical Connections SBY T2 T3 OS3 TLD ADR Mod LCD15CS3E Date T1 T2 T3 40 0 80 0 C cod SN2 PWR L N 230V 10 50 60 Hz 3W D E 7 2 A 7 2 A 7 Z A Parts Lists PC2H ZF High Temp System Description Part Number Item Description gt S CAJ9510Z 230 50 1 15422115 MX18TB R404 HBP 00 555675 T aaa Condenser Coil 00 555561 Ring Mount 25W C W Blade 00 555569 White Evaporator Fan Guard White Evaporator Coil 01 252381 01 00 555565 00 Evaporator Fan Ring Mount 25w C W Blade 00 555568 DML 033S 00 555388 Vap Tray Heater Rod PA389 2 250W 240V 15240025 Vap T
21. than 5 minutes as set in parameter ADO High Pressure Alarm Only applies to units fitted with a condenser probe Will be displayed HP This alarm relate to the condenser which must be checked and cleaned at regular intervals the frequency being determined by site conditions The alarm will sound but can be silenced by pressing any of the buttons and the unit will continue to operate however it will return after the pre set designated period as set in parameter ATH The unit returning to normal operating temperature will automatically cancel the alarm Possible Causes Condenser fan not working Condenser blocked dirty Condenser obstructed Air Temperature Probe Failure Ea Will be displayed The alarm will sound but can be silenced by pressing any button There is no further action that can be taken by the user in this instance During this period the unit will continue to operate but have a reduced performance with the compressor running for 7 minutes and resting for 3 minutes as set in parameter CDC Action Replace Probe Evaporator Temperature Probe Failure Automatic Defrost Cabinets Only E Will be displayed The alarm will sound but can be silenced by pressing any button There is no further action that can be taken by the user in this instance During this period the unit will continue to operate satisfactorily with the defrost being controlled on a timed basis and not temperature which may have an
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