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Service Manual - Foster web spares

1. END OF CYCLE ALARH i ELES imm UHLESS TATETL ORAM SHOW DE EHERSEEITL Mr Crees Oia FOSTER REFRIGERATOR U K LTD E BC 11 11 FITTED WITH FAM CHPACITOR ROAD KGS LIM HUEPULE FEIU HU o e o x o wo amp 35 Wiring Diagram BC21 BCF21 A B C D E F G j H 4 K j L j M N P a ae L EI Gel EN dE BT e Rh 38 2 188 ot B 133 m B br nc cux E CODE 2 ALL CABLES ARE UNLESS STATED THEI Er m z 3 SHOWN DE ENERDHSED CABRET BLAST CHILLERS 1 231729 m i ial wt ea ee 4 REN E 21 FOSTER REFRIGERATOR LTD z SHEET OF 1 MH 5 BE 21 21 FIED 007 CAPACITOR ML MAKE RD y OLDMEIDON EAD EINGE LYNN NWORFDLE FEM U en Wr OEE H TH WF WIU PEN E HA NH o vo j o sw o C M Wiring Diagram BC36 13amp singe phase version A B D J E F G H j 4 K L j M N P TERR CR DS EL ESI E EX Gel ER Ec SWITCH 4 Lj TRE a T x 3 3 EXO CIELE
2. proper air flow Make sure there is 9 least four inches of clearance from evaporator Wires or electrical components are Check for appropriate insulation on Replace fuse or reset circuit Fuse blown or circuit breaker tripped Sees Electrical Shocks AN in direct contact with metallic parts the connections of each component iso The refrigerator is not properly Check if the noise goes away after levelled you level the refrigerator Noise While the compressor is working The condenser is not fastened check to see if metal parts are in correctly Copper tubing is in contact contact with one another and or if with metal the screws that fasten the condenser are tightened Check if the fans are securely The evaporator and or condenser fastened Also check if the fan fans are loose blades are loose broken or crooked If so change the faulty blade If the noise persists after all other Compressor has an internal noise measures have been taken it may be originating from the compressor 1 Loosepats i Locate and tighten loose part s om ae Extreme condensation inside the Controller is set at a very cold Ee controller to a refrigerator position position amp check to see if compressor stops as should The outside environments relative oe of 52 es by humidity is very high over 75 ocal c imatic conditions and
3. OLDA S HF PROCUREMENT Cabinet Roll In amp Modular 2004 Blast Chiller amp Shock Freeze with Surf Navigation FCC Dial and Click Wheel Controllers ISO 14001 ISO 9001 L FOSTER Service Manual Issued October 2010 Contents Disposal Requirements 2 Print Test Operation 26027 modielon amp CabnerDeserplons 3 o ar Operations 4 IrDA Printer Installations 8 Operating Guide 28 Configuring the Print Function Further Operational Printer Technical Data 35 Service Manual Information The products and all information in this manual are subject to change without prior notice We assume by the information given that the person s working on these refrigeration units are fully trained and skilled in all aspects of their workings Also that they will use the appropriate safety equipment and take or meet precautions where required The service manual does not cover information on every variation of this unit neither does it cover the installation or every possible operating or maintenance instruction for the units Health amp Safety Warnings and Information Make sure the power supply is turned off before making any electrical repairs To minimise shock and fire hazards please do not plug or unplug the unit with wet hands During maintenance and cleaning please unplug the unit where required Care must be take
4. ar CTES 1 cuxE COLOUR DE REV A BXTE 3 DREUT SHOWN HERPES mu BUY MELLOW EARTH CABINET BLAST CHILLER pie FOSTER REFRIGERATOR LTD MH WHITE t zi OLDMEIK N EDAD WORFOLE HU o vo o sw ow mM 15 wERSKM OF BCI Wiring Diagram BC36 16 amp single phase version A B D J E F j H J j K L j M N j P SAFETY ATH wH FT lt td EA e e oD L L1 LJ nd Ex El EE 65 Co FFI FP2 FP Darme DERZ Fa 2 ALL CABLES Inm UNLESS STATED Er SHOWN DE ENERPIET MIU HS CREEN IELLIDM EARTH 1 23373 00 12 Hs S UAM FOSTER REFRIGERATOR LTD SHEET 1 oF 1 a RUD RD RID OLDMEIKYN EDAD EIHG E LYNN WORFOLE PEM 4U o ws Gs M WITH o vo o o w M Wiring Diagram BCF36 BC51 BCF51 3 phase A B D E F j G J K j L M N Pj 2 d 1 Ee E tem a SAFETY L RP re SWITCH PT a DTE OO BG Ecl E
5. 26 IrDA PRINTER INSTALLATION amp OPERATING GUIDE A044 FST FCC IRC COMPONENT REQUIREMENT SYSTEM TEST controller must have Software Revision 2a or later i e 2b 2c etc The software revision is displayed on the controller at the bottom of the SYSTEM TEST EXPERT screen during the first 3 seconds after mains electricity is supplied to the cabinet To check the Software Revision isolate and reinstate the electricity supply to the Software Revision 2b machine Bv LAE ELECTRONIC The controller system must have the optional IrDA PCB fitted to the unit cover and connected to the display PCB This is usually a factory fitted option but could be retrofitted by a competent service technician Foster part number 00 555461 FST FCC IRB The controller must be fitted with the appropriate label These as shown below not to scale lt PRE CHILL HARD CHILL SOFT CHILL Press Start Turn ioe Select PRE CHILL HARD CHILL gt SOFT CHILL Foster Cabinet Blast Chiller Label xk Press Start Turn do Select Foster Modular Blast Chiller Label e The printer selected for use must be capable of operating using a fully configured IrDA system The controller infra red system is a bi directional device utilising IrDA in the physical layer only The standard printer part number 00 555459 is such a device Additional information drivers etc can be downloaded
6. i8 o Aa o seg dog 15009 240g O E 230 1 50 400 3 50 LR NN PowerConsumptiat Watts 913 Watts 1246 Watts 1922 Per Phase Watts Watts 2242 Per Phase Amps 4 06 Amps 5 55 55 4 72 Per Phase a 5 5 35 Per Phase Power absorbed W 900 1275 Total Heat Rejection e 2876w 3748w Refrigerant Control Refrigerant Quantity 33 Modular o MBS MBC100 MBC150 MBC250 Nominal Chilling Capacity 75Kg 100g 15 Kg 2 gt 50 2 Duty 15 C 8 5kW 11 5kW 21kW Fans 22 3 598 64 Drain Connection 1 22mm mm 22mm mM Iletsze 12 40 1 TBS Outlet 71144 1148 7 11 48 5 1 J MBCF 5 MBCFH00 v MBCFiO MBCF250 Nominal Chilling Capacity 75Kg 1 100g 1590 gt 0 NominalFreezing Capacity 1 75Kg 100g 15 25Kg Duyo 300C 7 7 6 645 9 J 18 J Fans 33 7 3 64 O Drain Connection 1 1 22mom 2 mm Refrigerant R404a R404a R404a R404a mese Electrical Supply 230 1 50 16 A 230 1 50 16A 230 1 50 16A 400 3 50 16A phase 34 Wiring Diagram BC11 amp BCF11 Remote Models ee 1 ER JA L 59 H HU M M S E 1 _ OO LI LI DOOR 1
7. indicates 3 food probe temperature for E dem information only if this is not fitted print out B t A 5 5 shows B 1 12 ze at B 09 33 F 10 42 M B 09 35 45 The transition from Blast mode of the 09 39 chilling cycle to the Hold mode longer term 0942 ie 5e en storage There is a double reading of the 4 B 09 45 temperature at this point The logging B t HP indicates a power failure has occurred interval changes from the selected logging that has exceeded the 5 minute threshold period either 3 or 5 minutes to a fixed 15 ES idi 2 gt The controller automatically records the minutes E gae time when the power is re established B 09 57 4T 3 z along with the date in case of extended 10 00 d MJ power cuts um The next temperature recording occurs 15 41 mE zu Vs d iso A 55 d vim Ja minutes after power is re established ive es i es di standard hold time interval nde initiated A HD F it E ee The user can calculate the duration of the ic pr 22252 H 10 45 T et power cut by subtracting the last recorded deri od H 020 z EL ES time from the time when the power is re beyond the normal operating range established Along with the air and food 11 15 07 41 probe temperatures a decisi
8. 12 Start Turn do Select 5 If COMMUNICATION is shown on the controller then there has been a problem with the controller sending data to the printer i e printer not switched on too far away window not pointing at COMMUNICATION the controller etc After 2 seconds the message will disappear and the display will revert to the program selection menu Note Once a new chill cycle has been started all the data in the print memory will be lost 31 Print out Example amp Description Cabinet No is the unique cabinet identifying I ILTILIILILLLLLLLLLLILLLIIILIMLIIIILLLmEBILM Date is the day month year on which number generated by System Parameter CABINET 1 the chill cycle was started Based on Address date set in controller 14106104 SOFT CHILL Start Time is the actual time the Program is a description of the type of chill STAFT 08 30 cabinet chilling process was started cycle program that was selected END TIME 10 00 This is based on the 24 hour clock and CYCLE END 1220 determined by the time in the 1 controller End Time is the actual time the cabinet DURATION eu chilling process stopped and the controller START TEMP started the Hold cycle TC Cycle End is the actual time the This is based on the 24 hour clock and cabinet was stopped determined by the real time set in the control
9. 2 Hold Operation Function OFF CYCLE AUTO ON AUTO P69 DefrostType Function OFF ELE GAS P70 SmartDefrostinc Integer 0 20 355 P71 BDefostEndTime Minutes 1 460 20 P72 C 10 590 10 15 P73 jDranTime 0 7959 1 P74 Fan Delay Temp CS P75 DuyOCyle 15 10 10 760 2 P76 Comp RestTime Minutes 0 90 3 P80 DoorStop 0 790590 M P81 Door Alarm Delay Minutes 0 9 5 P82 KJ 50 10 P83 High Alarm Delay Minutes 0 1120 30 2 84 AlarmTime Minutes 0 10 1 P85 Alarm Repeat Minutes 0 140 0 P87 Air Probe Offset X 45 SO P88 Coil Probe Offset K 15 SO P89 Food Offst KOSS P90 Food2 Enable Function NO 5 NO P91 3 jFood2Offst KOSS P93 KS Parameter Definitions Pre Chill 01 Pre Chill Enable The air temperature which the air probe must read before the condensing system is de energised in the chill mode of the Pre Chill Program Range 15 to 15 C PO2 Chill Time The period Pre Chill is in the chill mode prior entering the Hold mode Range 5 minutes to 60 minutes Hold Temp The temperature which the air probe must read before the condensing system is de energised in the Hold mode of the Pre Chill program Range 15 to 15 C Soft Chill 4 Air Temp The temperature which the air probe
10. Rotate the dial or click wheel until HACCP SETTINGS is highlighted Press and release the dial or centre button to access the HACCP option screen Press and release the dial or centre button again to move to the selection screen for long or short reports rotate the dial or click wheel to select which option and once selected press and release the dial or centre button to confirm Press and release the dial or centre button to move to the selection screen for the print sample select 3 or 5 minute selection rate On completion press and hold the dial or centre button for 2 seconds to return to the program selection screen Print Data Whilst in the program selection screen press and hold the dial or centre button for 2 seconds the information screen will be displayed Rotate the dial or click wheel until PRINT DATA is highlighted If using a hand held printer switch the printer on now Point the printer at the infra red download sensor optional located in the display area press and release the dial or centre button to download the print data On completion press and hold the dial or centre button for 2 seconds to return to the program selection screen Set the Time and Date TINE _ CHILL TEMP HOLD TEMP _ INFORMATION SETTINGS PRINT DATS SET TIME DATE SERPICE Change Text Language SERVICE DIAGNOSTICS FOOTPRINT Screen Saver Whilst in the program selection screen press and h
11. before the condensing system is de energised in the chill mode of the Professional 1 program prior to entering the Hold mode of a temperature based cycle Range 15 to 15 C Chill Temp Minimum The minimum value that the temperature which Food Probe 1 must read before the condensing system is de energised in the chill mode of the Professional 1 program prior to entering the Hold mode of a temperature based cycle which it can be adjusted to by the operator Range 20 C to 5 C Chill Temp Maximum The maximum value that the temperature which Food Probe 1 must read before the condensing system is de energised in the chill mode of the Professional 1 program prior to entering the Hold mode of a temperature based cycle which it can be adjusted to by the operator Range 5 C to 15 Hold Temp Sid The standard temperature which the air probe must read before the condensing system is de energised in the Hold mode of the Professional 1 Program Range 15 to 15 C Hold Temp Minimum The minimum value that the Hold temperature set point can be adjusted to by the operator in the Professional 1 program Range 10 to O C Hold Temp Maximum The maximum value that the Hold temperature set point can be adjusted to by the operator in the Professional 1 program Range 0 C to 10 C Change Time The percentage period of a time based chill cycle which is to have passed before automatically adjusting the air temper
12. not by the refrigeration unit Check the door and or the magnetic The refrigerator door won t shut gasket Adjust the door hinges if completely needed replace the gasket if broken ee ee an inadequate location that produce too much heat ae Rr Condensing unit runs for long Advise user to ensure doors are periods of time closed when not in use and to avoid opening doors for long periods of time Ensure gaskets are snapped in completely Remove gasket and Door gasket s not sealing properly wash with soap and water Check condition of gasket amp replace if necessary Dirty condenser coil Clean condenser coil Unplug unit and allow coil to defrost Make sure thermostat is not set too Prolonged door opening or door ajar Evaporator coil iced over cold Ensure that door gasket s are sealing properly Select manual defrost and ensure system works 4 Notes 42 FOSTER Foster European Operations France Foster Refrigerator France SA Tel 33 01 34 30 22 22 Fax 33 01 30 37 68 74 Email commercial fosterfrance com Germany Foster Refrigerator Gmbh Tel 49 781 990 7840 Fax 49 781 990 7844 Email info foster gmbh de Foster Refrigerator Oldmedow Road Kings Lynn Norfolk PESO 4JU Tel 0843 216 8833 Fax 0843 216 4707 Website www fosterrefrigerator co uk Email support foster uk com a Division of ITW UK Ltd BCHILLEROA SURF DIAL amp CLICK SM 10
13. process to reduce the temperature of cooked food by swiftly arresting the cooking process locking in its colour flavour texture and nutritional value Department of health guidelines state that to safely blast chill food the temperature must be reduced from 70 to 3 c within 90 minutes Pre Chill ensures the correct cabinet temperature in the unit before chilling commences therefore improving the chilling performance Blast freezing also helps keep food looking good The slower food freezes the larger the ice crystals are formed and ice crystals can damage food dry it out and break down the physical structure leaving you with an unrecognisable product The blast freezing process requires that the food temperature be reduced from 70 to 18 c in no more than 240 minutes Soft Chilling Soft chilling is the process of rapid but gentle chilling of food This cycle brings down the food temperature to 3 c in no more than 90 minutes without the air or food temperature going below 0 c This prevents large ice crystals forming therefore maintaining the texture consistency and appearance of food such as vegetables rice pasta custard and fruit with no dehydration or cell damage Hard Chilling Hard chilling is the process of general purpose chilling This cycle brings down the food temperature to 3 c in no more than 90 minutes and is ideal for chilling meat pies lasagne pasta and individually portioned meals The air temperatur
14. temperature Wind Chill Effect This may lead to product discoloration dehydration localised freezing and spoilage of the food product ourface protection overcomes this by reducing the evaporation operation and hence the air speed at pre determined stages in the cycle to ensure that this does not happen This is a discreet function and happens automatically without any intervention from the operator To enable the surface protection and determine at what stage it would be activated values are set in the service operating parameters Longer Term Storage Hold Mode Conservation Upon the completion of the blast chilling cycle the controller will automatically enter the Hold mode This will either be because the selection set time has elapsed or the product core temperature has been achieved When the hold period commences an alarm will sound for a period denoted in the service operating parameters The controller will determine the temperature to be maintained during the hold phase based on the chilling or freezing cycle that has been completed If a soft or hard chill has taken place the controller will maintain an air temperature of 2 c if a shock freeze is completed the air temperature of 21 c will be maintained The hold mode is principally intended as a temporary storage facility offering the operator flexibility until the product can be unloaded into a longer term storage units at the correct storage temperature On occasion t
15. to 120 enabled set the time between 1 and 120 to determine the length of the program P59 HACCP Enable Determines whether the logging system is available to the user Function YES enabled NO disabled P60 Shock Freeze Temp Allows for the probe to be used in the Shock Freeze mode Function YES enables NO disables P61 Chill Hysteresis Allowable temperature increase from chill cycle air temperature Set Point before switching on the refrigeration system Range 02 to 20 P62 Hold Hysteresis Allowable temperature increase from hold cycle air temperature Set Point before switching on the refrigeration system Range 02 to 20 P63 Time Automatic Program Mode Time The time period that must pass before the air temperature and Food Probe 1 temperature are compared to determine whether the cycle is time or temperature based 00 Instantaneous decision 01 to 30 the time selected determines the start time decision P64 APM Differential Automatic Program Mode Differential The difference in temperature between the air temperature and food probe 1 temperature after APM time to determine whether the cycle is time or temperature based If air probe temperature the APM differential is greater than or equal to food temperature the chill cycle will be time based If air probe temperature APM differential is less than the food probe temperature the chill cycle will be temperature based Range 0 K to 20K P65 FAN 1
16. 10 43
17. DER WILL NO LONGER BE REQUIRED WHEN REPLACING THE CONTROLLER AND THE CABLES NETWORK CONNECTION CARD AND PCB BOARDS HAVE REMAINED THE SAME This manual provides information on both controllers Introduction and Cabinet Descriptions Cabinet Blast Chiller amp Freezers The entire cabinet range incorporate the refrigeration system mounted on the bottom of the unit with the evaporator located on the back wall The controls are located in the unit covers and the fan switches are operated by the door When the door is open the fans will stop Each have a dished base with drain to the vaporisation tray located in the unit compartment The Range BC11 BCF11 QC11 BC 21 BCF21 BC36 all 230 1 50Hz 13amp it is important to note that the BC36 13 amp option the chilling capacity reduces to 30kg BC11 BC36 230 1 50Hz 16amp option has 36kg capacity BCF36 BC51 BCF51 all 400 3 50Hz Capacities BC11 Blast Chiller 11kg capacity with three GN1 1 shelves BCF11 Blast Chill Shock Freeze 11kg capacity with three GN1 1 shelves QC11 Economy Blast Chiller 11kg capacity with three GN1 1 shelves BC21 Blast Chiller 21kg capacity with six GN1 1 shelves BCF 21 Blast Chill Shock Freeze 21kg capacity with six GN1 1 shelves BC 36 Blast Chiller 36kg capacity 13amp option 30kg capacity with ten GN1 1 shelves BCF 36 Blast Chill Shock Freeze 36kg capacity with ten GN1 1 shelves BC 51 Blast Chiller 51kg capacity with fourteen GN1 1 she
18. HARD CHILL The availability of these is dependent on how the controller has been configured The example shows the controller in Hard Chill mode with the previous and next programs indicated at the top of the display To change the program rotate the dial or click wheel by lightly touching with your finger either clockwise or anticlockwise to select the type of program you require for guidelines refer to page 8 amp 9 HARD CHILL TEE hen to Start Mete After which the intelligent probe determines if the cycle is controlled either by time as in above image or by temperature as displayed in the lower image NOTE On early versions of the controller the time displayed was 2 minutes a HOLD de On completion of the program the controller will cause the Blast Chiller to enter the Hold Mode as displayed on the left An alarm will sound press and release the dial or centre 00 0 0 button to cancel the alarm If the alarm is cancelled the Blast Chiller will still enter m the Hold Mode with the periodical sounding of the alarm To cancel press and release the dial or centre button Press to Mute To stop the Blast Chiller during operation press and hold the dial or centre button for 2 seconds the display returns to the program selection screen Hard Chill 11 20 9 31 START 4 5 gt FINISH 02 81 04 29 HE 4 5 n Pre Chill
19. Hold Operation Determines the evaporator fan relay energisation during Hold mode OFF Evaporator fan 1 relay is not energised in Hold CYCLE Evaporator fan 1 relay cycles with condensing system relay in Hold AUTO Evaporator fan 1 relay cycles with condensing system and fan hysteresis in Hold ON Evaporator fan 1 relay is always energised in Hold Note The fan 1 hold operation does not affect routine defrost operation P66 FAN 2 Hold Operation Determines the evaporator fan relay energisation during Hold mode OFF Evaporator fan 2 relay is not energised in Hold CYCLE Evaporator fan 2 relay cycles with condensing system relay in Hold AUTO Evaporator fan 2 relay cycles with condensing system and fan hysteresis in Hold ON Evaporator fan 2 relay is always energised in Hold Note The fan 2 hold operation does not affect routine defrost operation P67 Capacity Control Enable Determines if capacity control is enabled OFF Capacity Control is disabled AUTO Capacity control is enabled in chill and hold modes in conjunction with P68 Capacity Control Hysteresis ON Capacity is enabled in hold mode only in conjunction with P68 Capacity Control Hysteresis 21 P68 Capacity Control Hysteresis The function of Capacity Control is to reduce the refrigeration capacity of the condensing unit du
20. J3 HOLDTEMP J 5 5 J3 1 1 1 HARD CHILL NEN ARTEMP 115115 POS 1CHLLTME _ MINUTES s fo _ _ dn Pu 14 HOLD TEMP SHOCKFREEZE PROFFESSIONAL 1 2 Air Temp Std P23 Chill Time Std Minues 4 P25 90 P24 Chill Time Minimum Minutes 5 60 15 P25 Chill Time Maximum Minutes 60 495 240 P30 Hold Temp Minimum 40 Jo 0 2 P31 Hold Temp Maximum 0 10 10 P32 GhageTime 7 5 9 90 P33 7 ChaneTemp 5 9 80 PROFFESSIONAL2 P35 Chill Time Std Minues 6 P837 90 P36 Chill Time Minimum Minutes 5 60 5 P37 Chill Time Maximum Minutes 60 4050 P42 Hold Temp Minimum 40 Jo O 2 P43 Hold Temp Maximum 0 10 10 P44 COhageTime 7 5 95 80 2 P45 ChaneTemp 5 9 80 PROFESSIONAL3 1 1 P47 Chill Time Std Minutes P48 9 90 P48 Chill Time Minimum Minutes 5 60 55 P49 Chill Time Maximum Minutes 60 480 240 P54 Hold Temp Minimum 40 Jo O P55 Hold Temp Maximum C Jo 10 10 P56 ChangeTime _ 15 9 800 P57 ChaneTemp SHO SYSTEM 144 P58 UV Light Enable Minutes 0 710 40 2 P60 Shock Chill Temp Function NO YES NO P63 APMTime 0 7390 10 2 P64 APM Differential K 10 20 P66
21. P HOLD TEMP TNFORMATTON SETTINGS PRIN GATA SET TIME DATE CONTRAST Preece 2 Xe0 vu 1 8 a Then rotate the dial click wheel clockwise to increase the time and anticlockwise to CHILL TEMP decrease 4 Once the time has been selected press and release the dial or centre button and HACCP SETTINGS HOLD TEMP will be highlighted Follow the procedure for changing chill temp to E TATE change the hold temp CONTRAST On completion press and hold the dial or centre button for 2 seconds to return to the program selection screen to continue press and release the dial or centre button for the program to start The chill time and chill hold temperature adjusted settings are retained for Professional 1 2 and 3 programs and will not revert to the default Information uti Whilst in the program selection screen press and hold the dial or centre button for 2 d Th T seconds the information screen will be displayed Rotate the dial or click wheel until INFORMATION is highlighted Press and release the dial or centre button to display Tor the screen showing the last run cycle The information relates to date program run start Xr A 22 time start temperature and end temperature HACCP Settings Whilst in the program selection screen press and hold the dial or centre button for 2 seconds the information screen will be displayed
22. PRE CHILL Defrost DEFROST 455 43 4 DEFROST 9 9 DEFROST 4 45 At any time when the Blast Chiller is operational the dial or click wheel can be rotated to give information on the status of the particular mode of operation The display will remain for 10 seconds and then revert to the normal operating screen automatically This program is used to Pre Chill the cabinet prior to the first cycle This is done with the Blast Chiller empty and is a short time based program of about 20 minutes It is generally recognised as the correct method of preparing for a Blast Chill cycle The program is selected by rotating the dial or click wheel until the display shows press and release the dial or centre button to start the program Defrosting is not normally required but if there is an ice build up on the coil inside the cabinet a manual defrost can be selected Rotate the dial or click wheel until the Defrost screen is displayed Press and release the dial or centre button to start defrost During defrost the screens will alternate between the two screens shown on the left Defrost will last 20 minutes and when completed the alarm will sound Press the dial or centre button to acknowledge or if not wait until it comes to the end of the alarm period The alarm will stop and the display will revert to the previous screen Further Operational Features Chill Time Adjustment All programs excluding P
23. T HARD CHILL DE 1 Hand Chill CHILL TEMP HOLD THFORMATION SOCP SETTINGS PRINT DATA SET CONTRAST Presa 2 End t SERVICE DIAGNOSTICS FOOTPRINT SERVICE DIAGHOSTICS FOOTPRINT PASSCODE SERVICE changes to the controller settings When mains electrical power is first applied to the controller it will carry out a self test function for approximately 3 seconds This is to ensure that there are good connections between the component parts During this period the display shown to the left will show The information displayed in the centre of the screen refers to which of the profiles the controller is set for The software version relates to the software release with the number relating to the major operating changes or model variants The letter relates to the minor operating changes that may have been made from the original such as parameter settings On completion of the self test the controller will revert to the last chill program that was run Pre chill Soft Chill Hard Chill Hard Chill Max Shock Freeze Professional 1 Professional 2 or Professional 3 The availability of these is dependent on how the controller has been configured The example shows the controller in Hard Chill Press and hold the dial or centre button for 5 seconds The first display will show the information page Continue pressing until the SERVICE s
24. TTTTTITI E FPS DOR CORE Rs 4m DSFLAr Te Bi B EL TRAY HESTER MOTES L GABLE CHE L ML CABLES ARE Imm WHLESS STATED SAN DES BLAST CHILLER 1 233732 00 02 ie oa eee RE te edP Geese Do e FOSTER REFRIGERATOR LTD Bera BFE SHEET 1 oF 1 oo TER FD RED OLDMEDON ROAD EING E LYNN WORFDLE PEM HU DEDI M o vo o om um mM Troubleshooting Problem Possible Cause Compressor will not start No voltage in socket Use voltmeter to check cut continuity Defective electrical component thermostat relay thermal protector etc Measure ohmic resistance of main and auxiliary winding using ohmmeter Compare with correct values Compressor stuck Change compressor a control contacts are Check wiring diagram and correct 2 Replace fuse or reset circuit breaker Power cord unplugged Plug in power cord Controller set too high Set controller to lower temperature Cabinet in defrost cycle Wait for defrost cycle to finish oet to warmer position and check if i y the compressor stops according to position controllers operating range Controller does not disconnect the cheer condensing unit thermostat If problem persists change the thermostat Change th
25. after 570 seconds from start of test for 20 seconds de energises 420 seconds from start de energises 570 seconds from start de energises 540 seconds from start de energises 600 seconds from start de energises 450 seconds from start de energises 590 seconds from start omm dcm ccc All relays are de energised on completion of the test At any point during the test pressing and holding the dial or centre button for 2 seconds can stop it The test will be terminated and the display will revert to the last run cycle Upon normal completion of the test the display will revert to the last run cycle not the service parameters Probes Air and Evaporator Probes The air and evaporator probes are the same and are identified as T1 Air Probe and T2 Evaporator Probe These are the thermistor type and are fully enclosed to make it completely waterproof and resilient to temperature variation within the limits of rapid cycling The probe is capable of measuring temperature in excess of 30 C and 50 C with 1 K accuracy at 1 C and no more than 2 at the upper and lower temperature ranges Food Probe The food probe is inserted directly into the product that is being chilled to measure the core temperature The resistance values are the same as for the air and evaporator probes Probe temperature resistance values 0425 105 0166 115 0 099 0 683 65 70 143 75 067 80 85 90 95
26. ature set point to 1 C The range is adjustable in 5 increments Range 05 to 95 18 P33 Change Temp The percentage of a temperature based chill cycle which is passed before automatically adjusting the air temperature set point to 1 C The range is adjustable in 596 increments Range 5 to 95 Professional 2 P34 P35 P36 P37 P38 P39 P40 P41 P42 P43 P44 Air Temp Std The standard temperature which the air probe must read before the condensing system is de energised in the chill mode of the Professional 2 Program Range 20 C to 15 C Chill Time Std The standard period Professional 2 program is in chill mode prior to entering Hold mode in a time based chill cycle Range 5 minutes to 480 minutes Chill Time Minimum The minimum period Professional 2 program is in chill mode prior to entering Hold mode in a time based chill cycle that it can be adjusted to by the operator Range 5 minute to 60 minutes Chill Time Maximum The maximum period Professional 2 program is in chill mode prior to entering Hold mode in a time based chill cycle that it can be adjusted to by the operator Range 60 minute to 480 minutes Chill Temp Std The standard temperature which the Food Probe 1 must read before the condensing system is de energised in the chill mode of the Professional 2 program prior to entering the Hold mode of a temperature based cycle Range 15 to 15 C Chill Temp Minimum Th
27. based cycle which it can be adjusted to by the operator Range 20 C to 5 C Chill Temp Maximum The maximum value that the temperature which Food Probe 1 must read before the condensing system is de energised in the chill mode of the Professional 3 program prior to entering the Hold mode of a temperature based cycle which it can be adjusted to by the operator Range 5 C to 15 Hold Temp Std The standard temperature which the air probe must read before the condensing system is de energised in the Hold mode of the Professional 3 Program Range 15 C to 15 C Hold Temp Minimum The minimum value that the Hold temperature set point can be adjusted to by the operator in the Professional 3 program Range 10 C to 0 C Hold Temp Maximum The maximum value that the Hold temperature set point can be adjusted to by the operator in the Professional 3 program Range 0 C to 10 C Change Time The percentage period of a time based chill cycle which is to have passed before automatically adjusting the air temperature set point to 1 C The range is adjustable in 5 increments Range 05 to 95 20 P57 Change Temp The percentage of a temperature based chill cycle which is passed before automatically adjusting the air temperature set point to 1 C The range is adjustable in 5 increments Range 5 to 95 System P58 UV Light Enable Determines whether the user can select the UV sanitisation Minutes 0 disabled 1
28. chill cycle 160 chill time recordings 3 minute intervals 840 hold time recordings 15 minute intervals Total time span 218 hours 9 days 2 hours 480 minute maximum chill cycle 96 chill time recordings 5 minute intervals 904 hold time recordings 15 minute intervals Total time span 234 hours 9 days 18 hours Total time span 247 hours 10 days 7 hours Once the controller memory is full the controller will stop It will not over write the memory until a new chill cycle has started Technical Data BC51 BC51 QC BC11 BC21 BC36 Integral Nominal Chilling Capacity 11Kg 21Kg 36Kg 5 Kg Duty 15 C 82 1182w 19099 2756 Fans 1 1 7 2 72 1 27 Defrost Load amps Evaporating Temperature Refrigerant Control Refrigerant R404a R404a R404a R404a R404a 25509 25509 Refrigerant Quantity 1000g 2700g 230 1 50 400 3 50 230 1 50 16amp 16 amp per phase Electrical Supply 1500g 230 1 50 230 1 50 16amp 13amp 13amp Watts 738 Watts 1089 Watts 1994 Watts Watts 2435 Per Phase Gonsumplign Amps 3 44 qM 5 1 9 05 EB 5 95 Per Phase Power absorbed W Total Heat Rejection _ _ 51 51 Nominal Chilling Capacity ZEE uM ae 24 myene e n3 i w Fas i 8 8 8 Deroslosdamps 05
29. creen is displayed For changes to language see page 10 In the Service screen rotate the dial or click wheel until you reach Diagnostics Press and release the dial or centre button to highlight the component In this program you can test each of the major components on the machine in sequence 1 COMPRESSOR 2 FAN1 3 FAN2 4 DEFROST 5 ALARM 6 CCAP Capacity Control 7 UV L UV light if fitted ESC escape Rotate the dial or click wheel until the relay output is highlighted Once selected press and hold the dial or centre button to test the relay The relay will remain energised for as long as it is pressed 12 SERVICE Function Test Passcode y LANGUAGE _ HAGNISTICS T UNP FOOTPRINT y SEWICE _ SEWICE SIMPLE On completion of the test you must rotate the dial or click wheel until you highlight ESC press and release the dial or centre button to move to the next program Rotate the dial or click wheel until you reach FOOTPRINT press and release the dial or centre button to initiate the controller function self test oelf test allows the engineer to test the operation of the machine without having to wait for a full program to run The test lasts for ten minutes and should be carried out with the cabinet room empty Each of the relays will be energised to simulate the chill process Relay 1 COMPRESSOR Relay 2 FAN1 Relay 3 FAN2 Rela
30. door is open the fans are off The evaporator is wall mounted and uses R404a refrigerant with the option of Glycol cooling available The evaporator also has a drip tray beneath it with a stainless steel tube attached for connecting a 22mm Conex compression elbow Depending on the drain exit position a 35mm hole be placed through the wall panel at the front side or rear to allow a fall from the pan to an external drain Blast Chillers are supplied floorless whereas the Blast Freezer come with a 25mm built in floor The Range MBC 75 100 150 700mm and 900mm door opening 230 1 50Hz 20amp supply separate supply required for condensing unit MBC 250 700mm and 900mm door opening 400 3 50Hz 16amp supply separate supply required for condensing unit MBC 75 100 150 250 700mm and 900mm door opening 400 3 50Hz supply separate supply required for condensing unit Capacities MBC 75 Blast Chill shock Freeze 700mm and 900mm Door openings Chilling and nominal freezing capacity 75kg 1 x trolley MBC 100 Blast Chill shock Freeze 700mm and 900mm Door openings Chilling and nominal freezing capacity 100kg 1 x trolley MBC 150 Blast Chill shock Freeze 700mm and 900mm Door openings Chilling and nominal freezing capacity 150kg 1 x trolley MBC 250 Blast Chill shock Freeze 700mm and 900mm Door openings Chilling and nominal freezing capacity 250kg 2 x trolleys Operations Cook Chill Operation Blast chilling is a
31. e Time The percentage period of a time based chill cycle which is to have passed before automatically adjusting the air temperature set point to 1 C The range is adjustable 5 increments Range 05 to 95 P13 Change Temp The percentage of a temperature based chill cycle which is passed before automatically adjusting the air temperature set point to 1 C The range is adjustable in 5 increments Range 5 to 95 Hard Max P14 Air Temp The temperature which the air probe must read before the condensing system is de energised in the Chill mode of the Hard Chill Max Program Range 20 C to 15 C P15 Chill Time The period Hard Chill Max program is in Chill mode prior to entering Hold mode in a time based chill cycle Range 5 minutes to 480 minutes P16 Chill Temp The temperature which the Food Probe 1 must read before the condensing system is de energised in the Chill mode of the Hard Chill Max program prior to entering the Hold mode of a temperature based cycle Range 15 to 15 C P17 Hold Temp The temperature which the air probe must read before the condensing system is de energised in the Hold mode of the Hard Chill Max program Range 15 C to 15 C Shock Freeze P18 P19 P20 Air Temp The temperature which the air probe must read before the condensing system is de energised in the Chill mode of the Shock Freeze Program Range 35 C to 15 C Chill Time The period Shock Freeze program is in Chill mode pr
32. e control Check Control contacts are stuck closed Defective or incorrect temperature Determine correct control and control replace The temperature is not cold Controller is set at a very warm Adjust to colder setting enough position The unit must not be near stoves walls that are exposed to the sun or places that lack sufficient air flow Compressor motor has a winding open or shorted The temperature is too cold The refrigerator has been placed at an inadequate location Compressor is inefficient or there is a high pressure due to the air in the system If there is air in the system purge and recharge Check temperature control refrigerant charge and defrost mechanism Remove all ice OA Iced up evaporator coil manually and start over TER Locate exact point of restriction and y correct Check to see if condensation or ice The refrigerator has been crystals have formed on the suction overcharged with the refrigerant gas line If so charge with the correct amount of gas E Find the location of gas leak in order to seal and replace the defective The refrigerant gas is leaking component Change the drier Perform a good vacuum and recharge unit M 40 Check electrical connections and The evaporator and or condenser make sure that the fan blade isn t fans are not working stuck Replace the fan motor if it doesn t work Re arrange product to allow for aS
33. e for this process goes down to 15 c for the first 7096 of the cycle to extract the maximum amount of heat from the product quickly The air temperature then increases to 3 for the final 30 of the time to reduce surface damage and ensure quality Hard Chill Max Hard chill max brings down the food temperature to 3 c in no more than 90 minutes and is used for chilling high density or high fat content food such as meat joints stews or packaged products The air temperature during the cycle is allowed to go down to 20 c After either a pre designated time has elapsed or product temperature has been achieved the air temperature is allowed to rise to the hold value with the temperature being maintained at this level indefinitely Shock Freeze Shock freeze is the process of reducing the food product temperature to 18 c in less than 240 minutes Once in the frozen state longer term storage is enabled The air temperature during the freeze mode will be 35 c to 40 c The actual duration would depend on several factors including the type of product load how it is packaged and the initial entry temperature Surface Protection Removing the heat energy from food product as rapidly as possible by the combination of powerful refrigeration and evaporator fans moving large volumes of cooled air can cause damage to the food product The food product could have a form of Frost Burn caused by the fast moving air feeling cooler than the actual air
34. e minimum value that the temperature which Food Probe 1 must read before the condensing system is de energised in the chill mode of the Professional 2 program prior to entering the Hold mode of a temperature based cycle which it can be adjusted to by the operator Range 20 C to 5 C Chill Temp Maximum The maximum value that the temperature which Food Probe 1 must read before the condensing system is de energised in the chill mode of the Professional 2 program prior to entering the Hold mode of a temperature based cycle which it can be adjusted to by the operator Range 5 C to 15 Hold Temp Sid The standard temperature which the air probe must read before the condensing system is de energised in the Hold mode of the Professional 2 Program Range 15 to 15 C Hold Temp Minimum The minimum value that the Hold temperature set point can be adjusted to by the operator in the Professional 2 program Range 10 to 0 Hold Temp Maximum The maximum value that the Hold temperature set point can be adjusted to by the operator in the Professional 2 program Range 0 C to 10 C Change Time The percentage period of a time based chill cycle which is to have passed before automatically adjusting the air temperature set point to 1 C The range is adjustable 5 increments Range 05 to 95 19 P45 Change Temp The percentage of a temperature based chill cycle which is passed before automatically adjust
35. for both the cabinet and modular Blast Chiller controller For simplicity the diagrams below show just the cabinet variant but the principles can be directly applied to modular versions Prior to starting it is necessary to ensure that the controller has been correctly configured to allow printing and that the printer has sufficient battery charge and is correctly loaded with paper Note It is not possible to print details of a Pre Chill or Defrost cycle the last chill cycle details will be printed 1 With the blast chiller in Standby mode ARD not running a chill cycle or in half mode SOFT CHILL press the operating dial or centre button for 2seconds Press 12 Start Turn do Select 2 The display will show the Program Information Menu Rotating the dial or click wheel scroll down until PRINT DATA is highlighted 3 Press the black button 1 on the top of the printer to switch it on Align the printer LED lens 2 with the Blast chiller LED window 3 The lens and window should be directly facing each other and about 300mm 450mm 12 18 apart Press and releases the Blast Chiller operating dial or centre button 4 Once the printing has been complete 4 PRE CHLL HARD CHIL gt the display will revert to the Program SOFT CHILL selection menu Further copies of the x printout can be produced as required following the same procedure as in detailed in Points 1 to 3 Press
36. from the supplier website at http www custom it ing wireless O1 02 htm 21 Enabling the Printer Function The logging and printing system is enabled through the Service Parameters in the following manner 1 With the blast chiller in Standby mode not running in chill cycle or in hold mode press the operating dial or centre button for 5 seconds to show the SERVICE menu 3 Press and release the operating dial or centre button The display will change to highlight the PASSCODE value 5 The display will show the operating profile menu with SIMPLE highlighted 7 The display will show the operating program parameter setting screen with RE CHILL highlighted 9 The display will show the individual system parameters with UV Light Time highlighted 11 The display will show the value of HACCP Enable typically NO highlighted Rotate the dial or click wheel until the value changes to YES SERVICE 1 COMP m Z E 08 2 p 22222 Press 2 Sec for Exit G SERVICE 1 COMP m 2 E O 27 Press 2 Sec for Exit SERVICE gt gt gt po EXPERT 5 5 AUTO G SYSTEM 0 min AUTO 2 Min O gt gt 3 22 8 8005 2 2 2 2 Rotate the operating dial or click wheel to change the highlighted section on the display from LANGUAGE to PASCODE 4 Rotate the dial or click whee
37. have been printed check to see if they are the same as shown in the listing below SETUP DEFAULT 40 Col HEAD TEMP C 22 5 BATT TEMP C 22 5 indicates the status of the printer HEAD VOLT V 5 4 INTERFACE Infrared IR Protocol Enabled Baud Rate 9600 bps Data Length 8 Bits chr Parity None Handshaking XON XOFF Autofeed CR Enabled Battery 1850 mAh Standby 60 min Columns 40 col Print Mode Normal Aligment Disabled Print Dens 0 If the print out differs in any way change the settings to suit those listed To change the settings press and hold the button when the printer starts to print release the button and the first setting Interface Infrared will be printed If the setting printed defaults to an Interface RS232 a setting change is required change the setting by pressing and releasing the button Interface Infrared will be printed To save the change press and hold the button when the printer starts to print release the button and the next settings IR Protocol Enabled will be printed If this differs i e IR Protocol Disabled change the setting as previously described Continue through the settings and change accordingly NOTE Handshaking XON XOFF is not changeable Once all of the changes have been completed the new settings will be printed followed by PRINTER RESET the printer is now ready for use 30 Printing Operation The printing operating is identical
38. his hold period may become extended to operate overnight or to provide emergency refrigeration backup In such instances defrosting would automatically occur as necessary Controller Information Surf Navigation FCC Dial Used until June 2008 Display 00 555394 Dial Button 01 233329 01 Dial Shaft Encoder 00 555396 Surf Navigation FCC Click Wheel Introduced June 2008 Display 00 556021 Click Wheel 00 556020 Probes both controller types have the same Air Probe SN2K25P1 00 555909 Evaporator Probe SN2K25P2 00 555910 Food Probe 00 555663 Controller Description The FCC Dial Controller is a three piece unit made up of the Front Display and Dial Shaft Encoder Mother Board plus Evaporator Food and Air temperature probes The front display PCB and the CPU Switching PCB unit are interconnected by a ribbon cable The membrane attached to the front provides an IP rating of IP54 providing a scratch free wipe clean finish The control dial is the method by which the controller is accessed for all requirements It has three planes of movement clockwise anticlockwise and inwards The control dial allows the operator engineer to move forward and backwards through various menu selections shown on the display and enter a desired programme The control system will then respond appropriately either commencing the operating cycle or allowing further configuration The Click Wheel version works in the same way but in
39. ing the air temperature set point to 1 C The range is adjustable in 596 increments Range 5 to 95 Professional 3 P46 P47 P48 P49 P50 P51 P52 P53 P54 P55 P56 Air Temp Std The standard temperature which the air probe must read before the condensing system is de energised in the chill mode of the Professional 3 Program Range 20 C to 15 Chill Time Std The standard period Professional 3 program is in chill mode prior to entering Hold mode in a time based chill cycle Range 5 minutes to 480 minutes Chill Time Minimum The minimum period Professional 3 program is in chill mode prior to entering Hold mode in a time based chill cycle that it can be adjusted to by the operator Range 5 minute to 60 minutes Chill Time Maximum The maximum period Professional 3 program is in chill mode prior to entering Hold mode in a time based chill cycle that it can be adjusted to by the operator Range 60 minute to 480 minutes Chill Temp Std The standard temperature which the Food Probe 1 must read before the condensing system is de energised in the chill mode of the Professional 3 program prior to entering the Hold mode of a temperature based cycle Range 15 C to 15 C Chill Temp Minimum The minimum value that the temperature which Food Probe 1 must read before the condensing system is de energised in the chill mode of the Professional 3 program prior to entering the Hold mode of a temperature
40. int Function The printing function can be configured by the user in two ways to tailor the system to their specific requirements These are Data Rate Which is the frequency of or interval between temperature recordings during the chill cycle Type This determines if a complete time and temperature or summary printout is produced The logging and printing system is configured through the controller in the following manner x PIRE CHILL HARD CHILE gt 1 With the blast chiller in Standby mode not running a chill cycle or in hold mode press the operating dial or centre button for 2 seconds Prove to Juri Tun fo SOFT CHILL 2 The display will show the Program Information Menu Rotating the dial or click wheel scroll down until HACCP SETTINGS is highlighted 3 Press and release the dial or centre button This will cause the controller to display the HACCP SETTINGS menu 4 DATA RATE will be displayed highlighted This is the time interval between temperature values being recorded and subsequently printed during the chill part of the cycle 5 Pressing and releasing the dial or centre button will cause the value to be highlighted The data rate may then be changed from 3 minutes to 5 minutes by rotating the dial or click wheel Once the required value is displayed the dial or centre button is pressed to set it 6 From Point 4 the dial or click wheel can be rotated or by foll
41. ior to entering Hold mode in a time based chill cycle Range 5 minutes to 480 minutes Chill Temp The temperature which the Food Probe 1 must read before the condensing system is de energised in the chill mode of the Shock Freeze program prior to entering the Hold mode of a temperature based cycle Range 15 C to 15 C 17 P21 Hold Temp The temperature which the air probe must read before the condensing system is de energised in the Hold mode of the Shock Freeze program Range 35 C to 15 C Professional 1 P22 P23 P24 P25 P26 P27 P28 P29 P30 P31 P32 Air Temp Std The standard temperature which the air probe must read before the condensing system is de energised in the Chill mode of the Professional 1 Program Range 20 C to 15 C Chill Time Std The standard period Professional 1 program is in chill mode prior to entering Hold mode in a time based chill cycle Range 5 minutes to 480 minutes Chill Time Minimum The minimum period Professional 1 program is in chill mode prior to entering Hold mode in a time based chill cycle that it can be adjusted to by the operator Range 5 minute to 60 minutes Chill Time Maximum The maximum period Professional 1 program is in chill mode prior to entering Hold mode in a time based chill cycle that it can be adjusted to by the operator Range 60 minute to 480 minutes Chill Temp Std The standard temperature which the Food Probe 1 must read
42. l to change the displayed PASSCODE value to 131 Press and release the dial or centre button to enter the service program menu 6 Rotate the dial or click wheel to highlight the selected indicated by symbol gt gt gt beside the name or the required operating profile Press and release the dial or centre button 8 Rotate the dial or click wheel until the display changes to show SYSTEM highlighted on a page by itself Press and release the dial or centre button 10 Rotate the dial or click wheel to highlight the parameter HACCP Enable Press and release the dial or centre button 12 With the value changed the dial or centre button should be pressed and released The display will automatically highlight the next parameter Shock Chill Temp the dial or centre button should then be pressed and held for 2 seconds to exit the Service Settings menu 28 SERVICE 1 COMP m 2 Press 2 Sec for Exit SERVICE 131 1 COMP m 2 Press 2 Sec for Exit SERVICE SIMPLE ed EXPERT Press 2 Sec for Exit Q SYSTEM 0 min 2 Min Press 2 Sec for Exit zz AUTO SYSTEM 0 min in If this procedure is not followed and the HACCP Enabie parameter is not cnangea to YES the controller will not output any information to the printer or other device when asked to perform this function N alz lt m Q7 AUTO Configuring the Pr
43. ler STATIS Ee Blast H Hold Duration is the total length of time of the O Oefrast chill cycle Determined by the use of the Start Temp is the initial temperature recorded by the food probe Time Th TA ill ti u i uired ee e o E a 4 943 84 70 Status definitions as used the status E 08 36 gs column End Temp is the final temperature B i E ep recorded by the food probe before the 52 cabinet enters the Hold mode E 09 42 x 05 45 92 2 B A Full report column header B dE LL Depending on how the controller is ST indicates STATUS E 09 55 41 41 28 configured depends on how much E vay 7o u report is printed TIME indicates Time at which temperature 34 355 was recorded B 09 00 n zo If the TYPE of report is set to B pans iz T 55 SHORT only this summary section Ta indicates cabinet air temperature B 27 20 m will be printed Alternately if the TYPE were set to 1 indicates controlling food probe B 09 09 a FULL eile report would temperature E 332 2 24 produced ix nd E T2 indicates 2 food probe temperature for jp 18 information only if this is not fitted print out E 05 16 i i shows B 09 21 1 14 2 T3
44. lves BCF 51 Blast Chill Shock Freeze 51kg capacity with fourteen GN1 1 shelves Roll In Cabinet Blast Chillers amp Freezers The Roll In models have top mounted refrigeration systems compressor supplied and installed by Foster dealer using R404a refrigerant The evaporator is located on the rear wall of the cabinet with the fans being operated by the door switch When the door is open the fans will stop The Range BCCF 1 has a drip tray beneath the evaporator with drain tube exiting the bottom of the cabinet into the vaporiser tray located on slides attached to the base of the cabinet BCF RI 1 has a drip tray beneath the evaporator with the drain tube exiting the cabinet at the back left hand side viewed from the rear into a heated vaporisation tray attached to the rear of the cabinet BCCF1 BCF RI 1 supply option 230 1 50 20amp condensing unit requires separate supply BCCF1 RI 1 supply option 400 3 50Hz condensing unit requires separate supply Capacities BCCF 1 Blast Chill Shock Freeze chilling capacity 75kg freezing capacity 15kg with racking 600x550x1590 BCF RI 1 Blast Chill Shock Freeze chilling capacity 75kg freezing capacity 15kg with Trolley 680x640x1825 Modular Blast Chillers amp Freezers There are 4 Blast Chiller Freezers and each are constructed from modular panels for easy installation With the choice of 700mm and 900mm door opening widths The fans are operated by door switches and so when the
45. ly fitted to the evaporator fan door on Modular Blast Chillers 22 P79 P80 P81 P82 P83 P84 P85 P86 P87 P88 P89 P90 Door Switch 1 Determines if a door switch is fitted or not and consequently dictates Evaporator Fan operation UV Sanitisation operation and door alarm activation s Also used to initiate the controller from the energy saving mode NO No door switch fitted YES Door switch fitted Door Stop The delay period between the door being opened and the condensing unit stopping only active if the Door Switch is set to YES 00 minutes Condensing unit stops instantaneously 01 to 30 minutes Delay before unit stops Door Alarm Delay The delay following the Door Stop period before the door open alarm sounds Therefore if the Door Stop is set for 1 minute and the Door Alarm is set to 5 minutes the door alarm will sound 6 minutes after the door was opened Only active if Door Switch YES 00 minutes instantaneous door alarm 01 to 30 minutes Delay before alarm sounds High Alarm Temp The temperature at which the alarm will sound to warn that the measured air temperature value is too high The alarm sounding is dependent upon the selected program and the stage of the cycle l e during chill cycle if the measured temperature is greater than or equal to program air set point temperature chill hysteresis high alarm temperature value after the ap
46. me selected or the weight of product being chilled does not exceed the specification for the cabinet Possible causes Is the evaporator iced up Are the evaporator fans working Check door switch operation for the fan s Loss of refrigerant or Compressor failure HP Switch Causes for this alarm could be Does the product temperature exceed 90 Has too much product been placed in the cabinet Is the airflow to the condensing unit restricted Does the condenser filter require cleaning Is the condenser fan working On a pump down system is the solenoid valve energising Is the HP switch faulty Is the HP switch set to the correct operating pressure For pressure settings see below HP Switch 28 Bar 3 Bar Diff G63 LP Switch 2 5 Bar 0 5 Bar Diff G60 Power Fail If the power fails for up to five minutes the unit will re start on the resumption of the power supply without affecting the selected cycle If it is longer than five minutes the controller will enter the hold mode To check the cycle operation look in the information screen to check the cycle time To re start press and release the dial or centre button the screen will return to the hold screen Press and hold the dial or centre button for two seconds the display will return to the program selection Foot Print Test Operation The foot print test is a method of checking the operation of the process in a reduced time period as it only takes 10 minutes The first ten seconds a
47. must read before the condensing system is de energised in the Chill mode of the Soft Chill Program Range 10 C to 15 C PO5 Chill Time The period Soft Chill program is in Chill mode prior to entering Hold mode in a time based chill cycle Range 5 minutes to 480 minutes Temp The temperature which the Food Probe 1 must read before the condensing system is de energised in the Chill mode of the Soft Chill program prior to entering the Hold mode of a temperature based cycle Range 5 C to 15 C P07 Hold Temp The temperature which the air probe must read before the condensing system is de energised in the Hold mode of the Soft Chill program Range 5 C to 15 C 16 Hard Chill Air Temp The temperature which the air probe must read before the condensing system is de energised in the Chill mode of the Hard Chill Program Range 20 C to 15 C PO9 Chill Time The period Hard Chill program is in Chill mode prior to entering Hold mode in a time based chill cycle Range 5 minutes to 480 minutes P10 Chill Temp The temperature which the Food Probe 1 must read before the condensing system is de energised in the chill mode of the Hard Chill program prior to entering the Hold mode of a temperature based cycle Range 15 to 15 C P11 Hold Temp The temperature which the air probe must read before the condensing system is de energised in the Hold mode of the Hard Chill program Range 15 to 15 C P12 Chang
48. n when handling or working on the unit as sharp edges may cause V personal injury we recommend the wearing of suitable PPE Ensure the correct moving and lifting procedures used when relocating a unit Do NOT use abrasive cleaning products only those that are recommended Never scour any parts of the refrigerator Scouring pads or chemicals may cause damage by scratching or dulling polished surface finishes Failure to keep the condenser clean may cause premature failure of the motor compressor which will NOT be covered under warranty policy Do NOT touch the cold surfaces in the freezer compartment Particularly when hands are damp or wet skin may adhere to these extremely cold surfaces and cause frostbite Please ensure the appropriate use of safety aids or Personnel Protective Equipment V PPE are used for you own safety 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 supplier
49. ng pressure Is achieved High Pressure Air Probe Fault Evaporator Probe Fault Food Probe Fault If more than 1 probe is enabled the probe fault would be displayed accordingly 24 Door 2 Open Will not allow any chill defrost or UV sanitisation programs to be run if the door is open Safety Door Ribbon cable between the power switching PCB and the display disconnected also displayed if there is a communication error with the printer function ommunication Alarms and Actions Air Probe If this alarm occurs it will remain in the program selected until it is completed however no further operation will be possible Action Check connections or replace faulty probe Evap Probe If this alarm occurs it will remain in the program selected until it is completed However no further operation will be possible Action Check connections or replace faulty probe Food Probe If this alarm occurs it will automatically change to a timed program until it is completed further operation will be possible using time chill Action Check connections or replace faulty probe Door Open The display will continue to show the alarm message until the door is closed If this does not cancel the alarm check connections or replace faulty probe High Temperature This alarm will only occur in the hold mode Probe the product to determine it is at the correct temperature If the product temperature is above the guidelines check the chill ti
50. ograms are all available depending upon which of the profiles are selected see table below To change the profile rotate the dial or click wheel to select program press and release the dial or centre button to accept the change The 3 chevrons in the box opposite the selected program confirm the change The default operating profile is CHEF 13 This table identifies which programs are available from the profile selected fx _ x X v 1v lY orci HARD CHILL PROFESSIONAL x X x X X LY v X x x erros v 7 7 PTIONAL PTIONAL Parameter Access EXPERTS i OL From the profile screen once the selection has been made press and release the dial MAY or centre button to access the parameter list The screen will display the parameters as oe shown in the screen to the left PROFESSIONAL 2 PROFESSIONAL 3 Prous 2 Xe fer f To access the system parameters rotate the dial or click wheel anticlockwise oelections are made by pressing and releasing the dial or centre button The next table contains the complete parameter list and includes the selectable range and default values Parameters PARAMETER DESCRIPTION VALUE see MAXIMUM DEFAULT PRE CHILL pos Gri TIME MINUTES e Fs SOFT CHILL pd CHILLTIME MINUTES 5 400 90 2 PO6 CHLLTEPP 15 15
51. old mode Range 0 C to 10 C Drain Time The time period following the defrost routine terminated by time or temperature that is allowed for melt water to drain from the evaporator coil prior to the condensing system restarting 00 No drain down time 01 to 30 Drain down period in minutes Fan delay Temp The temperature the evaporator coil must reach following a defrost before the evaporator fan s are allowed to re start Range 15 to 15 C Duty Cycle The percentage time that the condensing system will operate in order to maintain Hold temperature in the event of an air probe failure Range 0 to 100 Comp Rest Time The forced rest period before the condensing system can be energised from when it was de energised 00 Excludes compressor rest period 01 to 30 Compressor rest period in minutes Note This is not a compressor start delay HP Switch Terminates the condensing system in the event of a high pressure developing in the refrigeration system as a result of to high food temperature condenser fan failure blocked condenser air flow restriction etc Automatically re sets when the normal working pressure is achieved YES enabled NO disabled Door Switch 2 Determines if a safety door switch is fitted If enabled this will not allow any chill defrost or UV Sanitisation programs to be run if the door is open NO No safety door switch fitted YES Safety door switch fitted Note Usual
52. old the dial or centre button for 2 seconds the information screen will be displayed Rotate the dial or click wheel until SET TIME DATE is highlighted Press and release the dial or centre button to access the service screen Press and release the dial or centre button to move to the displayed time in hours and minutes rotate the dial or click wheel to alter the time Once the correct time has been achieved press and release the dial or centre button to move to DAY If it is necessary to change the day month and year change the settings using the same procedure for setting the time On completion press and hold the dial or centre button for 2 seconds to return to the program selection screen Whilst in the program selection screen press and hold the dial or centre button for 2 seconds The information screen will be displayed continue by pressing the dial or centre button for a further 2 seconds to display the SERVICE MENU LANGUAGE will be highlighted press and release the dial or centre button ENG English will be highlighted Rotate the dial or click wheel to change the language Select the preferred language then press and release the dial or centre button to confirm The Screen saver is displayed if the machine is not used for 20 minutes providing power is connected It shows a series of Z s indicating sleep mode Pressing and releasing the dial or centre button or opening the door will awaken the uni
53. on could be P 11 29 TUR made the safety of the food product 1 40 F d 7 1 55 7 sz a 2 mas 42 If the food probe T1 is not inserted into the product the temperature measured by this probe may also rise Print Output An example of the printer output is shown above along with explanations of various aspects Please note that this is a sample printout the temperatures values against time are simulated and not taken from an actual cycle 32 The controller can record 1000 events That is 1000 time related readings independent of the number of food probes fitted Some samples of the time period that this allows are given below Data Rate set at 3 minutes 90 minutes chill cycle 30 chill time recordings 3 minute intervals 970 hold time recordings 15 minute intervals Total time span 244 hours 10 days 4 hours Data Rate set at 5 minutes 90 minutes chill cycle 18 chill time recordings 5 minute intervals 982 hold time recordings 15 minute intervals 240 minute chill freeze cycle 80 chill time recordings 3 minute intervals 920 hold time recordings 15 minute intervals Total time span 234 hours 9 days 18 hours 240 minute chill freeze cycle 48 chill time recordings 5 minute intervals 952 hold time recordings 15 minute intervals Total time span 242 hours 10 days 2 hours 480 minute maximum
54. owing through Point 5 the display will change to show TYPE highlighted To adjust the value of TYPE the dial or centre button must be pressed and released 7 The TYPE of printout can be changed from FULL a complete detailed record to SHORT a summary version by rotating the dial or click wheel Once the required value is displayed the dial or centre button is pressed to set it The display will revert to highlighting DATA RATE 29 8 When the HACCP SETTINGS have been configured the menu is exited either by pressing and holding the dial or centre button for 2 seconds or allowing the controller to revert after 20 seconds by itself IrDA Printer Setup Switching the printer ON and OFF To switch the printer ON press and release the button the indicator will flash ON and OFF intermittently at approximately 2 second intervals If the unit is not used it will switch OFF after 5 minutes If the unit doesn t respond it may require the batteries in the printer being re charged Plug the charger cable into the RS232 socket and the charger into the mains electrical supply and leave overnight To switch the printer OFF double press the button and the indicator will flash rapidly for 5 seconds and then stop the printer is now OFF Checking the Setup With the printer switched OFF press and hold the button until the default settings start to be printed then release Once the default settings
55. propriate alarm delay period the alarm will sound Similarly if the measured hold temperature is greater than or equal to program hold set point hold hysteresis high alarm temperature value the alarm will sound Range 1 C to 50 C High Alarm Delay The delay period between a temperature alarm condition occurring 00 minutes Instantaneous audible alarm 01 to 120 minutes period of delay Alarm Time The length of time which the alarm will sound for an end of program cycle alarm or any other alarm warning prior to automatically muting 00 minutes No alarm 01 to 120 minutes Alarm energised period Alarm Repeat Interval The length of time between an acknowledged alarm being automatically muted and the alarm sounder being re energised 00 minutes No alarm reminder 01 to 480 minutes Alarm reminder period Alarm Buzzer Enables or disables the board alarm buzzer NO Alarm disabled YES Alarm enabled Air Probe Offset Allows the value of the Air Probes to be offset allowing the product temperature to be accurately measured Range 15 C to 15 C Coil Probe Offset Allows the value of the Evaporator Coil Probe to be offset allowing the coil temperature to be accurately measured Range 15 C to 15 C Food 1 Offset Allows the value of Food Probe 1 to be offset allowing for the product temperature to be accurately measured Range 15 to 15 C Food 2 Enable Determines whether a second Food Probe is fit
56. re used for the display test after that the relays are energised in a simple operating pattern to ensure each are energised During the final ten seconds the alarm is sounded to indicate the end of the test 25 The graph below shows how the relays are energised relating to time The air coil and food temperature probes are disregarded the only exception is an over temperature alarm Foot Print Test Operation RELAY 1 CONDENSING SYSTEM RELAY 2 EVAPORATOR FAN 1 ON RELAY 3 EVAPORATOR FAN 2 RELAY 4 Function RELAY 5 RELAY 6 CAPACITY RELAY 7 uv LIGHT 50 100 150 200 250 300 350 400 450 500 550 600 Time seconds Operation Summary All relays commence Footprint test in the de energised state Relay 1 is energised after 10 seconds from start of test for 470 seconds de energises 480 seconds from start Relay 2 is energised after 60 seconds from start of test for 30 seconds de energises 90 seconds from start Relay 2 is energised again after 120 seconds from start of test for 300 seconds de energises 420 seconds from start Relay 3 is energised after 90 seconds from start of test for 330 seconds Relay 3 is energised after 540 seconds from start of test for 30 seconds Relay 4 is energised after 450 seconds from start of test for 90 seconds Relay 5 is energised after 590 seconds from start of test for 10 seconds Relay 6 is energised after 360 seconds from start of test for 90 seconds Relay 7 is energised
57. ring periods when the internal air temperature is above a set value Capacity control is achieved by unloading one cylinder of a multi cylinder compressor by means of a solenoid valve or by disabling a condenser fan on systems having multiple condensers fans this would be achieved by using a contactor Capacity Control when set to AUTO in the chill and hold cycle switches off the output to the condensing system when the internal air temperature goes below the Set Point 3 c Chill Hysteresis 4 Capacity Hysteresis 5 below the internal air temperature 12 c Capacity Control when set to AUTO or ON in the hold cycle switches off the output to the condensing system when the internal air temperature goes below the Hold Set Point c Hold Chill Hysteresis 4 Capacity Hysteresis 5 k below the internal air temperature 12 P69 P70 P71 P72 P73 P74 P75 P76 P77 P78 Defrost Type Identifies the type of defrost cycle to be initiated either standard or manually OFF Off cycle defrost ELE Electric defrost GAS Hot gas defrost Smart Defrost Inc DO NOT ADJUST Defrost End Time The length of time that the Defrost period will last before reverting to the chill or hold cycle Range 01minute to 60 minutes Defrost End Temp The coil temperature as detected by the evaporator probe at which the Defrost function will terminate before reverting back to chill or h
58. rofessional 1 2 or 3 D Hard Chill CHILL TEMP WOLD INFORMATION HACCP SETTINGS PRINT OTR SET CONTRAST D Hand Chill CHILL TIME CHILL TEMP HOLD TEMP INFORMATION SETTINGS PRINT DATA SET CONTRAST Press 2 Rec Whilst in the pre programmed selection screen press and hold the dial or centre button for 2 seconds the information screen will be displayed Press and release the dial or centre button to move to time set Rotate the dial or click wheel clockwise to increase and anticlockwise to decrease the time Once the time has been selected press and release the dial or centre button and CHILL TEMP will be highlighted On completion press and hold the dial or centre button for 2 seconds to return to the program selection screen Continue by pressing and releasing the dial or centre button for the program to start When the program has finished the time changes will revert to the default settings Chill Hold Temperature Adjustments Professional 1 2 or 3 only 4 ho freeze PROFESSIONAL 1 Professional 1 2 and 3 if configured are programs that can be used to tailor the chill time and temperature to suit specific product requirements CHILL TIME CHILL TEMP SET CONTRAST With CHILL TEMP highlighted see top image press and release the dial or centre button to move to the temp set See below IU TIME 88 CHILL TEM
59. rther 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 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 or 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 IMPORTANT CONTROLLER CHANGE INFORMATION AS OF 2 JUNE 2008 THE CONTROLLER LCD DISPLAY FST FCC DU1 00 555394 DIAL BUTTON ASSEMBLY FOR BC CONTROLLER 01 233329 01 HAVE BEEN CHANGED TO BLAST CHILLER DISPLAY FST FCC DU2 FOR CLICK WHEEL 00 556021 amp CONTROLLER CLICK WHEEL FST FCC DE2 00 556020 THE SHAFT ENCO
60. s 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 are 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 client s 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 and 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 fu
61. stead of the dial it has a touch sensitive click wheel therefore it does not require the Dial Shaft Encoder The selection of menus and settings is much the same only instead of turning the dial and pressing inwards to select you lightly drag you finger around the wheel to select the setting or menu then press the button in the centre of the wheel to confirm your selection Controller Use All of the following instructions are the same for both controllers The only difference is in how to select with the different dials shown below Dial Version ae Rotate to select Program Press and Release to Start Program Press and hold for 2 seconds to Stop the Program Click Wheel Version Move your finger lightly around the click wheel either clockwise or counter clockwise to select the programme you require Press and release the centre button to start the program Press and hold for 2 seconds to stop Blast Chill amp Shock Freeze Operating Instructions Standard Operation SYSTEM TEST When mains electrical power is first applied to the controller it will carry out a self test EXPERT function for approximately 3 seconds During this period the display will show as across On completion of the self test the controller will revert to the last chill program that was st run Pre chill Soft Chill Hard Chill Hard Chill Max Shock Freeze Professional 1 Professional 2 or Professional 3
62. t the program selection screen will be displayed Main Programmes There are four main programmes in the Blast Chiller or Freezer Soft Chill tor the safe chilling of delicate products such as gateaux and patisserie items and high water content items such as vegetables rice and pasta Hard Chill for general purpose chilling The Hard Chill cycle is ideal for chilling standard products such as meat pies lasagne individually portioned meals etc The later part of the program includes surface protection Hard Chill Max for high density and high fat content products such as meat joints stews and sous vide Shock Freeze for products to be frozen and that can be shock frozen to below 18 within 240 minutes 10 Guide for Blast Chilling amp Freezing Blast Chill Time required Time required to Food Includes Programme to Blast Chill Shock Freeze required Minutes Minutes Meat Beef pork lamb poultry amp mince 40 90 60 240 Fish Fried poached or baked haddock plaice Soft 30 90 60 240 salmon cod fillets etc Prepared Stews amp casseroles lasagne risotto shepherds 50 90 90 240 dishes pie pes Doce Sponge puddings and dense desserts such as 30 90 70 240 cheesecake NOTE All times listed should be used as a guide only and will depend on type size and quantity Electrical Connections Inputs L Mains Live supply 115V 230V 50Hz 60Hz 4
63. ted NO No second food probe fitted YES Second food probe fitted 23 P91 Food 2 Offset Allows the value of Food Probe 2 to be offset allowing for the product temperature to be accurately measured Range 15 to 15 C P92 Food 3 Enable Determines whether a third Food Probe is fitted NO No third food probe fitted YES Third food probe fitted P93 Food 3 Offset Allows the value of Food Probe 3 to be offset allowing for the product temperature to be accurately measured Range 15 to 15 C P94 Address The controller peripheral number This is only necessary when controller are linked via a network to a computer management and data recording system such as with the Foster TAB or ARGO systems Range 00 to 255 Alarms and Warnings In general if an alarm occurs the appropriate alarm symbol will be displayed and the alarm will sound to attract attention The cabinet will attempt to continue running or to finish the cycle if safe to do so The distinction between an alarm and a warning is that a warning may be a non critical occurrence such as door open or temporary power failure An alarm would be for a system failure such as a probe fault or high pressure fault which would require positive intervention temperature condenser fan failure blocked condenser air flow restriction etc i High pressure developing in the refrigeration system as a result of to high food Automatically re sets when the normal worki
64. terminals N Mains Neutral supply 16 terminals E Protective Earth 16 terminals DOOR Door Switching connection not voltage carrying DOOR2 Safety door switch connection not voltage carrying HP High Pressure switch connection not voltage carrying TA Air probe connection TE Evaporator probe connection FP 1 Food product temperature connection FP2 Additional second food product temperature probe connection FP3 Additional third food product temperature probe connection Outputs C1 Condensing system switched relay 30A 8A normally open NO output 3 terminals F1 Evaporator fan 1 switch relay 8A 4A normally open NO output 3 terminals F2 Evaporator fan 2 switch relay 8A 4A normally open NO output 3 terminals D1 Defrost system switched relay 8A 4A normally open NO output 3 terminals o1 UV light system switched relay 8A 4A normally open NO output 2 terminals A1 Alarm relay 8A 4A normally closed NC 1 terminal normally open NO 2 terminals P1 Capacity relay 8A 4A normally closed NC 1 terminal normally open NO 2 terminals Display Power Man Machine socket 2 way connection Display Data Man Machine RJ54 Type 4 way connection Logger 4 way RS 485 connections 11 Service Information It is important that a full understanding of the controller is obtained prior to making any EXPER
65. y 4 DEFROST Relay 5 ALARM Relay 6 CCAP Capacity Control and Relay 7 UV L will all be switched on and off automatically in a pre determined manner to simulate program operation whether they are connected or not The test is based around an algorithm built into the software Prior to starting the program it is advisable to place a probe in the centre of the cabinet room attached to an independent measuring device to check the air temperature as the air coil and food probes are not active during this program The temperature achieved will depend on the model The air temperature should be checked 5 to 6 minutes into the program The temperature achieved should be the minimum temperature and can be checked against the model type found in the parameter table starting on page 14 Once the test is completed the display reverts to the last chill program and not to the service parameters In the Service screen rotate the dial or click wheel until you reach PASSCODE Press and release the dial or centre button to highlight the code Rotate the dial or click wheel until you reach the code 131 Once achieved press and release the dial or centre button to acknowledge You are now in the program profiles The controller has 9 operating programs Pre Chill Soft Chill Hard Chill Hard Chill Max Shock Freeze Professional 1 Professional 2 Professional 3 Defrost and 2 optional programs UV Sanitisation and Information These pr

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