FOSTER DRP RBC MK 3 CONTROLLER SERVICE MANUAL
Contents
1. 25 i gt o gt F 1 SEE PACE 1 2 5 5 8 Sue 2 s 8 8 5 E 58 Eee zee 8 85 171 2 1121214 18516 7 a 5 SAL 53 50 5 2902 10 10 7 9 10 ox WATE2. 10 NOTES ALL GABLES ARE imm UNLESS STATED COWTROL COLOUR CODE COMTROL CRCUT WRIKG PHASE WIRING BLACK NELTRAL WIRING EARTH WHERE CABLES ARE USED STANDARD COLOUR COLE APPUES HETAORES SHOULO BE SONMECTED ACROSS THE COILS OF C1 G2 05 25 AND UOUDAWTER 824 ENOIDE PROWE RECOVERY PROVE RECOVERY DEFROST HUMIATS PRESSURE RELIEF CRANKCASE HEATER LEVEL SEAH TANK WATER LEVEL CIRCUIT BREAKERS h Eh Ca H3 35288558 EVAPORATOR 3 FIED GAP RI MODEL OHLY CONDENSING UNIT SUPPLY NEUTRAL l SoNDENSING UNIT CONDENSING UNIT L PRIVE RECOVERY HEATER CONDENSING UNIT L FROME RECOVERY HEATER PROVE RECOVERY HEATER HEATER PROVEREGOVERY HEATER L DEFROST HEATER DEFROST HEATER L HEATER HUMIDITY HEATER L EVAPORATOR FAN 1 EVAPORATOR FAN 1 L EVAPORATOR EVAPORATOR 2 EVAPORATOR 3 EVAPORATOR 3 L PRESSURE RELEF WWE HEATER HIGH PRESSURE L LIGHT OPTIONAL PRESSURE RELEF HEATER WATER LEVEL SOLENCID LOW PRESSURE SAICH j CONTROLLER 8 L AMEH CONTACT OPTISNAL INTERNAL LIGHT OFTONAL M WATER LEVEL SOLEMOI SARS HEATER
3. 24 19 L 15mm _ il 12 EJ Daye 2 N os Ln 4 31 21 80 MCE 1 2 1 4 MCB 5 10 10 ANP 2 AHP E AMP 5 30 42 E 4 4 4 5 gt SEE PAGE 2 SEE PAGE 2 33 39 5 SEE PAGE 2 Doo 0 5 6 5 3 5 41 8 7 DEFROST PROVE CRIP TREY HUMECATY GRAN HEATERS HEATER HEATER HEATER HEATER HEATER se l 1 1 0 0 00 00 69 T gt mme t SEE PAGE 2 CHANGED WAG REY DESCRIPTION DATE RATS 0 744539 00 10 OY FOSTER REFRIGERATOR U K POWER pstrieumon SHEET 1 oF 2 TER 22 aE OLDMEDOW RO4D KING S INN NORFOLK PESO WAG NTS 13 4 98
4. 14 LAUD UNE SOLENOID CONTROLLER 17 OVEN CONTACT OP TIGHALY CRANKGASE HEATER WATER LEVEL HIGH PROBE WATER LEVEL LOW PROBE WATER LEVEL COMMON WE REV DESCRIPTION BY DATE mE 0002 FOSTER REFRIGERATOR U K LTD BLOCK sheet 4 of 5 AND GENERAL NOTES DATE EDAD ENGS LYNN NORFOLE FESO 4 fy 9 DEP Rl 3 MaG WTS 18 2 98 ACO 23 CONDENSING WHERE FITTED PROVE RECOVERY HEATER 1 PROVE REVER HEATER 2 DEFROST HEATER HUMIDITY HEATER EVAPORATOR FAN 1 EVAPORATOR FAN 2 EVAPORATOR FAN 5 RELEF VALVE HEATER LIQUID SOLENOD WATER HIGH PRESSURE SWITCH WHERE FITTED LOW PRESSURE SWITCH WHERE FITTED GRANKGASE HEATER WATER LEVEL PROBE WATER LEVEL HIGH PROBE WATER LEVEL LOW PROBE J CRANK CASE HEATER ADDED TE ec 8066 00 02 FOSTER FOSTER REFRIGERATOR U K LTD INSTALLAMON CONNECTION 5 oF 5 DRP RI 2 T GRP RI 3 T sa OLDMEDOW ROAD KING S LYNN NORFOLK PESO NTS 19 2 476 THERES H ADSSREMACE
5. With the screen displayed press the DOWN RIGHT and LEFT keys together After pressing the DOWN RIGHT and LEFT keys together the Configuration Parameters Menu is shown Using the DOWN arrow select Reset Alarms and then press Select 13 Configuration Parameters Menu CONFIGURATION PARAMETERS Standard Parameter Setting Time Date Programs Manual Prove Manual Fast Chill Manual Storage Manual Recovery Service Reset Alarms End Times Select Exit The RESET ALARM Screen below will be displayed The alarm fault will be displayed e g Over Temperature Alarm RESET ALARMS Over Temperature Alarm Press Reset Resetting Alarms will flash on and off on the display RESET ALARMS Resetting Alarms Once the reset has taken place the screen below will be displayed RESET ALARMS No Current Alarms Press Exit to return to the Configuration Parameter Menu and then press Exit again to return to the SYSTEM OFF PRESS START Screen Controller Reset It may be necessary to reset the panel if it is felt that the controller has been compromised in any way To carry out Reset procedure turn the power off to the machine press and hold the Help button and switch on the power Remain holding the button until the flash test has been completed and the following screen will be displayed 14 LOAD DEFAULT VALUES Clear Datalog Buffer too YES
6. 3 05 LEVEL CONTROLER CHARGED TS DESCRIPTION By DATE mE OEG 0 838088 20 04 FOSTER REFRIGERATOR LTD auxiary CONTROL CIRCUIT 2 3 TER RI 3 REDUCED WIDTH OLDMEDOW ROAD KING LYNN MORFOLK PESO 41 py 4 7 WTS 24 6 99 CHECKED ATI FOAM HO MOR 28 10 SEE PACE BD 52 3 SEE PAGE 3 E N a 9 8 23 s SPREE 888 5 8 S 8 28 8 208 8 5 Eee 5 52 5 FILT
7. Configuration Program 4 Extra Prove Temp SELECT 30 C 40 C 25 C Exit Press SELECT and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT to return to the menu and Select Extra Prove Humidity press SELECT followed by YES to modify press CONFIRM and the following screen will be displayed Menu Extra Prove Humidity Configuration Program 4 Extra Prove Humidity Extra Prove Humidity MAX Extra Prove Humidity MIN SELECT 87 95 75 Exit Press SELECT and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT twice to return to the menu and Select Hold press YES to modify press CONFIRM and the following screen will be displayed Menu Hold Configuration Program 4 Hold Times Hold Temperature H
8. LEFT MIDDLE RIGHT Factory test 4 allows for the testing relay outputs When the screen is displayed the Periodic Test is in operation To change to Static Test press the middle button Each of the relay outputs relates to the following K1 7 8 9 Coil Fans 2 Interior Light 3 Liquid Solenoid Valve 4 Room Heating 5 Defrost Heaters 6 Water Solenoid Valve To continue to the next test press the RIGHT amp LEFT buttons simultaneously The next screen will display Factory Test Ver F203 5 Digital Input Test RIGHT LEFT Continue 123 456 LEFT MIDDLE RIGHT Factory test 5 tests the digital inputs 1 Overtemperature 2 Emergency Switch 3 Overpressure 4 to 6 Not used To continue to the next test press the RIGHT amp LEFT buttons simultaneously 12 next screen will display Factory Test Ver F203 6 Analog Input Test RIGHT LEFT Continue ANO AN1 2 0 0 0 0 AN4 AN5 AN6 AN7 4 889 746 640 92 65C 45C LEFT MIDDLE RIGHT Factory test 6 tests the gives the readings against individual probes ANO AN1 AN2 AN3 Not used AN4 Door contact AN5 Humidity Probe reading in ohms and percentage AN6 Evaporator Probe reading in ohms temperature C AN7 Air Probe reading on ohms and temperature C Values below AN4 5 6 7 for reference only these will change relative to sta
9. including management Similarly the parameters are pre set on commissioning to ensure consistent product quality and as such should not be adjusted under any circumstance without prior consent in writing from Head Office bakery personnel Note Although the controller has 9 programs only program 4 is used Upon initiation of a complete cycle the controller will display DO NOT LOAD PRODUCT until the chamber temperature reaches 5 c fast chill at this point it will sound an alarm and the display will show LOAD PRODUCT The fast chill program is set for 1hour On completion the temperature will be controlled at 5 c with the controller in the storage mode there is no fixed time to this section as the controller calculates how long this temperature is maintained based on the bake time and the remaining process times The recovery time is set for 6 hours and the prove time is set for 2 hours and 30 minutes An illustration of this is Assuming that the current time is 15 00 and the bake time is 06 00 the following day a total time for the cycle is 15 hours The controller calculates back from the bake time 06 00 for the prove time of 2 hours and 30 minutes plus the recovery time of 6 hours So with the with a fast chill time of 1 hour recovery of 6 hours prove of 2 hours and 30 minutes this will leave a storage time of 5 hours and 30 minutes When the calculated time for the phase is reached the controller will change f
10. 7 DATE 008581890009 FOSTER REFRIGERATOR U K LTD PONE DISTRIBUTION 1 oF 5 FOSTER RI 3 REDUCED WIDTH GLUNEDOW ROAD KING S LYNN NORFOLK PESO 470 24 6 93 APONDA WITH 26 59 WDE 27 SEE PAGE 1 lt 7 gt SEE PAGE 5 1 SAFETY STAT 7 gt SEE 5 gt SEE PAGE 3 SEE PADE 1 a PAGE 5 51 PAGE 5 134 2 a inca WATER CONTROL af CONTROLLER CONNECTIONS 4 Led 61 1 32 LC 1 LP H 1 Ti 8 9 09 49 9 p 18 19 20 16 HI LJ COMMON 68 PROBE PROBE 51 PRY CRANKCASE HEATER HEATER At 2 cs 1 7 H H N N SEE PAGE 1 lt lt N SEE
11. CRAFT MOD INTEGRAL CRAFT UPRIGHT Select Exit Press Exit to return to the configuration parameter screen 4 Time and Date Select Time and Date in the Configuration Parameters Menu and the following screen will appear CONFIGURE TIME amp DATE Current Time 10 40 Current Date 14 02 2009 EDIT EDIT ACCEPT TIME DATE EXIT For setting the Clock press EDIT TIME CONFIGURE TIME amp DATE Modify Parameter Current Time Value 10 45 A Accept SELECT EXIT changing of the date For setting the Date press EDIT DATE CONFIGURE TIME amp DATE Modify Parameter Current Date Value 14 02 2009 A Accept SELECT EXIT return to the Configuration Parameters Menu Programs It is important that the correct time and date are loaded ensuring the correct function of the machine The screen to the left will appear with Current Time flashing The first digit of the time will have a symbol beneath it and the value will flash on and off Modify each Digit with the up or down arrow keys confirm the sections by pressing SELECT and continue to change each of the segments in turn On completion press ACCEPT Press EXIT to exit without storing the modified values The screen will change to display the first screen to allow the The screen to the left will appear with Current Date flashing The first digit of the date will havea symbol beneat
12. Exit No LOAD DEFAULT VALUES Clear Datalog Buffer too Loading Service Parameters Loading Program Parameters Clear Datalog Buffer Address xxxxx of 35136 YES Press YES to start the reset program and the following program will be displayed and the reset program will start On completion of reset the display will return to the SYSTEM OFF PRESS START screen It will be necessary to install the default parameter settings for the particular model before starting any program 2 5 Fault Messages Wrong checksum after having exchanged the flash EPROM Press left amp right while switching on the auxiliary voltage to calculate a new checksum It is strictly necessary to carry out a Reset Procedure after changing the program Possible Fault Messages are 01 Air Sensor Short Circuit 02 Air Sensor Break 03 Coil Sensor Short Circuit 04 Coil Sensor Break 07 Humidity Sensor Short Circuit 08 Humidity Sensor Break 20 Defrost Term Fault Safety Time 45 Min 22 Door Open Fault 23 Temperature Fault 34 Overtemp Fault 37 Over Pressure 41 Emergency Stop 50 Routine Check 51 Steam Tank de scaling 52 Condenser Clean 53 Heaters check 60 Modem not ready 61 Modem Dial Number missing 63 Bus Read Fault Power Interrupt If there is a power interrupt all information is stored and the clock continues running for one day After power interrupt the unit tries to keep the programmed bake time Communication via
13. Parameters Select Recovery Temperatures from the menu press YES to modify and then press CONFIRM and the screen below will appear Configure Program 4 Recovery Humidity Recovery Duration SELECT EXIT Menu Recovery Temperatures Configure Program 4 Recovery Temperature Recovery Temperature 12 C Recovery Temperature MIN 05 C SELECT EXIT Select Recovery Temperature and the following screen will be displayed Press SELECT and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT twice to return to the menu and Select Recovery Humidity press SELECT followed by YES to modify press CONFIRM and the following screen will be displayed 7 Menu Recovery Humidity Configure Program 4 Recovery Humidity 75290661 Recovery Humidity 95 Recovery Humidity MIN 75 SELECT EXIT Press SELECT and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not
14. Press EXIT to return to the Configure Program 4 menu press EXIT twice to return to the CONFIGURATION PARAMETER screen Configure End Times Each of the days when the machines is required the end times can be pre set to enable the baker to start a program without having to set the end time To access the program select End Times from the Configure Program 4 menu and the following screen will appear CONFIGURATION PARAMETERS END TIMES Monday 03 00 Tuesd 03 00 Wednesday 03 00 Press EDIT SELECT and the following screen will appear Thursday 03 00 Friday 03 00 Saturday 03 00 Sunday 03 00 ACCEPT EDIT VALUES SELECT CONFIGURATION PARAMETERS END TIMES Press SELECT and the day and the first segment of the value time Modify Parameters will flash on and off Monday Alter the time by using the UP and DOWN arrows to suit the Min Value 03 00 individual requirement press SELECT to move from one segment 03 00 to next and when completed press ACCEPT Value Make the necessary changes to the days required and then press Max 03 00 ACCEPT VALUES to return to the Configuration Parameters ACCEPT SELECT completion of change press EXIT to return to the SYSTEM OFF PRESS START screen Factory Test Program The Factory Test Program is designed to enable the engineer to check the various functions outputs and probe readings as a means of resolving machine and or controller problems
15. You can start the factory test program switching off the power supply to the controller and press and hold in the UP and DOWN Arrow keys during switching on the auxiliary voltage and carrying out the Flash Test Remain holding the buttons until the flash test has been completed and the following screen will be displayed 11 Factory Test F203 1 Keyboard Test UP RIGHT LEFT Continue DOWN Factory test 1 allows for the Left Right Middle Up Down and Help buttons to be checked Press each button once for them to be displayed To continue to the next test press the RIGHT amp LEFT buttons simultaneously The next screen will display Factory Test Ver F203 2 Display Test RIGHT LEFT Continue Middle Start Test LEFT MIDDLE RIGHT Factory test 2 allows for the Display to be tested To continue to the next test press the RIGHT amp LEFT buttons simultaneously The next screen will display Factory Test Ver F203 3 5232 Bus Test RIGHT LEFT Continue Modem Factory test 3 allows for the testing of the Modem connections Modem Connections NOT USED To continue to the next test press the RIGHT amp LEFT buttons simultaneously The next screen will display Factory Test Ver F203 4 Relay Test RIGHT LEFT Continue LEFT Periodic Test MIDDLE Static Test 2345 67 10
16. a Software revision on the EPROM such as F203 Before any work is carried it out is advisable to check the customers settings so that the new EPROM can be set to the correct temperatures after fitting REMOVAL 1 Remove the Power supply to the machine and turn off the isolator on the Control Panel 2 Remove the front part of the Control Panel by removing the 3 screws on top of the Panel 3 Disconnect the Interconnecting cable between the Relay Board and the Display Panel The cover over the Display can then be removed exposing the relevant board The EPROM is located on the top board 4 Make a note of the orientation of the EPROM in the holder by way of the circular indentation on one edge See fig 1 Remove the EPROM from the holder using the correct lifting tool Removal has to be done carefully as the holder can easily be damaged Direction Marks REPLACEMENT 1 Locate the EPROM onto the holder and ensure it is perfectly square and carefully push fully home into the socket 2 Replace all panels and replace the Interconnecting cable 3 Re assemble Control Panel 4 The Controller will now need to be Reset Whilst restoring power hold down the Left amp Right keys and allow the Flash Test to be carried out Then follow the on screen prompt When asked to Clear Data Log Buffer select YES to continue On completion the controller display will return to the Start Screen 5 Check that the time and date
17. correct loading temperature Load the product and press START Program 4 28 7 15 5 5 Bake Date Thursday 09 40 LOAD PRODUCT PRESS START STOP START 7 When cycle is complete an audible alarm will sound press STOP check the product is fully proved remove and bake 8 Should an extra proving time be required select EXTRA TIME and press START For HELP press the Button located above the display PLEASE NOTE when changing the machine from Prove to Retard Overnight Operation allow 45 minutes for the cabinet to cool down In the event of an emergency switch off the machine at the MAIN ISOLATOR SWITCH 02 09 Rev 1 Controller Instructions The display is a yellow back lighted graphic display with a resolution of 320 240 dots Above the Display the Info key is located Press to display help and information at all times Under the Display the keys LEFT MIDDLE and RIGHT lt gt are located On the right side besides the Display the Arrow Keys UP and DOWN A are located v NOTE At any time during a program if the bottom button is pressed and help the display will show Temp Set Point Coil Temperature Winter Summer Time and the program number Setting of Parameters After switching the auxiliary voltage on the controller carries out a self test of the program and shows FLASH TEST FOR INTEGRITY for a few seconds followed by the program information including versio
18. is 2 hours 30 minutes If the product is not ready at the bake time then an Extra Prove 10 minutes can be selected for up to a maximum of 15 minutes PHASE 5 Hold On completion of the Prove phase if the load is not immediately required for baking off the product can be placed in the HOLD mode for 10 minutes when the air temperature will be reduced to 15 C in order to stabilize the product and can be held for up to a maximum of 20 minutes 2 1 To start the Operation Press START WEDNESDAY 14 02 2009 16 45 SYSTEM OFF PRESS START START 4 Enter the Bake Time Press ACCEPT or Press EDIT followed by the up or down arrows to change the time BAKE DAY TODAY BAKE TIME 18 34 OPERATING INSTRUCTIONS 2 Select the Bake Program from the menu If Prove only program is selected program will start automatically Retard amp Prove Timed Prove 1 Prv Brd amp French Prv Soft Rolls Prv Donuts SELECT EXIT 5 Press ACCEPT to Confirm Selected ACCEPT EDIT EXIT Cycle BAKE DAY TODAY WAIT BAKE TIME 09 48 FOR CONFIRM SELECTED CYCLE AUDIBLE ALARM ACCEPT EDIT EXIT 3 Enter the Bake Day for Retard amp Prove Press ACCEPT or Press the UP arrow to change the Bake Day BAKE DAY TODAY ENTER BAKE DAY ACCEPT EXIT 6 An Audible alarm will sound when the machine is at the
19. recommended to make changes to the values without managerial consent Press EXIT to return to the menu and Select Recovery Duration press SELECT followed by YES to modify press CONFIRM and the following screen will be displayed Menu Recovery Duration Configure Program 4 Recovery Plateau Time 25 SELECT EXIT Menu Recovery Duration Configure Program 4 Recovery Duration 06 00 Recovery Duration MAX 07 00 Recovery Duration MIN 04 00 Select Exi Select Recovery Duration and the following screen will be displayed Press SELECT and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT twice to return to the menu and Select Rec Plateau Time press SELECT and the following screen will be displayed Menu Recovery Plateau Time Configure Program 4 Recovery Plateau Time 25 Recovery Plateau Time MAX 50 Recovery Plateau Time MIN 10 Select Exit Press SELECT and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to ch
20. remote control is not possible during power interrupt Modem Dial Number Missing If the alarm message Modem Dial Number Missing is shown on the display it is necessary to reset the Remote Access Type value to SERIAL Press the DOWN RIGHT and LEFT keys together the Configuration Parameters Menu is shown see 2 2 1 Scroll the list and select Service Once selected the screen will change see 3 4 Service Parameters Select Remote Access After entering select Remote Access Type if Modem is shown on the right hand side press the middle bottom button EDIT SELECT 15 Access code will be requested enter the correct level access code to continue The next screen will display Remote Access Type flashing press the down pointing arrow to change it to display Serial Press ACCEPT The screen will return to the previous press ACCEPT VALUES Once the screen has changed press EXIT You will now be back to the Configuration Parameter press EXIT to store the change made NOTE Leave the unit for ten minutes to allow the controller to re set After the ten minutes has elapsed access the Configuration Parameters Menu and reset the alarm FITTING PROCEDURE FOR F206 SOFTWARE EPROM RBCMK3 CONTROLLER The EPROM is located on the PCB behind the Display Panel and not the Relay Board and is the only one of its type on this board so it can be easily identified There may already be
21. the change and the symbol will move to the next letter On completion press ACCEPT to store the changes made and the screen will revert back to the first screen Press EXIT to return to the menu and EXIT again to return to the Configure Program 4 menu Fast Chill Parameters Select Fast chill from the Configure Program 4 menu press SELECT and the screen below will appear Configure Program 4 Fast Chill Active Yes Modify YES EXIT NO Select YES the screen will change with Fast Chill Active and yes flashing on and off to proceed press CONFIRM To return to the menu press CANCEL The screen will change display the following screen Configure Program 4 Fast Chill Duration Fast Chill Temperature Modify Exit Select FAST CHILL DURATION and press MODIFY and the following screen will be displayed Menu Fast Chill Duration Configure Program 4 Fast Chill Duration 01 00 Fast Chill Duration MAX 02 30 Fast Chill Duration MIN 01 00 Modify Exit Press Modify and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT to return to the menu and Select FAST CHI
22. ER ry 8 8 oe 2086 07 166 SEE PAGE 2 5 5 SEE PACE 2 lt BS SEE PAGE 2 57 58 53 57 62 63 60 5 8 t gt SEE PAGE 1 2 3 49 00 5 5 4 2 54 gt SEE PAGE 1 12 4 13 14 LIGHT 1 863 E H H H H N H H 4 00 4 SEE PAGE 2 E 98 CONTROLLER CHANGED DESCRIPTION BY DATE DRAHE 38089 00 09 55 FOSTER REFRIGERATOR U K LTD erocess contrat sen 3 of 3 TER DRP RI 3 REDUCED WIDTH OLDMEDOW ROAD KING S LYNN NORFOLK 470 MAG NTS 24 6 99 29 S tos ER REFRIGERATOR 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 Ltd DRP F206 SM 19 09
23. HASE 2 PHASE 3 PHASE 4 PHASE 5 CHILL RETARD RECOVERY PROVE HOLD PHASE 1 Chill From Start the refrigeration attempts to reduce air temperature to 5 C While air temperature is above 0 C the display shows Do not load product Typically after 15 to 20 minutes the chamber has reduced to 5 C an alarm sounds indicating product can be loaded The duration of the Fast Freeze Phase is 1 hour PHASE 2 Retard From the end of Phase1 the air temperature is maintained at 5 C for the duration of the Retard Phase The length of the Retard Phase will depend on the required bake off time end of Phase 4 PHASE 3 Recovery From the end of Phase 2 the recovery phase is split into two segments 75 and 25 During the first 75 of Phase 412 hours the temperature rises from 5 C to 7 C During the final 25 of Phase 112 hours the temperature is maintained at 7 C Through out this period the humidity is around 82 The duration of Recovery Phase is 6 hours PHASE 4 Prove From completion of Phase 3 the Prove Phase starts and it is split into two segments 75 and 25 During the first 75 of Phase 4 1hour 52 minutes 30 seconds the temperature rises from 8 C to 28 Tesco 32 C During the second 25 of Phase 4 37 minutes 30 seconds the temperature is maintained at 28 C Tesco 32 C Through out this period the humidity is maintained at 87 The duration of Prove Phase
24. L FOSTER FOSTER DRP RBC MK 3 CONTROLLER Program Version F206 SERVICE MANUAL Revised 09 02 2009 Contents Introduction 1to2 Operator Program 2 Operating Instructions 3 Controller Instructions 4 Setting of Parameters 4to 11 Configuration Parameters 4 Standard Parameter Settings 4 Time and Date 5 Programs 5 106 6 Fast Chill Parameters 6 to 7 Storage Parameters 7 Recovery Parameters 7to8 Prove Parameters 8 to 11 Oven Contact Parameters 11 Configure End Times 11 Factory Test Program 11 to 13 Alarm Cancelation 13 to 14 Controller Reset 14 to 15 Fault Messages 15 Power Interrupt 15 Modem Dial Number Missing 15 to 16 Fitting Procedure for F206 Eprom 16 Probe Resistance Values 17 Overtemperature Stat Settings 17 Fault Diagnoses 17 to19 Wiring Diagrams 20 to 29 INTRODUCTION The cabinet and Modular DRP are designed to retard recover and prove dough products When utilised correctly the unit will enable a more consistent product quality to be achieved It is therefore important that prior to working on this equipment that this manual is read and understood If any point of operation is unclear the engineer should contact Foster Refrigerator UK Ltd on 01553 691122 The controller contains both User Parameters and also Machine Operating Parameters Neither of these parameter sets are accessible to the store operators and as such should not be disclosed to any member of store personnel
25. LL TEMPERATURE press Modify then press YES followed by CONFIRM and the following screen will be displayed Menu Fast Chill Temperature Configure Program 4 Fast Chill Temperature 05 Fast Chill Temperature 00 Fast Chill Temperature MIN 15 C Modify Exit Press Modify and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT three times to return to the Configure Program 4 menu Storage Parameters Select Storage Parameters from the Configure Program 4 menu press SELECT and the screen below will appear Configure Program 4 Storage Temperature 05 Storage Temperature MAX 00 C Storage Temperature MIN 10 C MODIFY EXIT Press Modify and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT to return to the menu and EXIT again to return to the Configure Program 4 menu Recovery
26. R LEVEL CONTROLLER CONNECTIONS 5 1 GA 121 152 45 1 E je 1 bile 2 8 6 9 9 0 9 9 18 19 20 54 i 10 48 14 61 PROBE PROBE 1 7 1 1 1 1 WATER 1 2 a 1 PAGE 1 H SOLENGD m SOLENOD 4 gt SEE PAGE 1 8 H 1 H g m 960 SEE PAGE 1 H L CONTROLLER ET 10 REY GESCRIPTION AMM OD 744 530 00 010 97 FOSTER REFRIGERATOR U K LTD HE 2 7 FOSTER ar m ROAD KING S LYNN NORFOLK PESO 420 TESCO SPECIFICATION MAG NTS 17 4 98 10 32 NCB NCE 6 CONTROL SAFETY 16 AWP B 5 2 x Se 58 JE E 57 6 4 4 8 5 6 2 a SEE PACE 2 56 gt SEE PAGE 5 5545 50 97 5 4 5 58 8 a N NHN NHN HN 0 SEE 2 91 LEVEL CONTROLLER CHUNGED HAG aire DESCRIPTION
27. ange the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT three times to return to the Configure Program 4 menu Prove Parameters Select Prove Parameters from the menu press SELECT followed by YES to modify press CONFIRM and the screen below will appear Menu Prove Configure Program 4 Prove Temperatures Prove Humidity Prove Duration Extra Prove Hold SELECT EXIT Menu Prove Temperatures Configure Program 4 Prove Temperature Prove Temperature MAX Prove Temperature MIN SELECT 35 35 C 25 C EXIT Select Prove Temperatures and the following screen will be displayed Press SELECT and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT to return to the menu and Select Prove Humidity press SELECT followed by YES to modify press CONFIRM and the following screen will be displayed Menu Prove Humidity Configure Program 4 Press SELECT and the screen will change to show the first digit for ST HERETO Use the UP d DOWN to ch the val d Humidity 95 se the an arrows to cha
28. are set correctly using the procedure in the Service Manual 6 Reset all other parameters to customer requirements Probe Resistance Values 16 Air Coil Probe PTC type Resistance values against temperature 55 C 490 Ohm 25 1000 Ohm 50 C 515 Ohm 30 C 1040 Ohm 40 C 567 Ohm 40 1122 Ohm 30 C 624 Ohm 50 C 1209 Ohm 20 C 684 Ohm 60 C 1299 Ohm 10 C 747 Ohm 70 C 1392 Ohm 0 C 815 80 C 1490 Ohm 10 C 886 Ohm 90 1591 Ohm 20 C 961 Ohm 100 C 1696 Ohm Technical Detail IP Rating IP65 Range 30 c to 90 c Tolerance 1 25 at 25 c 2 at 10 and 50 c 3 at 50 and 80 c Overtemperature Thermostat Setting The overtemperature setting is 60 c with a 10 c differential FAULT DIAGNOSIS The following section details a number of faults which may occur and their possible causes This list is not exhaustive TEMPERATURE SLOW PROVING Possible causes are prove heater failure or fan failure The most likely would be heater related as a fan failure would also cause problems related to low humidity uneven proving and or an over temperature fault TEMPERATURE FAULT ACTIVATED There are a number of possible causes for this fault The easiest method of diagnosis is to ascertain the time that the error occurred It should also be determined the exact condition which causes the fault See paragraph 3 4 2 From the time of occurrence it can be determined via the operating
29. er is connected If this is the case check that the level controll is operating Malfunction of the level controller is not necessarily an indication if a level controller failure see water overfilling below although failure to fill usually is Check the heater is operating correctly In all of the above prove negative ensure that the steam delivery pipes have not become scaled or the inside of the tank itself is not full of scale therefore preventing sufficient steam production WATER WATER OVERFILLING The water system is controlled by the level controller situated in the control panel The first check to make however is to ensure that no debris from the water supply has passed through the water strainer and become lodged in the solenoid valve thus preventing the valve from closing completely If the valve is permanently energised this can only be caused by the level controller However this does not necessarily indicate a level controller fault The level controller uses conductivity between the probes and the tank case to determine water level If the probes have become scaled due to water softening being inoperative this will prevent conductivity causing the controller to assume low level thus causing the solenoid valve to remain open It should also be ensured that the earth connection between the level controller and tank has not been disrupted in any way as this will cause the same scenario WATER OVERFLOWING DRAIN PAN Most likely ca
30. h it and the value will flash on and off Modify Digit with the up or down arrow keys confirm the sections by pressing SELECT and continue to change each of the segments in turn On completion press ACCEPT Press EXIT to exit without storing the modified values The screen will change to display the first screen press EXIT to This allows the selection and deselection of Program Parameters for Retard amp Prove First select Programs in the Configuration Parameters Menu and the following screen will appear CONFIGURE PROGRAMS Program 2 Program 3 Program 4 Program 5 Program 6 Program 7 Program 8 Program 9 Select Exit If the program is On then all parameters are then governed by their own individual parameters If the program is Off only the program name and program active screen will be visible It is important to note that only program 4 is switched ON all other programs are switched OFF Select from the listing using the Arrow Keys and then press SELECT Program 4 Program Active Yes Modify YES NO Exit The screen will change and display the selected program It is important to ensure that program 4 is ON and all other programs are switched OFF To modify the program press YES The screen will change and display the followi ng To modify the program it is necessary to enter the access code for level The screen will display 0000 witha beneath the fi
31. hange the value and press Breve 10 SELECT to move to the next digit SELECT Exit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT twice to return to the menu and Select Extra Prove press SELECT followed by YES to modify press CONFIRM and the following screen will be displayed Menu Extra Prove Configuration Program 4 Extra Prove Time Extra Prove Temperature Extra Prove Humidity SELECT Ext Select Extra Prove Time press YES to modify press CONFIRM and the following screen will be displayed Menu Extra Prove Time Configuration Program 4 Extea Prove Time Press SELECT and the screen will change to show the first digit for Extra Pr Max Ti 00 15 modification 00 20 Use the DOWN arrows to change the value press Extra Prove Time MIN 00 01 SELECT to move to the next digit Extra Pr Max Time MAX 00 30 Once the changes have been made press ACCEPT and proceed Extra Pr Max Time MIN 00 10 to change the other values if required SELECT Exi NOTE It is recommended to make changes to the values without managerial consent Press EXIT to return to the menu and Select Extra Prove Temperature press SELECT and the following screen will be displayed Menu Extra Prove Temperature
32. n and model details After that the Start Screen is shown Start Screen Monday 14 02 2009 08 11 SYSTEM OFF Press START START Configuration Parameters After pressing the DOWN RIGHT and LEFT keys together the Configuration Parameters Menu is shown These are machine default parameters that are stored in the controller Configuration Parameters Menu CONFIGURATION PARAMETERS Standard Parameter Setting Select Standard Parameter Settings using the Arrow Keys and then press SELECT Programs Manual Prove Manual Fast Chill Manual Storage Manual Recovery Service Reset Alarms End Times Select Exit Standard Parameter Setting Load Set of Parameters Once selected the following screen will appear It is important that the correct default parameters are selected for the machine e g does it have an integral condensing unit or is it remotely sited pack system is it constructed using modular panels or a cabinet DEFAULT PARAMETER SELECT Select from the listing using the Arrow Keys and then press TESCO MOD INTEGRAL SELECT TESCO DONUT UPRIGHT The screen will change and display the selected model followed by TESCO DONUT BENCH Loading Service Parameter and then Loading Program SAFEWAY MOD PACK Parameters SAFEWAY MOD HT PACK SAFEWAY MOD INTEGRAL When the parameters have been loaded the screen will revert back ASDA MOD PACK to the default parameters ASDA MOD INTEGRAL CRAFT MOD PACK
33. nge the value and press Sag SELECT to move to the next digit SELECT EXIT Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT twice to return to the menu and Select Prove Duration press SELECT followed by YES to modify press CONFIRM and the following screen will be displayed Menu Prove Duration Configure Program 4 Prove Duration Select Prove Duration and the following screen will be displayed Prove Plateau SELECT EXIT Menu Prove Duration Configuration Program 4 Press SELECT and the screen will change to show the first digit for Prove Duration Modification Prove Duration MAX 03 00 Use the UP and DOWN arrows to change the value and press Prove Duration MIN 00 30 SELECT to move to the next digit SELECT Exit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT to return to the menu and Select Prove Plateau press SELECT and the following screen will be displayed Menu Prove Plateau Configuration Program 4 Press SELECT and the screen will change to show the first digit for Prove Plateau Time 25 EE se the an arrows to c
34. old Humidity SELECT Exit Menu Hold Times Configuration Program 4 Hold Time 00 10 Hold Maximum Time 00 20 Hold Time MAX 00 15 Hold Time MIN 00 01 Hold Maximum Time MAX 00 30 HOld Maximum Time MIN 00 01 SELECT Exi Select Hold Times press YES to modify press CONFIRM and the following screen will be displayed Press SELECT and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT to return to the menu and Select Hold Temperature and the following screen will be displayed Menu Hold Temperature Configuration Program 4 Hold Temperature Hold Temperature MAX Hold Tempersture MIN SELECT 15 C 20 C 02 C Exit Press SELECT and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT twice to return to the menu and Select Hold Humidity press SELECT followed by YES to modify press CONFIRM and the following
35. program parameters which condition the machine was in at the time For example if the machine was in storage mode at the time the fault occurred the likely although not certain cause would refrigeration related Similarly if the machine was in recovery heaters would probably be a good place to start OVER TEMPERATURE TEMPERATURE FAULT ACTIVATED In all probability it is almost certain that this fault would be caused by one or all of the fans being rendered inoperative The cause would most probably be controller output or solid state relay failure Another cause may be a contactor sticking on thus causing the heaters to operate continuously HUMIDITY LOW OR NO HUMIDITY This can be caused by a number of faults First check that the water supply to the steam tank is operating By energising the solenoid valve and ensuring that water is entering the tank the later can usually be done audibly Confirm correct operation of the humidity sensor As an initial indication use the display on the controller For example if the room is obviously dry but the display is showing 90 humidity the likely cause would be a humidity sensor failure If everything appears normal use a calibrated hand held 17 humidity device to compare the value indicated on the display with that on your meter Small differences 15 can be expected although more should be viewed with suspicion Ensure that the tank contains water it may not be filling although wat
36. rom the Storage Mode RETARD mode to the Recovery mode During the recovery mode the controller increases the temperature of the chamber linearly 1 from the storage temperature to the recovery temperature over 75 of the given period of time If other parameters allow it up to 82 humidity may be introduced during this phase Upon completion of the Recovery phase the Prove cycle commences The chamber is then increased to a higher temperature over 75 of given set time period During this phase 87 humidity may introduced into the chamber as required to maintain the required humidity When the Prove phase of the cycle is complete the operator is advised both audibly and visually that the current program is complete and is given an option to either extend the prove time or hold the product Assuming that these options are not selected the cycle is complete and as such is halted If the product is not ready at the bake time then a Extra Prove 10 minutes for a maximum of 15 minutes can be selected Similarly if the product is ready but there is no oven capacity the product can be held in Hold 10 minutes The duration of both Extra Prove and Hold are governed by the machine parameters Operator Program Description Each stage of the Retarder Prover cycle is explained as follows Figure 1 Retarder Prover Operating Cycle 28 C 15 C 7 C 52C jaat tor at PHASE 1 P
37. rst 0 Use the up arrow to change the level code to 1122 Press the up arrow once to change the 0 to 1 and then press select to move to the next 0 Continue until 1122 is on the display and then press Confirm Access Level Enter Code for Level L3 0000 A Exit Select Confirm The screen will change and display the followi ng Program 4 Modify Parameter Program Active Value yes Program Active and yes will flash on and off to proceed press CONFIRM The screen will change and display the following screen CONFIRM CANCEL CONFIGURE Program 4 This menu allows for the particular program to default parameters CONFIGURE Program 4 Program Name Fast Chill Parameters Storage Parameters Recovery Parameters Prove Parameters Min Prove Time Param Oven Contact Select Exit Program Name be given a name and the parameters to be adjusted within the The pre defined name of the program can be changed if required Configure Program 4 Accept EDIT Exit Select Program Name in Program Configuration 4 and the screen to the left will be displayed The Name is now displayed in the Start Menu To insert a short description for the Operation Mode into the Program Name e g Ret amp Prv Bread select EDIT and the first letter will have a symbol under it Use the up or down arrow scroll through the alphabet press SELECT to confirm
38. screen will be displayed Menu Hold Humidity Configuration Program 4 Hold Humidity Hold Humidity MAX Hold Humidity MIN SELECT 87 95 75 Exit Press SELECT and the screen will change to show the first digit for modification Use the UP and DOWN arrows to change the value and press SELECT to move to the next digit Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT three times to return to the Configure Program 4 menu 10 Select Minimum Prove Time Param from menu press SELECT followed by YES to modify press CONFIRM and the screen below will appear Menu Min Prove Time Param Configure Program 4 Press SELECT and the screen will change to show the first digit for Minimum Prove Time DT Modification Minimum Prove Time MAX 01 00 Use the UP and DOWN arrows to change the value and press Minimum Prove Time MIN 04 00 SELECT to move to the next digit SELECT EXIT Once the changes have been made press ACCEPT and proceed to change the other values if required NOTE It is not recommended to make changes to the values without managerial consent Press EXIT to return to the Configure Program 4 menu Oven Contact Parameters The Oven Contact parameters are not switched on so modification is not required
39. troller parameters set correctly the temperature displayed on the controller correct with that inside the chamber the controller end time been set correctly the refrigeration system operating correctly Are the heaters operating at the correct time or is or more all the time els there any delay between product production and loading into the retarder prover the controller parameters set correctly the temperature displayed the controller correct with that inside the chamber 19 EVAPORATOR FANS FED OW 3 1 LEVEL CONTROLLER 18706 REV BY DATE mE 57 FOSTER REFRIGERATOR U K LTD power TER DRP RI 2 T DRP RI 3 T OLDMEDOW ROAD KING S LYNN NORFOLK PESO 420 PAGE 1 lt yo SS SEE PAGE 1 lt WATER CONTROL CONTROLLER CONNECTIONS le 1 51 LC 1 52 LC 1 59 06 LEVEL CONTROLLER CHANGED _______ FOSTER FOSTER REFRIGERATOR U K LTD AUXILLARY CONTROL OLDMEDOW ROAD KING S LYNN NORFOLK PESO 430 SEE PAGE 2 lt SE PAGE 2 lt 08 LEVEL CONTROLLER TRI REV DESCRIPTION ________ rs 8358068 00 08 FOSTER FOSTER REFRIGERATOR U K LTD process CIRCUIT SHET 3 OF 3 ROAD KING S LYNN NORFOLK PESO 4JU
40. tus To continue to the next test press the RIGHT amp LEFT buttons simultaneously The next screen will display Factory Test Ver F203 7 Buzzer Test RIGHT LEFT Continue UP Buzzer ON DOWN Buzzer OFF LEFT MIDDLE RIGHT Factory test 7 Buzzer Test Follow the instruction on the screen To continue to the next test press the RIGHT amp LEFT buttons simultaneously The next screen will display Factory Test Ver F203 8 EEPROM Test RIGHT LEFT Continue LEFT Start Short Test RIGHT MIDDLE Long Test MIDDLE Restart Test 1 LEFT MIDDLE RIGHT Factory test 8 EEPROM test Press the LEFT button for a short test Press the RIGHT MIDDLE buttons for a long test Press the Middle button to return to factory test 1 On completion of the selected test press the left and right to return to the SYSTEM OFF PRESS START Screen Alarm Cancelation The alarm is activated if a fault is active Prior to clearing the alarm it will be necessary to change the faulty component However in the case of Overtemp Fault Over Pressure and Emergency Stop these are fault messages relating to situations and not specific component failure so resetting is all that is required To clear the alarm set the program to the SYSTEM OF PRESS START screen as below Start Screen Monday 08 11 SYSTEM OFF Press START 14 02 2009 START
41. used by a drain pipe blockage although this could be a symptom of the steam tank overfilling PRODUCT DOUGH SKINNING Rack Badly Positioned els rack positioned centrally between guide rails 2 eCheck pull down performance should be 20 C to 5 C in 40 Slow Pull minutes with an empty chamber Down evaporator fans running els refrigeration system evaporating at 12 C to 15 C 2 eCheck machine humidity parameters should be 80 85 els water supply to steam tank working Check Solenoid valve operation level Water control system Check Humidity In Chamber els the steam element heavily scaled els the steam tank heater working correctly els the humidity displayed by the controller correct with that inside the chamber Bakery Operation els there any delay between product production and loading into the retarder prover 18 UNEVEN PRODUCT DEVLOPMENT One Part Of The Rack Is More Or Less Proved Than Another Product Is Not Ready On Time Product Is Ready To Early rack positioned centrally between guide rails Are all the evaporator fans running the controller end time been set correctly the refrigeration solenoid leaking when closed 2 Are all the heaters operating correctly the fan speeds set correctly the con
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