Follett FZR User Manual

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Page 1

FZR Series

Undercounter Freezer

Order parts online www.follettice.com

Installation, Operation and Service Manual

Serial numbers C45184 and above

Following installation, please forward this manual

to the appropriate operations person.

801 Church Lane • Easton, PA 18040, USA Toll free (800) 523-9361 • (610) 252-7301 Fax (610) 250-0696 • www.follettice.com

00193474R00

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Welcome to Follett

Follett equipment enjoys a well-deserved reputation for excellent performance, long-term reliability and outstanding after-the-sale support. To ensure that this product delivers that same degree of service, we ask that you take a moment to review this manual before beginning the installation. Should you have any questions or require technical help at any point, please call our technical service group at (800) 523-9361 or (610) 252-7301.

Before you begin

After uncrating and removing all packing material, inspect the equipment for concealed shipping damage. If damage is found, notify the shipper immediately and contact Follett Corporation so that we can help in the  ling of a claim, if necessary.

Speci cations

Series speci cations

FZR5 34" height for freestanding use or installation below standard 36" (915mm) high counter

4.0 cu ft (usable cubic volume)

FZR4-ADA

31.25" height for freestanding use or installation below 34" (864mm) high ADA-compatible counter

3.3 cu ft (usable cubic volume)

Electrical speci cations

115V, 60Hz, 1 phase

Full load amps: 8.0

Minimum circuit ampacity: 15 amp

Maximum size of branch circuit overcurrent device: 15 amp

Refrigeration speci cations

Refrigerant – R404A

Charge size – 10 oz

Maximum design pressures:

High side – 383psi Low side – 175psi

Installation speci cations

Ambient temperature must not exceed 100 F (38 C).

The front louvered panel must be kept free of any cabinet trim or obstructions to ensure proper ventilation of the refrigeration system.

Important cautions

• Equipment must be wired according to local and NEC codes.

• Always disconnect power before servicing freezer.

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Installation

Installing legs – required

1. Remove legs from plastic bag packed inside freezer.

2. Tip freezer back and screw legs in all the way to stop (they will extend 1/8" below base of freezer).

3. Adjust legs as needed to level freezer in both directions. To access legs, remove the lower front panel. Turn legs clockwise to extend legs.

Installing shelves – required

1. Remove shelves and shelf brackets packed inside freezer.

2. Install shelf brackets in pilasters (insert top tab, squeeze and push in lower tab).

Fig. 1

Fig. 2

Changing temperature controller settings – optional

Follett’s temperature controller is pre-programmed with a -25 C (-13 F) set point and degrees C display. The -25 C (-13 F) set point delivers a temperature range of -23 to -25 C (-9 to -13 F). Follett’s controller set point can be changed to deliver up to a -15 C (+5 F) temperature for applications where a lower temperature is not desired (i.e. ice cream). See page 6 to change controller settings.

Fig. 3

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Reversing the door swing – optional

NOTICE

When reinstalling latch and hinge screws, 242 blue Loctite* MUST be applied to screws. Torque screws to 25 in-lbs.

1. Remove screws and latch from refrigerator cabinet (Fig. 4.1).

2. Use  at screwdriver to carefully remove (do not scratch) hinge covers (Fig. 5.1).

Fig. 4

3. Support door and remove screws attaching hinge to refrigerator cabinet (Fig. 5.2).

4. Cover hinge screw holes with screw hole plugs removed from opposite side.

5. Reverse door. Apply 242 blue Loctite to hinge screws and reinstall torqued to 25 in-lbs.

6. Reinstall latch on opposite side.

7. Remove screws and handle from door (Fig. 6.1).

8. Rotate handle (Fig. 6.2).

9. Apply 242 blue Loctite to latch screws and reinstall torqued to 25 in-lbs.

Fig. 5

Fig. 6

Loctite is a registered trademark of Henkel Corporation in the United States and other countries.

Page 6

Controller operation

In normal operation the controller displays cabinet temperatures in degrees C (default) or user-selected degrees F. Degrees C temperatures are displayed to 1 decimal point.

Fig. 7

refrigeration system energized

evaporator fan energized

Rocker buttons to the right of the temperature display control all programming functions.

The controller is pre-programmed with a -25 C (-13 F) set point which provides a compressor cut-in at -23 C (-9 F) and cut-out at

-25 C (-13 F). The controller set point can be raised to -15 C (+5 F)

for nourishment applications where a lower temperature is not desired (i.e. ice cream). Follow instructions for changing temperature cut-out below.

All set points have a 2 C differential. The 2 C differential means that with a -25 C set point, for example, the compressor will turn off at -25 C (-13 F) and turn on when it reaches -23 C (-9 F).

- 25

defrost

°C

To display temperature cut-out

STEP INPUT DISPLAY

1 Press and release SET Current cut-out temperature will display for approximately 5 seconds. Display will return to current refrigerator temperature.

To change temperature cut-out

STEP INPUT DISPLAY

1 Press and hold SET for Current cut-out temperature displayed and °C (°F) will  ash 3 seconds

2 Press UP or DOWN arrows to New cut-out temperature displayed desired cut-out temperature

3 Press and release SET New cut-out temperature blinks three times, then current refrigerator temperature will display

To change temperature display from degrees C to degrees F

Follett includes a programming key (part# 00193375) that changes the display and temperature settings from degrees C to degrees F.

Programming freezer from a degree F key (download)

1. TURN OFF freezer.

2. Remove 6 screws from panel holding controller to access back of controller.

3. Insert degree F programmed key into 5 PIN receptacle on controller back.

4. TURN ON freezer.

5. Values from key automatically download to freezer (“dol” message blinks followed by “end”).

6. After 10 seconds display returns to current freezer temperature and controller will restart with new values.

7. TURN OFF.

8. Remove key.

9. Reinstall panel.

Note: An “Err” message displays for failed programming. Turn freezer OFF then ON to restart download, or remove key to abort.

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Controller security

The controller panel can be locked to prevent inadvertent or intentional programming changes. In locked mode, the controller will display cabinet temperature and cut-out set point only.

To lock the controller

1. Press the UP and DOWN ARROW buttons together for 3 seconds until “PoF” displays (will  ash 3 times).

2. Programmer is now locked.

To unlock the controller

1. Press UP and DOWN ARROW buttons together for 3 seconds until “Pon” displays (will  ash 3 times).

2. Programmer is now unlocked.

Controller programming key degrees C (optional accessory)

A controller programming key is available from Follett to provide fast and easy reprogramming of factory settings in degrees C (part# 00193383).

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Operation

The temperature controller and probe indicate when the refrigeration system is required to turn on and off.

The refrigeration system removes heat from the cabinet interior and rejects it to the surrounding room air. When the cabinet interior temperature reaches +2.2 C (+4 F) above the controller set point, the probe signals the controller to turn the refrigeration system on. The normally-open controller contacts 4 and 5 close and energize the evaporator and condenser fan motors, compressor and door heater. The snow ake and fan LED's on the controller will come on to indicate the refrigeration system is on. The compressor uses a current-style starting relay and a starting capacitor to start the compressor motor.

When the cabinet interior temperature falls to the set point, the probe signals the controller to turn the refrigeration system off. The controller contact 5 reopens, which de-energizes the condenser fan motor and the compressor. The snow ake LED will go out and the fan LED will remain on.

Any accumulated frost on the evaporator coils melts during the defrost cycle. Freezer products will remain at or below -15 C (-5 F) during the defrost cycle. The condensate drains to a drain pan mounted along the condensing unit. The heat from the condensing unit evaporates any condensate in the drain pan.

Temperature control

The temperature control system is preset by the factory to maintain a cabinet temperature of -23 C (-10 F). If desired, the cut-out temperature can be raised as high as -15 C (5 F) by following the instructions on page 6 for changing the temperature set point. The 2 C cut-out differential will be maintained regardless of the controller set point.

Defrosting

The FZR series undercounter freezers control frost accumulation on the evaporator through automatic timed defrost cycles. The defrost cycle is initiated by the temperature controller every 4 hours. Contacts 4 and 5 on the controller open and the refrigeration system is turned off. Contact 2 is closed and the defrost heater is energized. The melting snow ake LED on the controller will come on, and the temperature display will read: “dEF” to indicate the freezer is in the defrost cycle.

The heater warms the evaporator coil and drain pan to melt the frost and drain the water to the condensate pan. The temperature controller monitors evaporator temperature using a probe embedded in the coil. The controller terminates the defrost cycle when the evaporator temperature reaches +5 C (+41 F) or after 15 minutes of defrost time, whichever occurs  rst. As the defrost cycle terminates, the controller de-energizes the heater and restarts the compressor and condenser fan. The snow ake LED on the controller will come on to indicate the refrigeration system is running.

There is a 5 minute delay before the evaporator fan motor is re-energized. The fan LED on the controller will come on to indicate the fan is running and the temperature display resumes displaying cabinet temperature. A defrost cycle can be initiated manually at any time by depressing and holding the melting snow ake button for approximately three seconds. As a safety feature, a temperature safety switch mounted on the evaporator will turn off the defrost heater if the temperature of the evaporator reaches +27 C (+80 F) regardless of controller operation.

The FZR series freezers have been designed speci cally for the storage temperature–critical medications and vaccines. Other storage applications may require modi cations of the factory-programmed defrost cycle settings. Please consult Follett technical service of defrost modi cation is needed.

Cleaning

Use only non-chlorine-based cleaners. Cleaners containing chlorine can cause staining and pitting of the stainless steel.

Interior – Using a sponge or soft cloth, clean unit with a non-abrasive, non-chlorinated, all-purpose detergent.

Exterior – Wipe exterior with a soft cloth in the direction of grain as needed. Stainless steel polish may be used to

enhance the  nish of the unit.

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Annual cleaning

Easton Pennsylvania

MOTOR COMPRESSOR THER

MALLY PRO

TECTED

DESIGN PRESSURE HIGH SIDE

RAN

CH CIRCUIT AMP

ACITY

MAX. BRANC

H C

IRCUIT FUSE SIZE

SINGLE PHASE

LOW SIDE

THE USA

DE I

S F

U L

PART NO

CHARGE

VOLTS

CORPORATION

SERIAL NO

MODEL

FULL LOAD AMPS

REFRIGERANT

Removal of dust and other particulates from air intake areas and the condenser is important for proper operation. Some environments with large amounts of dust may require more frequent cleaning.

1. Disconnect power to unit by turning switch on the lower

front panel to the OFF position, switching circuit breaker to OFF position, and removing power cord from receptacle.

2. Remove lower front panel (Fig. 8.1).

Note: Front louvered panel may be completely removed

for easier cleaning by disconnecting the controller wiring plugs from the freezer.

3. Remove drain pan (Fig. 8.2).

4. Clean drain pan with a non-abrasive, non-chlorinated all-

purpose detergent.

5. Reinstall drain pan.

6. Use a vacuum cleaner with brush attachment to clean

condenser through lower front panel and compressor motor and related parts through lower rear panel.

7. Reinstall lower front panel.

Service

Fig. 8

Fig. 9

Latch adjustment

To adjust for proper latch engagement

1. Loosen striker plate mounting screws (Fig. 9.1).

2. Move striker plate up or down as required and tighten screws.

3. Test operation of latch.

To adjust for proper gasket seal

1. Loosen striker depth adjustment screw (Fig. 9.2).

2. Adjust stop in or out and tighten screws.

3. Test operation of latch.

Door gasket replacement

1. Remove existing gasket from mounting track.

2. Verify mounting track is free of any remaining gasket material.

3. Align new gasket with mounting track and press  rmly in place.

4. Open and close door, checking for proper gasket seal without pinching against freezer.

5. Adjust latch and or striker as necessary for proper door closure.

Fig. 10

Slide-out compressor tray

Follett’s slide-out compressor tray allows technicians to partially slide the condensing unit from the freezer back without cutting refrigerant lines.

1. Remove rear panel (Fig. 10.1).

2. Remove two bolts securing condensing unit to refrigerator base (Fig. 10.2).

3. Gently slide condensing unit out (Fig. 10.3).

Note: Do not put undue strain on the refrigerant lines.

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Controller replacement

1. Disconnect power to unit. a. Push front panel rocker switch to OFF position. b. Disconnect power cord.

2. Remove 6 screws from front panel and slide panel forward to access back of controller.

3. Disconnect front panel and wiring harness from freezer at the 3, 4, and 5 pin connectors and door heater connector to simplify replacement.

4. Push in on center of side brackets (on controller) to release and slide brackets back and off controller.

5. Push controller and wires out through front of front panel.

6. Using wiring schematic (attached to front panel and below) as a guide, remove wires one at a time from back of existing controller and connect to corresponding terminals on replacement controller.

7. Insert replacement controller back through front of panel.

8. Slide brackets onto sides of controller and push against back of front panel.

9. Reconnect 3, 4, and 5 pin connectors of wiring harness to freezer.

10. Keeping wiring clear of condenser, replace front panel.

11. Restore power and test operation. Reprogram replacement controller if necessary.

Wiring diagram

120 VAC 1 PHASE 15 AMPS

COMP

BLK

WHT

CONDENSING UNIT

GND

GROUND SCREWS

EVAPORATOR THERMISTOR

1110

1312

FAN

WHT

CHAMBER

THERMISTOR

BLU

DOOR

HEATER

RED

GRN

WHT

RED

BLK

SAFETY SWITCH

DEFROST

FAN

EVAPORATOR UNIT

1 2 3

1 2 3 4

1 2 3 4 5

HEATER

DEFROST

BLK

WHT

1 2 3

1 2 3 4 5

WHT

RED

BLK

BLU

YEL

WHT

VIO

BLK

SUPPLY

VAC

97654321 10

11 12

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Refrigeration system

The FZR series -20 C (-4 F) freezer refrigeration system is designed to give many years of trouble-free service. Except for routine cleaning of the air-cooled condenser and related parts, the refrigeration system requires no service or maintenance. The system uses a thermostatic expansion valve and is critically charged. Access  ttings are provided for ease of service. However, the connection of refrigeration service hoses to the  ttings will almost invariably result in a signi cant change in the system charge. This change can adversely affect the performance of your freezer. Therefore, Follett recommends that if hoses are ever connected to the refrigeration system for service, the refrigerant should be recovered, the system evacuated, and recharged by weighing in the correct refrigerant charge.

Note: Do not charge the system by pressures.

Checking refrigeration system pressures

1. Remove the rear access panel (Fig. 10).

2. Turn the power switch to the on position.

3. Following the instructions on page 6 verify that the temperature controller is set to the original factory cut-in setting of -23 C (-9 F).

4. Allow the freezer to operate and stabilize at least 60 minutes, verifying the cut-out temperature is being reached.

5. Connect refrigerant hoses to access  ttings and measure air temperature at condenser intake grille.

6. Verify correct pressures with the temperature chart below.

7. Troubleshoot refrigeration system as needed.

Condenser inlet air temperature 70 F 80 F 90 F 100 F

Discharge pressure (psi) 197 225 255 285

Suction pressure (psi) 12 13 14 15

Note: Do not attempt to obtain correct refrigeration pressures by adjusting the system charge.

Refrigeration system diagram

COMPRESSOR

10oz. Charge

Low Psi

Vapor

EVAPORATOR FAN

EVAPORATOR

DEFROST HEATER

LOW SIDE

SERVICE PORT

HIGH SIDE

SERVICE PORT

High Psi

Vapor

FA N

Low Psi

Liquid

EVAPORATOR/DEFROST UNIT

HIGH PRESSURE VAPOR LOW PRESSURE VAPORHIGH PRESSURE LIQUID LOW PRESSURE LIQUID

TXV

HEAT EXCHANGE

DRYER

High Psi

Liquid

CONDENSING UNIT

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Freezer troubleshooting guide

Before calling for service

1. Check that unit is plugged in.

2. Test outlet with another appliance to verify power.

Symptom

Freezer does not operate (no components run).

Compressor does not run.

Compressor and condenser fan do not run.

Evaporator fan motor does not run.

Freezer does not shut off.

Possible cause

1. Power switch faulty or in OFF position; loose connection.

2. Freezer not plugged in.

3. No power to cord.

4. Temp controller not energizing components.

5. Probe not sensing cut in temperature.

1. Thermal overload open or defective.

2. Capacitor and/or relay defective.

3. Compressor defective.

1. No power on terminal 5 of controller (during cooling).

1. No power on terminal 4 of controller (during cooling).

1. Controller not sensing cut off temperature.

2. Controller keeping refrigeration system energized.

Solution

1. Turn power switch to ON position; check switch and connections.

2. Connect plug.

3. Restore power.

4. Check controller contact terminals for power. Replace controller if needed.

5. Replace controller and/or probe.

1. Allow to cool or replace.

2. Replace as required.

3. Replace compressor.

1. Replace controller

1. Replace controller.

1. Replace controller and/or probe.

2. Replace controller.

Freezer does not maintain temperature (all components run).

Evaporator does not defrost.

If problems persist after following this basic troubleshooting guide, call Follett’s

technical service group at (800) 523-9361 or (610) 252-7301.

1. Condenser or evaporator coil needs cleaning.

2. Faulty door gasket.

3. Excessively high ambient.

4. Refrigerant leak.

5. Incorrect refrigerant charge.

6. Plugged expansion valve.

7. Inefficient compressor.

8. Evaporator coil blocked with ice.

1. Defective defrost heater.

2. Faulty heater safety switch.

3. No power on terminal 2 of controller (during defrost).

1. Clean coils as needed.

2. Replace door gasket.

3. Maximum recommended ambient is 100 degrees F.

4. Locate and repair leak.

5. Recover, evacuate and weigh in correct charge.

6. Replace expansion valve.

7. Consult technical service.

8. Depress defrost button on controller to defrost coil.

1. Replace defrost heater

2. Replace switch.

3. Replace controller.

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Accessories

Dip Switch OFF (factory default setting) ON

1 No alarm delay 45 minute alarm delay 2 Auto reset (alarm stops automatically as Manual reset of alarm (user must press soon as temperature returns to set range) RESET button to stop audible alarm even if temperature has returned to set range) 3 & 4 Audible alarm on (no snooze with both off) No audible alarm 3 Enables 5 min alarm “snooze” Enables 45 min alarm “snooze” when reset button is pressed (3 off with 4 on) when reset button is pressed (3 on with 4 off)

Black

White

Red

Com

Output

Sensor

Power

Temperature alarm

Before installing alarm

1. Remove supplied 9-volt back-up battery from packing box.

2. Remove 2 screws from module face and remove faceplate.

3. Install back-up battery on battery connector.

4. Locate DIP switches on the back of the faceplate (Fig. 11).

5. Review the factory DIP switch settings (Fig. 12) and make any changes required to meet the needs of your speci c application.

6. Reinstall faceplate.

Fig. 12

Fig. 11

POWER

SENSOR

OFF

OUTPUT

Installing alarm

Fig. 13

1. Mount alarm in desired location with screws (supplied by others) through back of housing. Do not place undue strain on probe cable.

Note: Do not modify length of probe wire. Probe will

not measure temperature correctly if wire length is changed.

2. Plug power cord into 110 outlet.

3. Push center tab of short bottle bracket into top of rear left pilaster (Fig. 13).

Note: Use longer bottle bracket for FZR5 freezers using

cut-out upper shelf accessory.

4. Fill bottle with glycerin or other liquid to increase accuracy of readings by simulating the internal temperature of medications.

5. Insert bottle into bottle bracket.

Fig. 14

6. Route probe through hole in refrigerator back and push probe down through gasketed bottle top.

Note: Alarm probe must be placed in bottle for

proper system operation. Refer to Fig. 14 if attaching alarm to central monitoring or central alarm system. A SPDT 1 amp 24V AC resistive relay is provided for this connection.

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Setting alarm temperatures

Fig. 15

1. After the installation is complete, allow 30 minutes for the system to stabilize to ambient temperature.

2. Calibrate temperature alarm to refrigerator display

a. Calibration is best done with the alarm probe removed from the

probe bottle and placed in the vicinity of the temperature controller probe. Allow at least 15 minutes for the probe temperature to stabilize.

b. Note the temperature value displayed on the refrigerator controller

and subtract the temperature value displayed on the alarm. This value is the differential.

Example: Temperature controller: 36 F Alarm: 38 F Controller – Alarm = Differential 36 – 38 = -2

c. Press SET until “CAL” is displayed (Fig. 15.1).

d. Press SET again to display “CAL” value (Fig. 15.1).

e. Press top or bottom of ADJUST arrow to display the calculated

differential (-2°F in example above).

3. Set high alarm limit a. Press SET until “HSP” is displayed (Fig. 15.1).

b. Press SET again to display HSP value (Fig. 15.1).

c. Press top or bottom of ADJUST arrow until desired HSP value is

displayed (Fig. 17.2).

4. Set low alarm limit a. Press SET until “LSP” is displayed (Fig. 15.1).

b. Press SET again to display LSP value (Fig. 15.1).

c. Press top or bottom of ADJUST arrow until desired LSP value is displayed (Fig. 15.2).

5. Display will return to temperature display in approximately 15 seconds.

6. Place alarm probe back in probe bottle.

Viewing high/low log

Follett’s alarm module allows users to view the highest and lowest temperatures recorded since the last time the RESET button was pressed.

To view high and low log values

1. Press SET button until “HI” appears.

2. Press SET button to view HI log value.

3. Press SET button until “LOW” appears.

4. Press SET button to view low log value.

5. Press RESET button to clear log.

Alarm operation facts

The back-up battery will continue to provide alarm protection during power failure but will alarm ONLY if temperatures go out of the selected range. During power failure the alarm face will be dark but temperatures can be read by pressing the RESET button.

Because the temperature alarm display simulates the true temperature of stored medications rather than the air temperature inside the freezer, we suggest that staff refer to the alarm display to log temperatures for JCAHO compliance.

Automated medication dispensing and inventory systems interface

(Pyxis*, Omnicell*, MedSelect*, etc.)

Follett refrigerators and freezers are compatible with most major automatic medication and inventory systems. In some cases a Follett bracket accessory is required. Contact factory for further information.

*Pyxis is a registered trademark of Cardinal Health in the United States and other countries. *Omnicell is a registered trademark of Omnicell, Inc. in the United States. *MedSelect is a registered trademark of AmerisourceBergen Technology Group, in the United States.

Page 15