Foster EcoPro G2 Series Original Service Manual

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By Appointment to

Her Majesty Queen Elizabeth II

Suppliers of Commercial Refrigeration

Foster Refrigerator, King’s Lynn

Call: [phone] Fax: [phone] Email: [e-mail]

www.fosterrefrigerator.co.uk

A Division of ITW Ltd
Foster Refrigerator,

Oldmedow Road,
King’s Lynn,
Norfolk, PE30 4JU
United Kingdom

ISO 9001 ISO 14001

Original Service Manual

EcoPro G2 Cabinets

FD1-11 Controller & Display

March 2012 Version 1

English

0771

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1

Manual Information & Health & Safety Notes

1

Environmental Management Policy

2

Disposal Requirements & Electrical Safety

2

EcoPro G2 Cabinet Description

3

Display Icons & Switches

3

Start up, Standby, User Adjustments

4

Temperature Sensitivity, Key Security, Light Function, Downloading, Defrost Function &
Reduced Energy Control.

5
FD1-11 Controller Connection Drawing, Technical Data & Configuration of Parameters

6

Default Parameters Explained

7 to 12

Individual EcoPro G2 Cabinet Parameter Values

13 to 15

Technical Data

16 to 17

Wiring Diagrams & Probe details

18 to 20

Troubleshooting & Notes

21 to 24

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 taken when handling or working on the unit as sharp edges

may cause personal injury, we recommend the wearing of suitable PPE.

Ensure the correct moving and lifting procedures are 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 (PPE) are used for you own safety.

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.

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Product Support and Installation Contractors.

Foster Refrigerator recognises that its activities, products and services can have an adverse impact
upon the environment.
The organisation is committed to implementing systems and controls to manage, reduce and
eliminate its adverse environmental impacts wherever possible, and has formulated an
Environmental Policy outlining our core aims. A copy of the Environmental Policy is available to all
contractors and suppliers upon request.
The organisation is committed to working with suppliers and contractors where their activities have
the potential to impact upon the environment. To achieve the aims stated in the Environmental
Policy we require that all suppliers and contractors operate in compliance with the law and are
committed to best practice in environmental management.
Product Support and Installation contractors 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 further information if necessary.

5. Ensure that all waste is removed by a registered waste carrier, a carrier in possession of a waste
management licence, or a carrier holding an appropriate exemption. Ensure the person receiving the
waste at its ultimate destination is in receipt of a waste management licence or valid exemption.

6. 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 into storm
drains, foul drain, or surface water to soil.

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.

Foster Refrigerator recommends that the equipment is electrically connected via a Residual Current
Device; such as a Residual Current Circuit Breaker (RCCB) type socket, or through a Residual Current
Circuit Breaker with Overload Protection (RCBO) supplied circuit.

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The EcoPro G2 range comes as a Full Gastronorm format in a variety of capacities and
temperatures. A standard unit comes with 2/1 shelves (3 with a single model, 6 with a double
model).
The fish model comes fitted with fixed racking to take 7 fish boxes (198kgs) as standard whereas
the wine version comes with a racking assembly that holds either 140x75cl bottles (for a single
model) or 280 x 75cl (for a double model).
The units are manufactured as a one piece shell with easy clean stainless steel exterior. Each
conforms to the current legislation and exceeds the Montreal protocol by using zero ODP (ozone
depleting substances) refrigerants and insulation. There is also the added option of having
Hydrocarbon refrigerant with certain model variations.

Each unit’s temperature is controlled by a microprocessor with digital temperature display. There are

several temperature options available exceeding the Climate Class 5 operations by giving an
ambient temperature to 43°C.
Each temperature display is also easy to read with a wipe clean finish.

The standard form of refrigeration system in this unit is integrated with an air-cooled condensing
unit that allows cooled air to circulate through the evaporator, via the fan into storage areas. It does
this by distributing the refrigerant into the evaporator controlled by a capillary.
Remote systems are also available as an option, the difference being, the evaporator is controlled by
an expansion valve instead of capillary.
Other points to be made on these units are that they have coated coils to prevent corrosion and to
help prolong the refrigerator’s life.

Cabinets come with an easily removable plug box and lid.

Keypad Lock

Warning/ Alarm

Service Mode

Temperature Setting

Functions Icons

Temperature Display

Compressor Function

Defrost Function

Evaporator Fan Function

Reduced Energy Mode

Data Download Switch

Light Switch

Power Switch

Decrease Switch

Increase Switch

(Some icons or switches are only visible during adjustment, when activated by parameters or

through operation/manual selection).

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Initial Set Up
After unpacking clean and allow the cabinet to stand for 2 hours before turning on.

Ensure the cabinet is situated where neither hot nor cold air sources will affect its performance.
Make sure that a minimum clearance of 310mm above and 50mm around the cabinet is available for
ventilation and effective operation.

Initial Start up

Connect the unit to a suitable mains power outlet and turn the supply on. Please do not plug or
unplug the unit with wet hands.

The cabinet will energise briefly showing -- followed by the power switch slowly pulsing with a

blank display. The unit is now in standby.

Pressing this switch for 3 seconds will turn the unit on (the switch backlight is static and the display
shows the operating temperature) or put into standby (the switch backlight pulses slowly on & off).
As the operating temperature has been pre-set no adjustments are required. Allow the cabinet to
reach its normal/set operating temperature before loading.

You are required to enter this mode to make any setup changes.
These include Set Point, Keypad Security, and display of T1, 2 or 3 probe temperatures.

Press and immediately release , after which the and switches will flash/pulse together.

Press to scroll through the following screens:

To exit this mode scroll back to the adjustment screen and press or wait for 30 seconds and the
display will revert to the normal display showing the operating temperature.

Access the adjustment mode as described above. Using the or switches to scroll to the mode

that requires adjustment i.e. ‘Set Point’ this is the minimum temperature the cabinet is allowed to

cool down to (the display shows the temperature and flash/pulsing icon).

To adjust this press and release the icon will show constantly. Adjust the setting with the

or switch. Confirm the change by pressing and releasing again, the next mode will

automatically show. Scroll through the modes with the or switch until you return to the

adjustment screen and press and release to exit and save.

If at any point the display is left for 30 seconds it will revert to the normal display and no
changes will be saved.

T1

Probe

Temperature

Keypad

Security

Screen

Set

Point

Screen

Adjustment

Screen

T2 Probe

Temperature

T3 Probe

Temperature

Only visible when fitted

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If you require the cabinet to have a more accurate or increased sensitivity to temperature and the
warnings this controls, the controller is able to measure temperature in 1/10ths of a degree (0.1°)
instead of whole degrees.
With parameter ‘SC’ set to ‘1C’ the display will show the temperature as 1/10ths of a degree on the
scale between -9.9°C to +9.9°C.

Also, with parameter ‘SC’ set to ‘1F’ the controller has the facility to show the temperature in Fahrenheit (between ­58°F to 99°F). However if this is selected all other temperature related parameter values will have to be set

accordingly to this change. (See ‘Configuration of Parameters’ for information on how to access this).

Access the ‘Keypad Security’ screen as described before.

The screen will show the current status, initially pre-set to ‘ ’, with flashing. Press and release

and will show constantly. (If you modify this setting with to show ‘ ’ the keypad will be

locked, will show constantly and the cabinet will not be able to be put into standby, carry out a
manual defrost, adjust temperature set point, download data or switch on/off the units lights. To

confirm any change you must press again so the next screen ‘ ’ shows).
Exit any of the ‘Adjustment Modes’ as described before.

To switch on the lights press and release so that the switch backlight is on continuously. To

switch off press and release and the switch backlight will flash/pulse.

This option is only available when enabled via parameters and the cabinet has the additional FCOM1
device available –this availability will be shown by the data switch being constantly illuminated.

To download the data the switch should be pressed and then released. The information will then begin
downloading to the appropriate printer or PC and the backlight of the switch will flash. On completion the switch will
return to constant state of illumination.

All Foster G2 cabinets are fitted with a fully automatic defrost system to ensure that the evaporator
coil remains free from ice during normal use. Melt-water is evaporated using either the heat from
the refrigeration system or a separate electric heater (dependent upon model and configuration).

To activate a manual defrost – while the cabinet is in ‘run’ mode press and hold for 5
seconds. After 3 seconds the display will go blank then return after a further 2 seconds. At this point
a defrost will be performed (subject to underlying operating parameters), this will terminate
automatically.

The reduced energy control mode (‘e’ mode) detects when the unit has reached the selected
temperature set-point and the operating conditions (such as usage rate) have become less
demanding.
When enabled, the controller will modify the compressor, evaporator fan and defrost operation in

order to reduce the energy consumed. During the reduced energy control mode is illuminated at
the bottom right corner of the display.
Upon an increase in operating demand the controller reverts back to the standard operating settings

with the symbol extinguished. The ‘e’ mode is enabled by setting parameter ‘iiM’ to ‘Au’. Further

parameter settings (‘iiS’, ‘iit’, ‘iiP’, ‘iiY’, ‘iiF’, ‘iid’, and ‘iiE’) control the temperature cycle during the
reduced energy control mode. Setting parameter ‘iiM’ to ‘no’ disables the ‘e’ mode.

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Power Supply

FD1-11
230Vac±10%,
50/60Hz, Operating 3.2W, Standby 0.9W

Measurement Range

-50…120°C, -55…240°F

-50 / -9.9…19.9 / 80°C (NTC 10K Only)

Relay Output

Compressor - 16(8) A 240Vac
Defrost - 16(4) A 240Vac

Measurement Accuracy

<0.5°C within the measurement range

Evap. Fan - 16(4) A 240Vac
Auxiliary Loads 1 - 8(2) A 240Vac

Input

NTC 10KΩ@25°C

CE (Reference norms)

EN60730-1; EN60730-2-9
EN55022 (Class B)
EN50082-1

Parameters should not be changed unless you have an understanding of their purpose and
the following instructions are fully understood.

To gain access to the parameters use the ‘Adjustment Mode’. This is accessed by pressing

and releasing the switch. After selecting this mode press and hold and together
for 5 seconds. The first parameter will show on the display.

Using the and switches you can scroll through all parameters and their values.

If you wish to change a parameter value press and release the switch when one the

desired mnemonic. Once selected in this way use the and switches to modify. When

the new reuired value is shown it will be saved by pressing and relaeasing the switch.
After which the display will show the next parameter.

To exit this mode or revert to normal operating mode, press and together then
release.

If at any point no buttons are pressed for 30 seconds without saving a new value the display will
return to the standard temperature display without changes being made.

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EcoPro G2 FD1-11 Controller Default Parameter Values

Para Cond Range Description Dim FD1-11

SL -50 ... SH Minimum limit for ‘SP’ setting °C 1

SH SL … 90° Maximum limit for ‘SP’ setting °C 3

SP SL ... SH Temperature set point to be achieved °C 1.5

CH RF - HE Refrigeration or Heating control mode Flag RF

HY 1 … 9.9° Off/On thermostat differential °K 3

CR 0 ... 30min Compressor Rest Time Min 2

C1 0 ... 30min

Thermostat run times with faulty T1
probe (‘C’ = 0 output with faulty T1 will
always be off).

Min 6

C2 0 ... 30min

Thermostat run times with faulty T1
probe (‘C1’ = ‘0’ & ‘C1’ => ‘0’ output with
faulty T1 will always be on

Min 4

CS 0 ... 30min

Compressor stop delay after door has
been opened (only if ‘DS’ – ‘1’)

Min 1

DM

Defrost start mode:

Func. TM

NO

Defrost is disabled (the following
parameter will be ‘FM’)

TM Regular time defrost

FR

Defrost time elapses only in condition of
frost accumulation

DB

‘DM’ = ‘TM’ or ‘FR’

0 ... 90 Hrs Time interval between defrosts Hrs 6

DF

Defrost tmer clock:

Flag YS

YS

Following mains interruption, timer
resumes count

NO

Following mains interruption, timer
restarts from zero

DL -50 … 90°

Defrost end temperature (only if ‘T2’ =
‘1’)

°C 15

DT 1 ... -0min Maximum defrost duration Min 20

DY

Defrost type:

Func. OF

OF

Timed off cycle defrost (compressor and
heater off)

EL

Electric heater defrost (compressor and
heater on).

GS

Hot gas defrost (compressor and heater
on)

DS

Defrost synchronisation:

Func. HI

OF

No synchronisation (defrost occurs
immediately when scheduled).

LO

Defrost waits until T1 = lowest part of
cycle (when compressor would normally
‘cut-off’).

HI

Defrost waits until T1 = highest part of
cycle (when compressor would normally
‘cut-in’).

ST 0 ... 30min

Defrost synchronisation time out when
‘DS’ = ‘LO’ to provide maximum time
defrost can be deferred.

Min 5

DP 0 ... 90sec

Evaporator pump down. Timed pause at
start of defrost

Sec 0

DR 0 ... 20sec

Defrost pressure reduction. At end of de­frsot, time compressor continues running
after hot gas solenoid valve shuts

Sec 3

DN 0 ... 30min Drain down period Min 1