Foster FCI30, F40, FCI20, F85, FCI85 User Manual

S e r v i c e M a n u a l

F20, F40, F60, F85

&

FCI20, FCI30, FCI40

FCI60, FCI85

Cube Ice Maker

CONTENTS

Page

1. General Information and Installation Instructions 2

1.1 Introduction 2

1.2 Unpacking and Inspection 2

1.3 Location and Leveling 2

1.4 Water Supply and Drain Connections 2-3

1.5 Final Checklist 3

1.6 Installation Practice 3

2. F20 and F40 Technical Data and Operating Instructions 4

3. F60 and F85 Technical Data and Operating Instructions 5-6

3.2 Cleaning/Rinsing For F20, F40, F60, F85 6

3.3 F20 F40, F60 F85, Wiring Diagrams 7

4. Technical Specification R22 Machines FCI 20, 30, 40, 60, 85 8

5. Operating Instructions 8-9

6. Principles of Operation 9-11
Wiring Diagrams

7. Dip Switch Positions And Settings 12
Plus Dip Switch Settings for FCI 20,30, R134A Machines

8. Circuit Board and Component Sequence of Operation 13

9. Technical Specification R134A Machines FCI 40,60,85 14

10. Operating Instructions 14-16

11. Principles of Operation 16-17

12. Components Description 17-18

13. Dip Switch Settings 18

14. Wiring Diagram 19

15. Circuit Board and Component Sequence of Operation 20

16. Maintenance and Cleaning Instructions All Models 21-22

Foster Ice Cuber Machine

1

1. General Information and Installation Instructions

1.1 Introduction

The Electronic Cubers are quality designed, engineered and manufactured.
Their ice making systems are thoroughly tested providing the utmost in flexibility to fit the needs of a particular user.
These icemakers have been engineered to our own rigid safety and performance standards.
The VDE – SEV – WRC seals signify that it is listed with them and that it complies with the materials and manufacturing standards of them.

Note. To retain the safety and performance built into this icemaker, it is important that installation and maintenance is conducted as

outlined in this manual.

1.2 Unpacking and Inspection.

1. Visually inspect the exterior of the packaging and pallet. Report any damage to the delivery carrier and your distributor.

2. a) Cut and remove the plastic strip securing the carton to the pallet.
b) Cut open the top of the carton and remove the polystyrene protection sheet.
c) Pull out the polystyrene posts from the corners and then remove the carton.

3. Remove the front and rear panels of the unit and inspect for any concealed damage. Report the damage to the distributor.

4. Remove all internal support packing and masking tape.

5. Check that refrigerant lines do not rub against or touch other lines or surfaces, and that the fan blade moves freely.

6. Use a clean damp cloth to wipe the surfaces inside the storage bin and the exterior of the cabinet.

7. See the data plate on the rear of the machine and check that the local mains voltage corresponds with the voltage specified on the plate.

CAUTION. INCORRECT VOLTAGE APPLIED TO THE MACHINE WILL INVALIDATE THE WARRANTY.

1.3 Location and Leveling.

Warning. This Ice Cuber is designed for indoor installation only. Extended periods of operation at temperatures exceeding the following

limitations will constitute misuse under the terms of the Manufacturers Limited Warranty resulting in Loss of warranty coverage.

1. Position the machine in the selected permanent location. The criteria for the location includes:
a) Minimum room temperature 10°C (50°F) and maximum room temperature 40°C (100°F°
b) Water inlet temperatures: minimum 5°C (40°F) and maximum 40°C (100°F)
c) Well ventilated location for air cooled models. Clean the air cooled condenser at regular intervals.
d) Service access: adequate space must be left for all service connections through the rear of the ice maker. A minimum clearance of 15cm
(6in) must be left at the sides of the machine for routing cooling air drawn into and exhausted out of the compartment to maintain proper
condensing operation of the air cooled models.

NOTE. With the machine in ‘built-in’ conditions, the ice product is gradually reduced in respect of the levels shown in the table, up to a maximum

of 10% at room temperatures higher than 32°C.

The daily ice-making capacity is directly related to the condenser air inlet temperature, water temperature and also the age of the machine.
To keep the CUBER at peak performance levels, periodic maintenance checks must be carried out as indicated in the Cleaning Section of this

manual.

2. Level the unit in both left to right and front to rear directions.

3. ELECTRICAL CONNECTIONS.
See data plate for current requirements to determine wire size to be used on electrical connections. All ice makers require solid earth wire.

The ‘F’ series ice machines are supplied from the factory pre- wired and are fitted with a suitably fused thirteen Amp UK plug. The FCI models

have a power cable that requires electrical connections to be made to the cable at the back of the machine, making sure that it is connected to
its own circuit and individually fused (see data for the correctly fuse size).

The maximum allowable voltage variation should not exceed –10% and +6% of the data plate rating. Low voltage can cause faulty functioning

and may be responsible for serious damage to the overload switch and motor windings.

NOTE. All external wiring should conform to national, state and local standards and regulations.
Check voltage on the line and the ice machines data before connecting the unit.

1.4 Water Supply and Drain Connections.

GENERAL.
When choosing the water supply for the ice cuber consideration should be given to:
a) Length of run.
b) Water clarity and purity.
c) Adequate water supply pressure.
Since water is the most important single ingredient in producing ice you cannot emphasize too much the three items listed above.
Low water pressure below 1bar may cause the malfunction of the machine.
Water containing excessive minerals will tend to produce cloudy coloured ice cubes, plus scale build-up on parts of the water system

WATER SUPPLY.

Connect the male fitting of the solenoid water inlet valve, using the flexible tubing supplied, to the cold water supply line with regular plumbing

2

fittings and a shut off valve installed in an accessible position between the water supply line and the unit.

WATER SUPPLY - WATER COOLED MODELS.

The water cooled versions require two separate inlet water supplies on models 40 and 60, one to supply water for the ice production and one

for the water cooled condenser.

Connect the male fitting of the condenser water inlet solenoid valve, using the second flexible tubing supplied, to the cold water supply line

with regular plumbing fittings and a shut off valve installed in an accessible position between the water supply line and the unit.

WATER DRAIN.
The recommended drain tube is a plastic or flexible tube with 18mm (3/4in) I.D. that runs to an open trapped and vented drain. When the drain

is along run, allow 3cm pitch per metre (1/4in per foot).

A vertical open vent, at the unit drain connection is also required for proper sump drainage.

WATER DRAIN – WATER COOLED MODELS.

The water drain line from the condenser, on water cooled versions, is internally connected with the drain fitting of the unit.
It is strongly recommended therefore to install a vertical open vent to the high point of the drain line high enough to ensure good drainage and

to direct the drain line to a trapped and vented floor drain receptacle.

This ensures proper flow of the drained water as, in the case of poor drainage, the water running out of the condenser may leak through the

unit drain tubing into the ice storage bin or into the sump reservoir.

NOTE. The water supply and the water drain must be installed to conform to the local codes. In some cases a licensed plumber and/or

a plumbing permit is required.

1.5 Final Checklist.

1. Is the machine in a room where the ambient temperatures are within a minimum of 10°C (50°F) even in winter months?

2. Is there at least a 15cm (6in) clearance around the unit for proper air circulation?

3. Is the machine level? (IMPORTANT)

4. Have all the electrical and plumbing connections been made, and is the water supply shut-off valve open?

5. Has the voltage been tested and checked against the rating on the data plate?

6. Has the water supply pressure been checked to ensure a water pressure of at least 1 bar (14psi)?

7. Check all refrigerant lines and conduit lines to guard against vibration and possible failure?

8. Has the bin liner and cabinet been wiped clean?

9. Has the owner/user been given the User Manual and been instructed on the importance of periodic maintenance checks?

10. Has the owner/user been given the name and telephone number of the authorised Service Agency in case of breakdown.

3

2. F20 and F40 Technical Data and Operating Instructions

2.1 Technical Data

Model F20 F40

Output – kg/24hr 19.5 34.5
Bin storage capacity – kg 6.5 15
Cubes per cycle 16 24
Cubes kg per cycle 0.28 0.42
Cycle time – minutes 20.7 17.5
Amps start/run 11Amps/2Amps 17Amps/3.3Amps
Watts consumption (30°C Ambient Temp) 320w 450w
Water consumption (Water Temp at 15°C Ambient Temp 21°C) 8.5 8.5
Refrigerant R134A R134A
Refrigerant charge grams 250 grms 320 grms
Evaporator Temp with Gas Pressure at 10.5 Bar ( Ambient Temp 21°C) -7°C -9°C
Evaporator Temp with Gas Pressure at 7.5 Bar ( Ambient Temp 21°C) -27°C -24°C
Evaporator Temp with Gas Pressure at 13 Bar ( Ambient Temp 32°C) -5°C -6°C
Evaporator Temp with Gas Pressure at 8 Bar ( Ambient Temp 32°C) -26°C -24°C
Heat Emission, watts 540 850
Noise Level dBA at 2 meters 55dBA 58 dBA

2.2 Start Up

After having correctly installed the ice machine and completed the plumbing and electrical connections, perform the following “Start-up”

procedure.

A Switch on the power to the machine. The unit starts its first freezing cycle with the following components in operation:
COMPRESSOR
WATER PUMP
FAN MOTOR. (The condenser fan is controlled by a thermostat, factory set at approximately 33°C).

B Check through the ice discharge opening that the spray plate is correctly seated and that the water jets uniformly reach the interior of the inverted

cup molds; also make sure that the plastic curtain is hanging freely and that water is not spilling through it excessively.

C The ice making process takes place thereby, the water is sprayed into the molds which gets gradually refrigerated by the heat exchanged with

the refrigerant flowing into the evaporator serpentine.

D When the evaporator temperature reaches a pre-set value the evaporator thermostat changes its contacts, the freezing cycle ends and the

defrost/harvest cycle starts.

Freezing time will range between 17 and 22 minutes (depending on model, see table) in a 21°C ambient. Longer time for temperature above,

shorter when below.

Average complete cycle range is about 17 to 25 minutes (depending on model, see table above)

E Check, during the first defrost/harvest cycle, that the incoming water flows correctly into the sump reservoir in order to re-fill it and the surplus

overflows down the overflow drain tube.
During this cycle the components energised are:
COMPRESSOR.
HOT GAS SOLENOID.
WATER INLET SOLENOID VALVE.
The FAN MOTOR and the WATER PUMP are also in operation if ambient temperature exceeds 33°C.
Note. During the defrost cycle, the water inlet solenoid valve is energised. The water flows through the valve to the back of the

evaporator platen and then down to fill up the icemaker sump tank for the next freezing cycle.

F Check the texture of the ice cubes just released. The correct size has a small depression (about 5-6mm) in their crown. If not, wait for the second

defrost/harvest cycle before making any adjustments.

2.3 Adjustments

G If after the second harvest the cubes are not correct adjustment to the evaporator thermostat may be necessary.
Remove the front panel and locate the cube size thermostat, using a flat bladed screwdriver turn towards the ‘+’ to increase the cube size and

towards the ‘-’ to decrease the cube size. (See fig 1)

H To check the bin full thermostat hold a handful of ice against the bulb of the storage bin

thermostat, the ice maker will switch off in about one to two minutes.
Once the machine has stopped remove the ice and dispose of it, the machine will restart

automatically in three to four minutes.
Note. The bin thermostat is factory set at 1°C (35°F) CUT OUT and 4°C (39°F) CUT IN.

(The set temperature can be adjusted if required by using a flat bladed screwdriver

turn towards the ‘+’ to increase the bin temperature and towards the ‘-’ to decrease

the bin temperature). (See fig 1)

Refit the bottom front panel then instruct the owner/user on the general operation of the

machine and about the cleaning and care it requires.

I. The machine may stop working if the condenser temperature exceeds the pre-set temperature

of the Over Temperature Thermostat (non-adjustable) due to a very high ambient temperature,

condenser fan failure, dirty/ blocked condenser. To restart the machine depresses the

protruding button on the Alarm Reset.

Fig. 1

4

3. F60 and F85 Technical Data and Operating Instructions

3.1 Technical Data

Model F60 F85

Output – kg/24hr 60 83
Bin storage capacity – kg 27 27
Cubes per cycle 48 48
Cubes kg per cycle 0.84 0.84
Cycle time – minutes 19.0 15.5
Amps start/run 19/4.1 26/5.5
Watts consumption (30°C Ambient Temp) 630 780
Water consumption (Water Temp at 15°C Air Temp 21°C) 12.0 16.0
Refrigerant R134A R134A
Refrigerant charge grams 450 grms 540 grms
Evaporator Temp with Gas Pressure at 10.5 Bar ( Ambient Temp 21°C) -10°C -26°C
Evaporator Temp with Gas Pressure at 7.5 Bar ( Ambient Temp 21°C) -6°C -25°C
Evaporator Temp with Gas Pressure at 13 Bar ( Ambient Temp 32°C) -10°C -28°C
Evaporator Temp with Gas Pressure at 8 Bar ( Ambient Temp 32°C) -7°C -24°C
Heat Emission, watts 1100 1400
Noise Level dBA at 2 meters 60 63

3.2 Start Up

After having correctly installed the ice machine and completed the plumbing and electrical connections, perform the following “Start-up”

procedure.

A. Switch on the power to the machine. The unit starts its first freezing cycle with the following components in operation:
COMPRESSOR
WATER PUMP
FAN MOTOR. (The condenser fan is controlled by a thermostat, which is factory set).

B. Check through the ice discharge opening that the spray plate is correctly seated and that the water jets uniformly reach the interior of the inverted

cup molds; also make sure that the plastic curtain is hanging freely and that water is not spilling through it excessively.

C. The ice making process takes place thereby, the water is sprayed into the molds which gets gradually refrigerated by the heat exchanged with

the refrigerant flowing into the evaporator serpentine.

D. When the evaporator temperature reaches a pre-set value (approximately -15°C) the evaporator thermostat changes its contacts and starts the

time clock, when the first timed portion has elapsed the freezing cycle ends and the second timed portion starts the defrost/harvest cycle.
Freezing time will range between 20 and 22 minutes (depending on model, see table) in a 21°C ambient. Longer time for temperature above,

shorter when below.
Average complete cycle range is about 23 to 25 minutes (depending on model, see table above)

E. Check, during the first defrost/harvest cycle, that the incoming water flows correctly into the sump reservoir in order to re-fill it and the surplus

overflows down the overflow drain tube.
During this cycle the components energised are:
COMPRESSOR.
HOT GAS SOLENOID.
WATER INLET SOLENOID VALVE.
TIMER MOTOR
FAN MOTOR (if ambient temperature exceeds 30°C).

Note. During the defrost cycle, the water inlet solenoid valve is energised. The

water flows through the valve to the back side of the evaporator platen and

then down to fill up the icemaker sump tank for the next freezing cycle.

C. Check the texture of the ice cubes just released. The correct size has a small

depression (about 5-6mm) in their crown. If not, wait for the second defrost/harvest

cycle before making any adjustments.

3.3 Adjustments

G. If after the second harvest the cubes are not correct adjustment to the cube size

thermostat may be necessary.
Using a flat bladed screwdriver turn towards the ‘+’ to increase the cube size and

towards the ‘-’ to decrease the cube size. (See fig 2)

H. To check the bin full thermostat hold a handful of ice against the bulb of the storage

bin thermostat, the ice maker will switch off in about one to two minutes.
Once the machine has stopped remove the ice and dispose of it, the machine will

restart automatically in three to four minutes.
Note. The bin thermostat is factory set at 1°C (35°F) CUT OUT and 4°C (39°F)

CUT IN. (The set temperature can be adjusted if required by using a flat bladed

screwdriver turn towards the ‘+’ to increase the bin temperature and towards

the ‘-‘ to decrease the bin temperature). (See fig 2)

Refit the bottom front panel then instruct the owner/user on the general operation

of the machine and about the cleaning and care it requires.

Fig 2

5

I. The machine may stop working if the condenser temperature exceeds the pre-set temperature of the Over Temperature Thermostat (non-

adjustable) due to a very high ambient temperature, condenser fan failure, dirty/ blocked condenser. To restart the machine, depress the

protruding button on the Alarm Reset.

J. Changes to the defrost time. Under normal circumstances no adjustments should be necessary.
The fixed time can be adjusted by releasing the tension on the cam screw, turning the dial anti-clockwise to increase the defrost time and

clockwise to decrease the defrost time, retighten the screw when the adjustment has been completed.
Note. If adjustment are made it will effect the freeze cycle.

Increasing the defrost time will shorten the freeze time so adjustments to the cube size thermostat may need to be made to increase

the freeze temperature.
Decreasing the defrost time will increase the freeze time so adjustments to the cube size thermostat may need to be made to decrease

the freeze temperature.

3.4 Cleaning/Rinsing For F20, 40, 60, 85

A. Remove the bottom front panel and locate the changeover switch.

B. Remove the top cover to gain access to the evaporator.

D. Wait till the machine finishes its freeze cycle and then turn off the electrical supply to the machine.

D. Prepare the cleaning solution as per the manufactures instructions on the Ice Machine Cleaner.
Warning. The Ice Machine Cleaner contains Phosphoric and Hydroxyacetic acids. These compounds are corrosive and may cause burns if

swallowed. If swallowed DO NOT induce vomiting, drink lots of water or milk and contact your Doctor immediately.
In case of external contact wash off with clean water.

E. Scoop out all of the ice cubes stored in the bin in order to prevent them from being contaminated by the cleaning solution then drain the water

from the sump reservoir by removing the plastic overflow pipe. Once the water has drained from the sump replace the pipe.

F. Remove the evaporator cover and slowly pour the solution onto the evaporator platen. Use a soft brush if necessary to remove stubborn

deposits.

G. Press the switch to the clean position and restore the electrical supply to the machine.

H. Leave the machine in the cleaning/rinsing mode for at least twenty minutes then turn the machine off at the electrical supply to the machine.
It may be necessary to clean the water spray separately. If required remove the spray plate from the machine, mix a solution of the cleaner in

a bowl or bucket and immerse the plate in it. When clean thoroughly rinse with clean water and re-fit it into the machine.

I. Drain the cleaning solution from the sump reservoir by removing the plastic overflow pipe. Once the solution has drained from the sump replace

the pipe.

J. Pour two to three litres of clean water over the evaporator platen to rinse of the remaining solution and ensure sufficient water is in the reservoir.

Ensure that the switch is still in the ‘CLEAN’ position and turn on the electrical supply to the machine. Leave the machine in the cleaning mode

for at least five minutes to thoroughly rinse the entire water system.

K. Drain the rinsing water from the sump reservoir by removing the plastic overflow pipe. Once the rinsing water has drained from the sump replace

the pipe and thoroughly wipe the interior of the machine.

L. Replace the evaporator cover and top service panel, turn on the electrical supply to the machine with the switch still in the wash position.
Leave the switch in this position for approximately five minutes to allow the water reservoir to fill up.

M. Change the switch setting to the freeze position to start the freeze process.

N. At the completion of the freezing and harvest cycle make sure the ice cubes are the proper texture and do not have an acid taste.
Attention. If the ice cubes are cloudy-white and have an acid taste, discard them immediately by pouring warm water over them to prevent them

from being used.

O. Once you are satisfied that all of the cleaning solution has been removed from the machine rinse the storage bin with clean water and wipe

clean.
Remember. To prevent the accumulation of undesirable bacteria it is necessary to sanitize the interior of the storage bin with an anti-

algae solution each week.

6