Foster FD2-10 Service Manual

Foster Prep Station

with

FD2-10 Controller

Service Manual

Issued August 2010

ISO 14001

ISO 9001

1

Contents

Manual Information & Health & Safety Notes

1

Environmental Management Policy

2

Disposal Requirements

2

Cabinet & Counter Description

3

Controller Relevance Table & Operation

3-4

User Functions

4-5

Defrost Operation & Fuzzy Logic

5

Wiring Diagram for Defrost & Technical Data

6

Configuration of Parameters

6

Prep Station Controller Default

7-10

Cabinet Arrangement Diagrams

11-12

Technical Data

13

Individual Unit Controller Parameter Values

14-16

Wiring Diagrams & Probe details

17-18

Troubleshooting & Notes

19-21

Service Manual Information

The products and all information in this manual are subject to change without prior notice.
We assume by the information given that the person(s) working on these refrigeration units are fully trained and
skilled in all aspects of their workings. Also that they will use the appropriate safety equipment and take or meet

precautions where required.

The service manual does not cover information on every variation of this unit; neither does it cover the

installation or every possible operating or maintenance instruction for the units.

Health & Safety Warnings and Information

Make sure the power supply is turned off before making any electrical repairs.

To minimise shock and fire hazards, please do not plug or unplug the unit with wet

hands.

During maintenance and cleaning, please unplug the unit where required.

Care must be 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.

2

Environmental Management Policy for Service Manuals and Duets.

Product Support and Installation Contractors

Foster Refrigerator recognises that its activities, products and services can have an adverse impact upon the
environment.
The organisation is committed to implementing systems and controls to manage, reduce and eliminate its
adverse environmental impacts wherever possible, and has formulated an Environmental Policy outlining our
core aims. A copy of the Environmental Policy is available to all contractors and suppliers upon request.

The organisation is committed to working with 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 six­digit 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 to

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

Disposal Requirements

If not disposed of properly all refrigerators have components that can be harmful to the environment. All old

refrigerators must be disposed of by appropriately registered and licensed waste contractors, and in accordance

with national laws and regulations.

3

Foster Prep Station Descriptions

The range consists of 2 to 5 door models with a storage capacity ranging from 270 to 720 litres.
The cabinets are manufactured as a one piece foam shell with easy clean stainless steel exterior
All conform to current legislation and exceed the Montreal protocol using zero ODP refrigerants and insulation.
The temperature is controlled by a LAE microprocessor control with digital temperature display.
Easy accessible condensing unit fitted at the rear for ease of servicing.
The standard refrigeration system is integral with an air-cooled condensing unit with the refrigerant distribution
into the evaporator controlled by capillary.
The cooled air is circulated through the evaporator, via the fan into the storage area.
Coated coils prevent corrosion and prolong refrigeration life.
Easy to read temperature display with wipe clean finish.
Wide magnetic gasket giving a positive door seal.

Temperature and Capacities

Model

FPS 2HR

FPS 3HR

FPS 4HR

FPS 5HR

Counter Base Storage Temperature

+1 to +4°C

+1 to +4°C

+1 to +4°C

+1 to +4°C

Pan Storage Temperature (with Lids Fitted)

+3 to +5°C

+3 to +5°C

+3 to +5°C

+3 to +5°C

Nett Capacity (litres)

270

420

570

720

Pan Clear Opening

1058 x 305

1640 x 305

2222 x 305

2804 x 305

Max Number of 1/3 Pans per Opening

6 9 12

16

Door Opening (w x h) Per Door

450 x 604

450 x 604

450 x 604

450 x 604

Door Opening Depth

1345

1345

1345

1345

Shelf Size

417 x 410

417 x 410

417 x 410

417 x 410

Number of Shelves Supplied Per Unit

4 6 8

10

Number OF Castors Supplied

5 5 5

6

Controller Relavance Table

Model

1st Serial Number

Issued

Manufacturer

Date from

Counter

E5269275

05.07.2010

Controller Operation

FD2-10 Controller (00-556241)
Probe Evap 2.5M SN4K15H2 (00-556251)
Probe Air 2.5M SN4K15H1 (00-556248)
LCD 5S Display (00-555992)

LCD5 Connecting Ribbon 1.5m (00-555741)
LCD5 Connecting Ribbon 3m (00-555814)
(Normally only used on FPS4 & 5’S Models)

LCD 5S Display (00-555992)

Indicators and Buttons

Symbol

Reason

Button

Use

Alarm

Info / Set Point Button

Thermostat Output

Manual Defrost / Decrease Button

Fan Output

Increase Button / Manual Activation

Defrost Output

Stand-by Button

Activation of 2nd parameter set

4

Display

During normal operation the display shows either the temperature measured or one of the following indicators:

Information Menu

The information available in the menu is shown below:

* Displayed only if enabled (see configuration parameters)
** Displayed only if ACC > 0

User Functions
Start Sequence

For normal operation

Press and hold the button for 3 seconds then release.

If pressed and held for 5 seconds then released this will start the „Test Sequence‟.
The test function is a defined sequence of events that will follow a prescribed pattern (dependent upon

parameter values). In turn it will operate all electrical elements of the system, simulating a short operating
pattern. This was designed to provide a quick and simple evaluation tool to use either during manufacturing or
when servicing.

To cancel the Test Sequence

Press and release the button during the test sequence.
If not pressed the test will continue and when complete the controller will wait for 1 min, then resume normal
operation. (The controller will count to 530 then show „end‟. It will then show the current unit temperature)

Access to the menu and information displayed

Press and immediately release button

With button or select the data to be displayed

Press button to display the value

To exit from the menu, press button or wait for 10 seconds.

Set point: Display and modification

Press button for at least half a second to display the set point.

By keeping button pressed, use button or to set the desired value (adjustment is within the

minimum SPL and the maximum SPH limit)

When button is released, the new value is stored.

Symbol

Reason

Symbol

Reason

Defrost in progress

Condenser high pressure alarm

Controller in stand-by

Room high temperature alarm

Condenser clean warning

Room low temperature alarm

Door open alarm

Probe T1 failure

Condenser high temperature alarm

Probe T2 failure

Symbol

Reason

Symbol

Reason

Instant probe 1 temperature

Minimum probe 1 temperature recorded

Instant probe 2 temperature *

Compressor working weeks **

Instant probe 3 temperature *

Keypad state lock

Maximum probe 1 temperature recorded

5

Reset of THI, TLO, CND recordings

With button or select the data to be reset

Display the value with button

While keeping button pressed, use button .

Standby

When pressing the button for 3 seconds, will allow the controller to be put on a standby or output control to
be resumed (with SB = YES only). When on Standby will be displayed.

Selection of second parameter group

It is possible to select control parameters between two different pre-programmed groups, in order for the
fundamental control parameters to be adapted to changing needs. Changeover from Group I to Group II (and

visa versa) may take place Manually by pressing for 2 seconds (with IISM = MAN), or Automatically when
heavy duty conditions are detected (with IISM = HDD), or when IISM =D12 and the Auxiliary Input D12 is
activated (the activation of D12 selects Group II). If IISM = NON, switchover to Group II is inhibited. The
activation of Group II is signalled by the lighting up of relevant LED on the controller display.

Defrost

Automatic Defrost.

Defrost starts automatically as soon as the time set with parameter DFT has elapsed.

Time Defrost With DFM = TIM defrost takes place at regular intervals when the timer reaches the value

DFT. For example, with DFM = TIM and DFT = 06, a defrost will take place every 6 hours.

Defrost time count backup At the power–up, if DFB = YES, the defrost timer resumes the time count

from where it was left off before the power interruption. Visa versa with DFB=NO, the time count re­starts from 0. In stand-by the accumulated time count is frozen.

Defrost type

Once defrost has started, compressor and defrost outputs are controlled according to parameter DTY. If FID
=YES, the evaporator fans are active during defrost.

Resuming Thermostatic Cycle

When defrost is over, if DRN is greater then 0, all outputs will remain off the DRN minutes, in order for the ice to
melt completely and the resulting water to drain.

Manual Defrost

To initiate a manual defrost press and hold the defrost button for 2 seconds.

Fuzzy Logic.

This setting is not available with any of these units.

6

Parameter Setting Wiring Diagram for Synchronising Defrost Start and Termination

Technical Data

Power Supply

FD2-10 230Vac±10%, 50/60Hz, 3W

Relay Output

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

Input

NTC 10KΩ@25°C

Measurement Range

-50…120°C, -55…240°F

-50 / -9.9…19.9 / 80°C (NTC 10K Only)

Measurement Accuracy

<0.5°C within the measurement range

CE (Reference norms)

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

Configuration Parameters

To get access to the parameter configuration menu, press + for 5 seconds

With button or select the parameter to be modified.

Press button and hold briefly to display the value. On releasing the button the controller will then

show the next parameter.

By keeping button pressed, use button or to set the desired value. On releasing the button

the controller will store the amended value and then show the next parameter.

To exit from the setup, press button or wait for 30 seconds.