Original Service Manual

XR10, XR20 & XR35 Blast Chiller Cabinets

LAE CIB-BC-PU1 Controller

English

A Division of ITW Ltd

Foster Refrigerator
Oldmedow Road
King’s Lynn
Norfolk, PE30 4JU
April 2014 Issue 2 United Kingdom

Call: +44 (0)843 216 8800 Fax: +44 (0)843 216 4700 Email: [email protected]
www.fosterrefrigerator.co.uk 0772
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Manual Information & Health & Safety Notes 1

Environmental Management Policy with Disposal Requirements & General Electrical Safety 2
Start Up & Operation 3 to 4
User Settings 4 to 5
Parameters 5 to 9
Technical Data for Blast Chiller 10 to 11
Servicing/Cleaning 12 to 14
Wiring Diagrams 15
Troubleshooting & Alarms 16
Notes 17

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.

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.

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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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Initial Set Up
After unpacking, clean and allow the cabinet to stand for 2 hours before turning on
(cleaning directions supplied within this manual). Ensure the cabinet is situated away from
both hot and cold air sources, as this will affect its performance. Make sure that a minimum
clearance of 10cm around the cabinet is available for ventilation and effective operation.
Install the drip tray underneath the cabinet after placing the unit in position.
Connect the unit to a suitable mains power outlet and turn the supply on. Do not plug or unplug the
unit with wet hands.

Standby
When left for several minutes the cabinet will automatically switch to standby, this helps reduce
energy consumption.
When in standby mode the cabinet will show the middle LED on the main display flashing green
slowly.

During this time the controller is still connected to the mains and standby does not cut off the main
power supply. As a consequence only the compressor and condenser are switched off during this
time.
If the cabinet is going to be unused for a prolonged amount of time than the units power supply
should be switched off and or disconnected from the mains supply.
To exit standby press any button on the keypad and the controller will revert to displaying the
current temperature.

Button 1 Button 2 Button 3 Display 1 LED 4 LED 5

LED 1 LED 2 LED 3 Display 2 LED 7 LED 6

Buttons & Icons

Button 1 Decrease Value/ Information LED 1 Cycle Indicator ‘ Soft Chill’
Button 2 Select Cycle and Increase Value LED 2 Cycle Indicator ‘Defrost’
Button 3 Start/Launch Cycle LED 3 Cycle in Progress
Display 1 Main Temperature
Display 2 Cycle Status Display

Other Visible Indicators:

LED 4 Temperature shown in °C LED 6 Probe Cycle Mode Active
LED 5 Temperature shown in °F LED 7 Timer Cycle Mode Active

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Button Description
Button 1 – Decrease/ Information - This button is used as a decrease button and when pressed
will show the current controller information i.e. time remaining when using a cycle and the current
temperature.

Button 2 – Choice of Cycle & Increase - From here you can select either ‘Soft Chill’ or ‘Defrost’
cycles. By selecting this button the LED for the relevant cycle will illuminate. From this point you can
use button 3 to confirm and launch the selected cycle.
This is also used as an increase button when amending parameter values.

Button 3 – Start/Launch Cycle - This will start a cycle and then the LED’s around this button
(LED 3) will illuminate in a circular chase pattern confirming the action. If pressed and held this
button will also stop a cycle.

Before starting a cycle we advise that you bring the cabinet down to temperature for
optimum performance. Select a Soft Chill Cycle (as described below) but only run this for
15 minutes. To stop after this time press and hold the Start/Launch button until the cycle
stops. Warning ‘rEG’ will show on the display to acknowledge that the cycle didn’t
complete as determined by the parameters, this will clear after selecting your preferred
cycle.

Selecting a Soft Chill

Activate a cycle by pressing the ‘Select Cycle’ button until the ‘Soft Chill’ LED is illuminated. Press
the ‘Start/ Launch Cycle’ button to start the cycle. The cabinet will decide if this cycle should be run
by a probe or timer mode at the start of the cycle (as described below).

Cycle Run Type

After pressing the ‘Start/Launch Cycle’ button and the unit will automatically detect if the cabinet
should run in a ‘Probe’ or ‘Time’ cycle. A ‘Probe’ cycle is determined by the temperature read from
the food probe already inserted in the product at the start of the cycle. The ‘Time’ cycle is
determined if the food probe is not inserted in the product at the start of the cycle. Please Note: If
this button is pressed without selecting either a Soft Chill or Defrost cycle the unit will
continually run on a probe detection cycle until 90 minutes is up and there is no
temperature control with this type of cycle.

Defrost & the Drip Tray

Check no foreign bodies obstruct the waste in the base of the cabinet. The drip tray is situated
underneath the cabinet and should be emptied regularly as water will collect here.
There are two methods of defrost:
> Natural Defrost
Turn the cabinet off at the mains and or stop any cycles. Leave the cabinet door ajar and the
frost will melt and collect in the drip tray.
> Forced Defrost
Press the ‘Select Cycle’ button followed by ‘Defrost Cycle’.
Press the ‘Start/Launch Cycle’ and a defrost will take place showing LED 2 illuminated.

Modifying the End of Cycle Time or Temperature

While the current cycle is running press button 3. You will then be able to use buttons 1 and 2 to
increase or decrease the values.

Stopping a Cycle or Function

It is possible to stop or interrupt a cycle at any time by pressing the ‘Start/Launch’ button and
holding for several seconds. After doing this ‘rEG’ will show on the display to acknowledge that the
cycle didn’t complete as determined by the parameters.

End of Cycle Alarm

At the end of each cycle the audible alarm will sound to notify the user. This can be silenced by
pressing any button on the keyboard.
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Cabinets have their parameters set at point of build to the correct settings.
If you wish to modify these set points then you should have a full understanding of their
purpose and the following instructions.

To amend any parameter press buttons 1 & 2 together for 5 seconds.

Parameter ‘P01’ will be displayed when the menu has been successfully accessed.

To move to the next parameter press button 1 or 2. Once on the parameter you wish to adjust press
and hold button 3 while also using button’s 1 or 2 to modify the pre-set value.
After adjustment has been made release button 3 to save the changes. The menu will automatically
show the next parameter.

If no buttons are pressed for 5 seconds then the controller will leave the adjustment menu.

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Parameters highlighted in grey are not visible under the Foster standard parameter set up.

All XR
Parameter Description Range/Parameter Information Min Max Units
Models
1=°C
P01 Temperature scale 1 2 1
2=°F
P02 Ambient probe calibration -10 10 °K 0
0=NO
P03 Skewer probe activation 0 1 1
1=YES
P04 Skewer probe calibration -10 10 °K 0
0=NON
P05 Action digital entry 1 0 1 0
1=DOOR
0=NO
P06 Polarity Digital Entry 1 0 1 0
1=NF
0=NON
P07 Action Digital Entry 2 1=DIG INP 0 2 0
2=EVP
0=NO
P08 Polarity Digital Entry 2 0 1 0
1=NF
0=CD
P09 Display Digital Entry 2 0 1 0
1=HP
P10 Evaporator probe calibration -10 10 °K 0
0 : No
P11 Presence of bar graph 0 1 1
1 : Yes
0: No
P12 Presence of light key 1: Light key 0 2 1
2: Progression cycle
0: Frequency 1 (0.5s ON, 0.5s OFF)
P13 Type of buzzing sound 1: Frequency 2 (0.35s ON, 0.35s OFF) 0 2 0
2: Frequency 3 (0.25s ON, 0.25s OFF)
P14 Max duration of sound alarm -1 = Buzzer never stops -1 99 min 1
P15 Alarm repeated afterwards -1 = No repeat -1 99 min -1
0=NO
P16 Function Standby 0 1 1
1=YES
P17 Standby timer 1 60 min 10
0=NO
P18 Anti-smell function 0 1 0
1=YES
P19 Anti-smell timer Interval between the start of two functions 1 120 min 60
P20 Anti-smell duration Duration of function 1 120 min 30

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Maximum duration of the anti-smell

P69 -1 24 hrs. 6
function
P21 Display slowdown 0 100 0
P22 Machine number 1 255 1
0=NO
P23 Manual defrost activated 0 1 1
1=YES
P24 Interval between 2 defrosting operations 0 99 hrs. 6
P25 Temperature at end of defrost Evaporator probe -50 100 °C 10
P26 Max. duration of defrost 1 99 min 30
0=OFF
P27 Type of defrost 1=ELE 0 2 0
2=GAS
P28 Drainage time 0 99 min 3
P29 Check display on defrosting 0 60 min 10
0=NO,
P30 Ventilators activated during defrost 0 1 1
1=YES
Temperature at ventilator switching on Evaporator probe
P31 -50 100 °C -5
after defrosting
P32 Ventilators switched off after defrost 0 60 min 0
0=NO,
P33 Defrost at the beginning of cooling cycle 0 1 0
1=YES
Defrost at the beginning of conservation 0=NO,
P34 0 1 0
cycle 1=YES
Defrost delayed at the beginning of
P35 0 99 min 10
conservation cycle
P36 Compressor delayed after switching on 0 30 min 0
Min. time between 2 start-ups of
P37 0 30 min 1
compressor
Minimum standby duration after
P38 0 30 min 1
compressor is switched off
P39 Compressor on with failing probe T1 0 30 min 3
Compressor stopped with failing probe
P40 0 30 min 6
T1
Compressor stop delayed by door
P41 0 30 min 1
opening

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0 = Refrigeration. + S.P.
1 = Delayed Refrigeration
P42 Choice of cycle by default 0 3 0
2 = Freezing + S.P.
3 = Delayed Freezing
Set point of ambient probe
P43 Set point refrigeration conservation -50 100 °C 3
for conservation
Selection of soft chill cycle function 0=NO
P44 0 1 1
activated 1=YES
Set point of ambient probe
P45 Set point soft chill ambient probe -50 100 °C -5
during refrigeration cycle
0=NO
P46 Selection of freezing cycle activated 0 1 0
1=YES
Set point of ambient probe
P47 Set point freezing conservation -50 100 °C -21
for conservation
P48 Regulation differential 1 15 °K 3
P49 Duration of skewer probe presence test 0 99 s 60
P50 Check skewer probe inserted 0 99 °K 5
Duration of pressure on key to switch
P51 0 20 s 4
off cycle in progress
0=FRA
P52 Regulation type 1=UK 0 2 1
2=Specified by user
63°C for FRA
P53 High refrigeration limit -50 100 °C 70
70°C for UK
10°C for FRA
P54 Set point of refrigeration cycle -50 100 °C 3
03°C for UK
120min for FRA
P55 Max. duration of refrigeration 1 180 min 80
90 min for UK
63°C for FRA
P56 High freezing limit -50 100 °C 70
70°C for UK
-18°C for FRA
P57 Set point freezing cycle -50 100 °C -18
-18°C for UK
300 min for FR
P58 Max. duration of freezing 1 400 min 270
270 min for UK
0=NO
P59 Temperature alarm mode 1=ABS 0 2 0
2=REL
P60 Low temperature absolute alarm -50 100 °C -50
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P61 High alarm absolute temperature -50 100 °C 100

P62 Low alarm differential -12 0 °K 0
P63 High alarm differential 0 12 °K 0
P64 Temperature alarm delayed 0 120 min 60
P65 Door alarm delayed 0 30 min 5
0=NO
P66 Operation with condenser alarm 1=ALR 0 2 0
2=STP
0=E2
P67 Display with sounding skewer probe. 0 1 0
1=UN
P68 Reset 0 1 0

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XR10 & 20 Models

XR10 XR20
Chilling Capacity per Cycle (Kg) 12 20
Cooling Duty@ -15°C (Watts) 510 920
Number of Fans 1 1
Evaporating Temperature (°C) -15 -15
Compressor Hermetic Hermetic
Gas R404a R404a
Gas Charge (Grams) 300 450
Power Consumption (Watts) 600 900
Current Consumption (Amps) 3.1 4.2
Electrical Supply 230/1/50 13A 230/1/50 13A
Total Heat Rejection (Watts) 1514 3052
Maximum Ambient Room Temperature +43°C +43°C

(1) - Evacuation of water from defrost 20

(2) - Electric supply cable

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XR35 Model
XR35
Chilling Capacity per Cycle (Kg) 35
Cooling Duty@ -15°C (Watts) 2080
Number of Fans 1
Evaporating Temperature (°C) -15
Compressor Hermetic
Gas R404a
Gas Charge (Grams) 1400
Power Consumption (Watts) 1600
Current Consumption (Amps) 5.1
Electrical Supply 230/1/50 13A
Total Heat Rejection (Watts) 5120
Maximum Ambient Room Temperature +43°C

(1) - Evacuation of water from defrost 20

(2) - Electric supply cable

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Important: Before cleaning or the removal of any parts, the unit should be put into
standby and then the power supply should be turned off at the mains.
Please do not plug or unplug the unit with wet hands. Only when cleaning has been
completed and the unit is dry should the cabinet be turned back on at the mains. Using
high pressure water jets or lances is prohibited; the warranty policy will not cover
problems that result from failure to heed the above warning.

Removing the Unitcover

You should only be required to remove the unitcover for access to the condenser, compressor and or
controller electrics.

Remove both the fixing screws situated at the bottom on the unitcover. Tilt the cover forward and
pull towards you. Refitting is the same action but in reverse ensuring the fixing screws are refit.

XR10 & 20 Models

Condenser

Controller Electrics

Unitcover

Fixing Screws

XR35 Model

Condenser Fan Motor/ Plate

Unitcover

Fixing Screws
Controller
Electrics

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Cleaning the Condenser

XR10 & XR20 models will clearly see the condenser after removal of the unitcover.
XR35 model will have to also remove the Condenser Fan Plate and motor.

To do this unscrew the two fixing screws positioned on

The top of the condenser fan plate.
Tilt the plate forward on the rubber pivots and
then remove from the unit. You will now be
able to access the condenser for cleaning.

Fixing Screws

Once the unitcover is removed please do not leave the unit unattended.

Cleaning the condenser should be scheduled every 3 to 6 months and carried out by a service
engineer. Use a soft brush or vacuum cleaner to remove dirt/dust.
If there are any stubborn grease deposits left on or through the condenser call your supplier to carry
out a full service (this is normally chargeable). Failure to maintain the condenser may invalidate the
warranty of the condensing unit and cause premature failure of the motor/compressor. DO NOT use
a wire brush to clean the condenser. Re-fit any panels removed after cleaning.

Access to the Evaporator

Rear of Cabinet/ Birds Eye

View
Air
Probe
Evaporator
Coil
Rubber
Pivot
Expansion
Valve

Locking Evaporator
Screw Fan

Racking

After opening the door you will be able to see the evaporator assembly situated at the rear of the
cabinet.
> Firstly, remove all shelves or pans and ladderacking before trying to proceed with the
following instructions.
> To remove the fan and or guard unscrew the guard fixings and pull it towards you.
> To access the reducer valve, evaporator coil and air probe, remove one or more of the
locking screws and then pivot the fan motor baffle on its rubber mounts. This baffle can be
totally removed if required.

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Door Removal
Pivot
Pivot Screw
Top Hinge Bracket
& fixing screws

Firstly remove the unitcover (as described before), and

unscrew the pivot screw from the top of the door. You can
now remove the door from the upper hinge bracket.
To refit reverse these instructions and make sure to refit the
Door spacer washer.
(The unitcover is only visible on this image for illustrative
purposes)

Door Gaskets
Door gaskets should be inspected on a regular basis and replaced if damaged. To clean, wipe with a
warm damp soapy cloth followed by a clean damp cloth. Finally thoroughly dry before closing the
door.

Regular Cabinet Cleaning

As and when required remove all product and shelving (beware of cold and or sharp components)
from the unit. Clean exterior and interior surfaces with mild liquid detergent, following the directions
on the pack at all times. Rinse surfaces with a damp cloth containing clean water. Never use wire
wool, scouring pads/powders or high alkaline cleaning agents i.e. bleaches, acids and chlorines as
these may cause damage. Dry the unit thoroughly before re-using.

Shelves, Pans and Supports

Shelves, Pans and their supports should be removed to clean. The shelves and pans are dishwasher
safe; however the supports should be cleaned with warm soapy water then rinsed and dried .

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Diagram for XR10, 20, 35 Model

Supply 1~230v

SdA : Ambient probe

Black
SdP : Core probe
Blue Cp : Compressor
Vc : Condenser Fan
Brown
Ve : Evaporator Fan
Cd : Evaporator Fan Capacitor
Black
Rev : Evaporator Coil Heater (option)
Vo : Anti-smell fan (option)
Blue
Brown Model Specific Details :
. without Cd1 for model XR10
. without Ve2 for models XR10, XR20 and XR35

Control Board
Front USB Connector

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Fault Cause of Fault Action /Solution To Rectify

Safety & Utility
> Indicates a communication
cE problem between the display
PCB and the controller PCB.
> Indicates a defrost cycle is in > Press any button to acknowledge the warning
dEF progress. & clear the fault
> Indicates that the cycle has
rEG not progressed according to
how the parameters are set.
Function Faults
> Acknowledge the alarm by pressing any key to
silence the audible alarm.
E1 > Faulty Air Probe.
> Check and replace the probe if and where
required.
> Acknowledge the alarm by pressing any key to
> Faulty Food Probe – If the silence the audible alarm.
probe is faulty, it is possible to > In the case of a faulty food probe it is always
E2 use the cabinet in ‘Time possible to run a cycle in timer mode.
Cycle’. > Check and replace the probe if and where
required.
> Acknowledge the alarm by pressing any key to
silence the audible alarm.
> If the duration of the power cut is unknown
> Power Failure – the cycle will
the regulator will switch to conservation mode
ELE have stopped and a hold cycle
and display rEG.
will be active.
> If the power was cut during the conservation
cycle the regulator will carry on this mode
when power is resumed.
Corrosion Issues – Listed below are the most common reasons of corrosion on Stainless
Steel. Before reporting any issues of corrosion please ensure the following has been adhered too.
> Floor Cleaner – Splashes of floor cleaner can cause signs of corrosion on the cabinet
base and side panels. This is due to floor chemicals being a lot higher in acidity then
standard stainless cleaner. Also the vapour from these chemicals can hang in the air and
prolong the damage.
> Incorrect Use Of Cleaning Products – Bleaches, acids and soda have a high acidic
content and should be avoided on the cabinet’s internal and external parts. Only stainless
specific products should be used or warm soapy water. Even when using these methods a
clean warm water wipe down should be used to ensure all chemicals have been removed
from the panels. Drying the unit thoroughly can also help.
> Area Where Water/ Chemicals Can Gather – As build-up of product could gather
on/in the cabinet likewise this can also gather in nearby gulley’s, drains etc. Please
ensure these are also run clean of any chemicals.
> High Temperatures - Cleaning solutions can become more aggressive when used with
and in high temperatures. Ensure temperatures do not exceed 60°C thus avoiding
blackening of stainless steel surfaces.
> Salt and Brine - If salt or foods containing a brine is used within the area of the blast
chiller pitting in the stainless could be visible if not cleaned regularly. Any spillage of salt
or brine should be cleaned off the surface first by a soft cloth and then rinsing with warm
soapy & clean water.
> Chlorination – at times water chlorine levels can be high and this can have a corrosive
effect on stainless. Although rare this is a factor that should be made aware of.

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Before calling your supplier please make sure that:

a) The plug has not come out of the socket and the mains power supply is on i.e. is the
controller illuminated?
b) Check to see if the unit is in standby
c) The fuse has not blown
d) The cabinet is positioned correctly – cold or warm air sources are not affecting the
performance
e) The condenser is neither blocked nor dirty
f) The products are placed in the unit correctly
g) Defrost is not in progress or required

If the reason for the malfunction cannot be identified, disconnect the electrical supply to the unit and
contact your supplier. When requesting a service call, please quote the model and serial number
(a 9 digit number) which can be found on the silver label located on the inside of the unit.

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Foster European Operations

France
Foster Refrigerator France SA
Tel: (33) 01 34 30 22 22. Fax: (33) 01 30 37 68 74.
Email: [email protected]

Germany
Foster Refrigerator Gmbh,
Tel: (49) 781 990 7840. Fax (49) 781 990 7844.
Email: [email protected]

Foster Refrigerator
Oldmedow Road
Kings Lynn
Norfolk
PE30 4JU

Tel: 0843 216 8833

Fax: 0843 216 4707
Website: www.fosterrefrigerator.co.uk
Email: [email protected]

a Division of ‘ITW (UK) Ltd’

XR10 – XR35/SM 04/14v2 UK