Foster Freezer LC125 Meatwell LDU15 & AT1 5 Service Manual (re1010)

User Manual: Foster Freezer LC125

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LC125 Meatwell

with

LDU15 Controller (Feb

‘04 till July ‘09)

then

AT1-5 Controller (July

‘09 onwards)

Service Manual

Re-Issued October 2010

Original Aug 09

ISO 14001

ISO 9001

1

Contents

Manual Information & Health & Safety Notes

1

Environmental Management Policy

2

Disposal Requirements

2

Important Controller Change Information

3

Description, Maintenance & Technical Information

3

AT1-5 Controller Information

3 to 4

Alarms and Warnings

4 to 5

Probe Setting, Parameters & Adjustments

5 to 6

AT1-5 Wiring Diagram

7

LDU15 Controller Information

8

Parameters & Electrical Connections

9

LDU15 Wiring Diagram

10

Troubleshooting & Notes

11 to 13

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 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 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

IMPORTANT CONTROLLER CHANGE INFORMATION

AS OF FEB 2004 THIS UNIT HAD THE LDU15 (00-555357) CONTROLLER.

AS OF 22ND JULY 2009 THIS HAS NOW BEEN REPLACED WITH AN AT1-5 (00-556223) CONTROLLER.

PLEASE NOTE THAT IF YOU ARE REPLACING THE LDU15 CONTROLLER TO THE NEW AT1-5

CONTROLLER YOU WILL ALSO HAVE TO REPLACE THE AIR PROBE WITH SN4K150P1 (00-556187).

This manual provides information on both controllers.

Meatwell Description

This is a one piece foam shell with a skin evaporator and bottom mount condensing system. The condensing

system uses R134a refrigerant. The cabinet is designed for the storage of frozen products and is top loading.

It is fitted with four 60mm castors, rubber bumpers to each corner and a front smash bar is available as an added

option (but fitted as standard to Burger King units).

Routine Maintenance

In order to keep the unit operating reliably and efficiently periodical cleaning of the condenser is necessary. (The

frequency being determined by site conditions)

This operation is to be carried out with the unit turned OFF.

We advise the use of a soft long haired brush on the outside of the condenser taking care not to damage the fins.

Warning: Condenser fins have sharp edges so care must be taken to avoid injury

Technical Information

Temperature Set Point

-21ºC

Refrigerant

R134A

Refrigerant Charge

180grms

Capillary

4.4mts x 042

Power Supply

230/50/1

Controller Information for models using the LAE AT1-5BS6E-FS1 Controller (00-556223)

Operation Guidelines –

Please note the unit has a rest time of 10mins before start up will begin.

Initial Start Up

Start Up & self Test:

The indication is only displayed during the first three seconds following the mains electrical power being applied to

the unit. During this period the controller performs a self-check.

Once the self-check has been completed will be displayed.

Press and hold for three seconds. The unit will start and the air temperature will be displayed.

Check temperature set point.

To make adjustments to the set point it is necessary to access the parameter and alter SPL and SPH accordingly.

OFF

4

Check set point by pressing the button

To increase set point press + until required temperature is displayed.

To decrease set point press + until required temperature is displayed.

Exit from set up occurs after 10 seconds if no button is pressed.

Manual Defrost

To initiate a manual defrost press and hold .

will be displayed release .

On completion of the defrost will be displayed until the cabinet temperature is achieved and then it will

revert to displaying the normal cabinet temperature.

Set Unit to Standby

Press , in the display will show

This indication is displayed while the unit is not operating but with mains power applied to the unit. This mode may

be used for internal cleaning regimes and short periods when the unit is not required.

For extended periods of inactivity the mains supply should be isolated.

Alarm and Warnings

High Temperature Alarm

Will be displayed.

The alarm will sound but can be silenced by pressing any of the buttons, however it will return after the pre-set

designated period. The unit will return to normal operating temperature and will automatically cancel the alarm.

Possible Causes: The evaporator fan is not working; there is a restricted airflow through the air duct. The

evaporator is iced up or the compressor is not working.

Low Temperature Alarm.

Will be displayed.

The alarm will sound but can be silenced by pressing any of the buttons, however it will return after the pre-set

designated period. The unit will return to normal operating temperature and will automatically cancel the alarm

Possible Causes: Controller is faulty (not switching compressor off). The compressors secondary relay will not de-

energise (low temperature models).

Air Temperature Probe Failure

Will be displayed.

The alarm will sound but can be silenced by pressing any button.

There is no further action that can be taken by the user in this instance. During this period the unit will continue to

operate but have a reduced performance.

Action: Replace Probe.

Information Menu

Pressing and releasing activates the information menu. From this menu you can display the

temperature relating to T1 (air probe), T2 (evaporator probe, if fitted) and T3 (condenser probe, if fitted).

The maximum temperature (THI) and the minimum temperature (TLO) the cabinet has achieved since it was last

re-set.

The total operating time of the condenser (CND) since it was last cleaned, and the keyboard status (LOC).

The information to be displayed can be selected sequentially by pressing repeatedly or scrolling

E1

LO

OFF

REC

dEF

HI

5

through the menu using the or buttons.

Once selected press to display the value.

Exit from the info menu by pressing or it will automatically exit after 6 seconds if no buttons are

pressed.

To reset the temperature settings recorded in THI and TLO and the hours counted in CND, access the info menu

press to display the value plus simultaneously for resetting to be completed.

To check the LOC status scroll through to LOC, press to display status – YES to lock keys. – NO to

leave keys accessible.

NOTE: with the keys locked it is not possible to turn the unit OFF or ON or to check the set point.

Parameter Setting and Adjustment

It is strongly advised that before adjusting any Service Parameters a thorough understanding of the

following instructions should be obtained.

The parameters are accessed by pressing the following keys in succession +

and keeping them pressed for 5 seconds.

After this period the first parameter ‘SCL’ will be displayed.

Press button to pass from one parameter to the next and button to go back.

Press to display the value followed by or to change it.

Exit from set up is by pressing or automatic if no buttons are pressed for 30 seconds.

Probe Identification

The probe fitted to this controller is the 10k NTC type (LAE SN4K15P1, Part number 00-556187) with red letter

identification.

LAE NTC10K Temperature Resistance Table

Temperature(°C)

R-mid (K)

Temperature(°C)

R-mid (K)

Temperature(°C)

R-mid (K)

-25

87.559

-5

33.892

15

14.674

-20

68.237

0

27.219

20

12.081

-15

53.65

5

21.63

25

10

-10

42.506

10

17.926

30

8.315

6

LAE AT1-5BS6E-FS1 Controller Parameter List

Mnem.

Definition

Min

Max

Default

Dim

Setting

SCL

Readout Scale

1ºC ; 2 ºC ; F º

2

flag

2 ºC

SPL

Minimum Set Point (1)

-50

SPH

-5

ºC

-21

SPH

Maximum Set Point (1)

SPL

120

5

ºC

-21

SP

Set Point (1)

SPL

SPH

0

ºC

-21

C-H

Refrigeration / Heating

REF

HEA

REF

flag

REF

HYS

Thermostat Hysteresis

1

100

3

ºK

3

CRT

Minimum Compressor Rest Time

0

30

3

min

10

CT1

Compressor Run with T1 Failure

0

30

3

min

7

CT2

Compressor Stop With T1 Failure

0

30

6

min

3

CSD

Compressor Stop Delay From Door Opening

0

30

1

min

1

DFR

Defrost Frequency / 24h

0

24

3

1/24

0

DLI

Defrost End Temperature

-30

30

6

ºC

15

DTO

Maximum Defrost Duration

1

120

20

min

20

DTY

Defrost Type

OFF; ELE; GAS

ELE

Flag

OFF

DDY

Defrost Display Control

0

60

10

Min

20

ATM

Alarm Threshold Control

NON; ABS; REL

ABS

flag

REL

ALA(’R)

Low Temperature Alarm Threshold

-50 (-120)

+120 (0)

-50

ºC/ ºK

-25

AHA(‘R)

High Temperature Alarm Threshold

-50 (0)

+120 (120)

120

ºC/ ºK

-10

ALR

Low Temperature Alarm Differential

-12

0

ºK

-5

AHR

High Temperature Alarm Differential

0

12

ºK

5

ATD

Alarm Temperature Delay

0

120

30

min

90

ADO

Door Alarm Delay

0

30

5

min

5

ACC

Condenser Cleaning Period

0

52

0

wks

0

SB

Button 0/1 Enabling

YES

NO

YES

flag

YES

DS

Door Switch Enabling

YES

NO

NO

flag

NO

OAU

AUX Output Control

NON;0-1:LGT;FAN;AL1

LGT

flag

NON

INP

SN4 / ST1

SN4; ST1

SN4

flag

SN4

OS1

T1 (air) Probe Offset

-125

125

0

ºK

0

T2

T2 (evaporator) Probe Enabling

YES

NO

NO

flag

NO

OS2

T2 (evaporator) Probe Offset

-125

125

0

ºK

0

TLD

Delay for Minimum / Maximum Temperature Storage

1

30

5

min

5

SIM

Display Slowdown

0

100

0

exp

50

ADR

Unit Peripheral Address

1

255

1

exp

1

7

LC125 Wiring Diagram with the LAE AT1-5BS6E-FS1 Controller

8

Controller Information for models using the LDU 151E-BG Controller (00-555357)

When the controller is switched on a single line appears on the display for 3 seconds to indicate the autotest

period.

After this period the air temperature measured by the T1 probe is displayed.

It is strongly advised that before adjusting any Service Parameters a thorough understanding of the

following instructions should be obtained.

LDU 15 Controller

Check temperature set point.

Check set point by pressing the “set” button

To increase set point press “set” +

To decrease set point press “set” +

Factory Temperature Set Point -21°C.

Exit from set up occurs after 10 seconds if no button is pressed.

Manual Defrost.

To initiate a manual defrost press buttons and simultaneously.

Controller Set Up.

The parameters are accessed by pressing the following keys in succession + “set” + and keeping

them pressed for 3 seconds.

Access to the parameters has been achieved with the first parameter SCL being displayed.

To pass from one parameter to the next press either the or key.

To display the value press. “set”

To change the value press “set” + to increase, or “set” + to decrease.

Exit from set up by pressing “aux” or is automatic after 30 seconds if no buttons are pressed.

Alarms and Warnings

HI

High Temperature Alarm

LO

Low Temperature Alarm

E1

T1 Probe Failure

DF

Defrosting in Progress

CLN

Condenser

aux

lae

set

aux

9

Parameters for Cabinets with the LDU15 1E-B Controller

Display

Parameter

LDU151E-B

Default Values

LC 125

SCL

Readout Scale

2°C

2°C

SPL

Minimum Temperature Set Point

05

-25

SPH

Maximum Temperature Set Point

01

-15

SP

Effective Temperature Set Point

03

-21

HYS

Hysteresis

3

+3

CRT

Compressor Rest Time (minutes)

10

0

CDC

Compressor Regulation with T1 Fail

20

7

DFR

Defrosting Frequency (/24 hours)

4

0

DTO

Defrosting Duration (minutes)

20

20

DDY

Defrost Display Control

1

1

ATL

Low Alarm Differential

-5

-10

ATH

High Alarm Differential

5

10

ATD

Temperature Alarm Delay (minutes)

60

90

ACC

Condenser Clean Interval

05

0

OAU

Auxiliary Output Mode of Operation

30

NON

BAU

Auxiliary Button Mode of Operation

05

NON

OS1

T1 Offset

00

00

SIM

Display Slowdown

00

00

ADR

Address

01

01

LDU 151E-BG Electrical Connections

PWR

1 2 3 4 5 6 7 8 9 10

11

AUX

T1

DATA

10

Wiring Diagram for Models Using the LDU15 Controller

11

Troubleshooting

Problem

Possible Cause

Solution

Compressor will not start

No voltage in socket

Use voltmeter to check

Electrical conductor or wires may be

cut

Use ohmmeter to check for

continuity

Defective electrical component:

thermostat, relay, thermal protector

etc

Replace defective component

Compressor motor has a winding

open or shorted

Measure ohmic resistance of main

and auxiliary winding using

ohmmeter. Compare with correct

values

Compressor stuck

Change compressor

Temperature control contacts are

open

Repair or replace the contacts

Incorrect wiring

Check wiring diagram and correct

Fuse blown or circuit breaker

tripped.

Replace fuse or reset circuit breaker

Power cord unplugged

Plug in power cord.

Controller set too high

Set controller to lower temperature.

Cabinet in defrost cycle

Wait for defrost cycle to finish

The temperature is too cold

Controller is set at a very cold

position

Set to warmer position and check if

the compressor stops according to

controllers operating range.

Controller does not disconnect the

condensing unit

Check the insulation of the

thermostat. If problem persists,

change the thermostat

Control contacts are stuck closed

Change the control. Check

amperage load

Defective or incorrect temperature

control

Determine correct control and

replace.

The temperature is not cold

enough

Controller is set at a very warm

position

Adjust to colder setting

Condenser is dirty

Clean condenser

The refrigerator has been placed at

an inadequate location

The unit must not be near stoves,

walls that are exposed to the sun, or

places that lack sufficient air flow.

Compressor is inefficient or there is

a high pressure due to the air in the

system

If there is air in the system, purge

and recharge

Iced up evaporator coil

Check temperature control,

refrigerant charge, and defrost

mechanism. Remove all ice

manually and start over.

Restriction in system

Locate exact point of restriction and

correct

The refrigerator has been used

improperly

The shelves must never be covered

with any type of plastic or other

material that will block the

circulation of cold air within the

refrigerator.

Too many door openings

Advise user to decrease if possible

Excessive heat load placed in

cabinet

Advise user not to put in products

that are too hot.

12

The refrigerator has been

overcharged with the refrigerant gas

Check to see if condensation or ice

crystals have formed on the suction

line. If so, charge with the correct

amount of gas.

The refrigerant gas is leaking

Find the location of gas leak in order

to seal and replace the defective

component. Change the drier.

Perform a good vacuum and

recharge unit.

The evaporator and/or condenser

fans are not working

Check electrical connections and

make sure that the fan blade isn‟t

stuck. Replace the fan motor if it

doesn‟t work.

Blocking air flow

Re-arrange product to allow for

proper air flow. Make sure there is

at least four inches of clearance

from evaporator.

Fuse blown or circuit breaker tripped

Replace fuse or reset circuit

breaker.

Electrical Shocks

Wires or electrical components are

in direct contact with metallic parts.

Check for appropriate insulation on

the connections of each component.

Noise

The refrigerator is not properly

levelled

Check if the noise goes away after

you level the refrigerator

The condenser is not fastened

correctly. Copper tubing is in contact

with metal

While the compressor is working,

check to see if metal parts are in

contact with one another and/or if

the screws that fasten the

condenser are tightened.

The evaporator and/or condenser

fans are loose

Check if the fans are securely

fastened. Also, check if the fan

blades are loose, broken or

crooked. If so, change the faulty

blade.

Compressor has an internal noise

If the noise persists after all other

measures have been taken, it may

be originating from the compressor.

Loose part(s)

Locate and tighten loose part(s)

Extreme condensation inside the

refrigerator

Controller is set at a very cold

position

Set the controller to a warmer

position & check to see if

compressor stops as should.

The outside environment‟s relative

humidity is very high (over 75%)

This type of occurrence is caused

by local climatic conditions and not

by the refrigeration unit.

The refrigerator door wont shut

completely

Check the door and/or the magnetic

gasket. Adjust the door hinges if

needed; replace the gasket if

broken.

The refrigerator had been placed at

an inadequate location

The unit must not be near sources

that produce too much heat.

No illumination (Glass door

models only)

The light switch is “off” position

Press the light switch to “on”

position

False contact on the light switch, the

fluorescent tube, or the ballast

Inspect all connections

Light switch, ballast and/or

fluorescent tube are damaged

Replace the damaged component.

13

Condensing unit runs for

long periods of time

Excessive amount of warm product

placed in cabinet

Advise user to leave adequate time

for products to cool down

Prolonged door opening or door ajar

Advise user to ensure doors are

closed when not in use and to avoid

opening doors for long periods of

time.

Door gasket(s) not sealing properly

Ensure gaskets are snapped in

completely. Remove gasket and

wash with soap and water. Check

condition of gasket & replace if

necessary

Dirty condenser coil

Clean condenser coil

Evaporator coil iced over

Unplug unit and allow coil to defrost.

Make sure thermostat is not set too

cold. Ensure that door gasket(s) are

sealing properly. Select manual

defrost and ensure system works.

Notes

14

Foster European Operations

France

Foster Refrigerator France SA

Tel: (33) 01 34 30 22 22. Fax: (33) 01 30 37 68 74.

Email: commercial@fosterfrance.com

Germany

Foster Refrigerator Gmbh,

Tel: (49) 781 990 7840. Fax (49) 781 990 7844.

Email: info@foster-gmbh.de

Foster Refrigerator

Oldmedow Road

Kings Lynn

Norfolk

PE30 4JU

Tel: 0843 216 8833

Fax: 0843 216 4707

Website: www.fosterrefrigerator.co.uk

Email: support@foster-uk.com

a Division of „ITW (UK) Ltd‟

LCU15/LDU15 & ATI-5/SM 10/10