HR/LR 410
Economy Cabinet
with
BIT 20B11E Controller
&
LAE BIT 12 RU Display
Service Manual
Re-Issued September 2010
ISO 14001
ISO 9001
1
Contents
Manual Information & Health & Safety Notes
1
Environmental Management Policy
2
Disposal Requirements
2
410 Cabinet Description
3
Temperatures & Capacities
3
Controller Operation & diagram
4
Controller Settings
5
Electrical Connections
6
Parts Replacement Instructions
7 to 10
Technical Specification & Parts List
11
Wiring Diagrams
12 to 13
Troubleshooting & Notes
14 to 16
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 PARAMETER CHANGE INFORMATION
AS OF 27
th
SEPTEMBER 2010 HR410 AND LR410 WILL HAVE ONLY THE PARAMETERS AS STATED
BELOW.
THIS WAS PUT INTO PLACE TO STOP PARAMETERS BEING MODIFIED THAT WOULD CAUSE
SEBSEQUENT ISSUES AND REQUIRE SERVICE VISITS
410 Economy Cabinets
The cabinets are manufactured as a one piece formed shell with the condensing unit located on the base of the
cabinet. They conform to ISO Climate Class 4 (32
0
c with 40% RH).
Temperature is controlled by a LAE microprocessor controller with digital temperature display. The units‟
refrigeration system is integral with an air-cooled compressor and static condenser with the refrigerant distribution
into the evaporator controlled by capillary.
Also the condensation vaporisation is provided by a self contained condensate vaporiser tray attached to the top of
the compressor.
The low temperature units refrigeration is provided by static freezer shelves requiring manual defrost.
The doors are fitted with pivot hinges, stainless steel door handle and magnetic door gasket.
All models are fitted with roller castors to the rear and M8 adjustable levelling bolts to front.
On glass door models the interior light is fitted to the top of the storage area at the front. The on/off switch is
incorporated in the light.
Nomenclature based on –
H = High Temperature.
L = Low Temperature.
R = Refrigerator.
410 = Net Capacity (litres).
G = Glass Door
Temperatures and Capacities
Model Ref
HR 410
LR 410
Temperature range
+3
0
c to + 5
0
c
-18
0
c to -21
0
c
Capacity - litres
410
410
Shelves
4 x nylon
coated
shelves
6
(fixed freezer
shelves)
Internal fittings
Fixed shelf
supports.
Static
refrigerated
shelves
Refrigerant
180 grms
R134a
200 grms
R134a
External Dimensions
H 1875mm x
W 600mm x
D 652mm
H 1875mm x
W 600mm x
D 652mm
4
Controller Operation
The BIT 20B11E is fitted to the HR410 and LR410.
With this controller also the LAE BIT 12 RU front display is installed.
The Control Unit is fitted at the rear of the cabinet with the Display Unit fitted into the front top right hand side of the
cabinet, interconnected by a ribbon cable.
Defrost type for HR models is a timed off cycle, defrost for the LR410 switches the machine off and allows the ice
to melt, once it is clear of ice, dry the cabinet thoroughly before switching the machine back on.
One probe is fitted measuring air temperature and is used to control cabinet temperature.
In the event of probe failure “E1” will be displayed.
In the event of air probe failure on HR model the refrigeration system will be controlled by a timed sequence. The
controller parameter setting cF is set at 00 which allows for the compressor to be on for 3 minute and off for 4
minutes.
In the event of air probe failure on LR models the compressor will run continuously, the controller parameter setting
cF is set at 1.
Controller and display diagram
Controller – 00-554860
Display – 0-554167
Control Unit
Display Unit
Button 2
Button 3
Button 1
5
Controller Settings
Check set point 1.
Press button 1
Increase set point
Press and hold button 1
Press button 2 until required temperature is displayed.
Decrease set point
Press and hold button 1
Press button 3 until required temperature is displayed.
Controller set up
Access to the controller is achieved by pressing in sequence: –
+ + And holding the keys in for a period of 4 seconds.
It is possible to scroll through the parameters by pressing or .
The value of a selected parameter is checked by pressing and may be
Altered by pressing or whilst still pressing .
Exit from set up occurs after 15 seconds if no button is pressed.
BIT 20B 11E Controller settings for 410 models
Parameter
Description
Standard
Settings
HR 410
Settings
LR 410
Settings
SP
Temperature Set Point
3
3
-21
SL
Min. Set Point
-3
3
-21
Sh
Max. Set Point
12
3
-21
Hy
Hysteresis
3
3
3
cr
Compressor Min. Pause
3
4
4
cF
Operation with T1 Fail
0
0
1
dF
Defrost Frequency
6
4
0
dt
Max. Defrost duration
20
10
1
dL
Defrost Limit Temp
10
10
10
dm
Defrost Mode
1
0
0
dr
Drain Time
3
3
0
th
Display During Defrost
10
0
0
to
Display Offset
0
0
0
tS
Display Slow Down
3
0
0
6
Electrical Connections
BIT 20 B11E Controller. (Foster part No. 00-554860)
Power Supply N = Neutral
Power Supply L = Live
L = Power in plus evaporator fan and light (if fitted)
live feed.
N = Neutral in.
L1 = Compressor feed.
L2 and L3 not used.
N1= Compressor, evaporator fan and light (if fitted) neutral.
N2 and N3 not used.
N3
N2
N1
POWER
N L L L L
1 2 3
7
Parts Replacement HR 150, HR 410, LR150 and LR 410
IMPORTANT- all repairs must be carried out with the mains electrical supply
disconnected and by a competent person. Failure to do so may invalidate the warrantry.
1) Access To Electrical Connections.
Access to the electrical connections is via the back of the cabinet. All electrical connections are in the BIT 20
controller.
Remove the three screws securing the controller to the bracket. Rotate the controller to gain access to the
electrical connections.
2) Evaporator Fan Replacement HR410
Remove the rear shelf supports from the cabinet interior.
Loosen the two retaining screws at the bottom of the airduct.
Remove the three screws securing the airduct to the top of the cabinet and ease it away from the rear of the
cabinet. (See Fig 1)
Sever the power cables and disconnect the earth wire from the motor.
Remove the plastic fan guard securing the fan motor to the duct.
Prior to fitting the replacement it is important to note the air is circulated across the evaporator plate and blows
through the fan into the storage area, an arrow can be found on the motor housing indicating airflow.
Secure the fan to the airduct using the fan guard incorporating the four fixing studs.
Note: It may be necessary to change the fan guard as unless care is taken it is possible to break the fixing studs
during this process.
Connect the power cables using suitable water tight cable connectors and connect the earth cable to the motor
housing.
Refit all panels ensuring they are located correctly and fitted securely.
Note:- The capillary
(Fig 1)
8
3) Air Probe Replacement HR410
Remove the Shelf supports and airduct as described in 2.
Remove the two screws securing the evaporator to the rear of the cabinet. (See Fig 1).
Unclip the air probe.
Disconnect the probe wires as described in 1.
Remove the two screws from the left-hand side of the condenser securing it to the cabinet.
Ease the condenser away from the back of the cabinet to expose the probe wires.
Release the probe and probe cable from the clips and remove it from the cabinet.
To replace the probe reverse the procedure ensuring probe and probe cable is secured firmly in the connector
block and retaining clips.
Refit all panels ensuring they are located correctly and fitted securely.
4) Compressor Fan Replacement.
Remove the screws securing the fan housing to the inside of the unit compartment and the rear right hand side of
the cabinet.
Remove the compressor electrical box and disconnect the fan cables from the terminals.
Slide the fan housing out of the unit compartment.
Remove the plastic fan guard securing the fan motor to the housing.
Note: It may be necessary to change the fan guard, as unless care is taken it is possible to break the fixing studs
during this process.
Prior to fitting the replacement it is important to note the air is circulated through the fan and blows across the
compressor, an arrow can be found on the motor housing indicating airflow.
Secure the fan to the housing using the fan guard incorporating the four fixing studs.
To refit reverse the procedure ensuring the electrical connections are firmly connected and all covers are located
correctly and fitted securely.
Note: On glass door models a ring mount fan motor is fitted, it is necessary to remove the rear fan guard to gain
access. Unscrew the four screws securing the fan to the housing and remove it. Prior to fitting the replacement cut
two portions from the ring of the fan to match the original and refit. On completion refit the rear fan guard.
5 ) Controller Display Replacement.
Unplug the ribbon cable from the controller.
Remove top cover from the cabinet by unscrewing the four screws securing it to the sides and the three screws
from the front underside. See Fig 2.
Slide the cover forward and lift it from the cabinet.
Pull the ribbon cable out from behind the condenser.
Depress the two retaining lugs on either side of the display and remove it.
To fit the replacement reverse the procedure ensuring all covers are located correctly and fitted firmly.
(Fig 2)
6) Controller Replacement.
Remove the controller as described in 1.
Unplug the ribbon cable and disconnect all electrical connections.
To replace reverse the procedure ensuring all electrical connections are attached firmly in the correct positions.
Refit the controller to its bracket.
To access the controller and for resetting the parameters see the instructions on page 5.
9
7) Door Lock Replacement.
Remove the top cover as described in 5.
Remove the screw securing the locking arm to the lock assembly.
Remove the spring retaining clip securing the lock to the cover using a small bladed screwdriver and remove the
lock assembly from the housing.
To fit the replacement remove the locking arm from the lock assembly.
Insert the lock assembly through the obround hole in the cover ensuring it is in the correct position for locking and
held firmly in place by the spring clip.
Fit the locking arm and check that it locks correctly.
Reverse the procedure as described in 5 for fitting the top cover.
8) Compressor Replacement.
Reclaim the refrigerant.
Disconnect all electrical connections.
On satisfactory reclamation of the refrigerant disconnect the pipework from the compressor and tape the ends of
the pipes to avoid moisture ingress into the system.
It is important to note that the compressor manufacturer recommend that the replacement should be completed
within fifteen minutes to avoid contamination of the lubricating oil due to moisture ingress.
With the pipes disconnected remove the four clips securing the compressor to the base plate and remove.
Fit the anti vibration rubber mounts to the new compressor prior to re-installation ensuring that the metal spacers
are fitted correctly.
Fit the securing clips.
Remove the tape from the ends of the pipes and connect the pipe work ensuring that when brazing the flame does
not come into contact with the cabinet exterior.
It is good refrigeration practice to replace the drier when replacing component parts in the refrigeration system.
Reconnect all electrical connections.
Evacuate the system and charge with the correct amount of refrigerant as shown in the technical data on page 11.
When satisfied replace all components ensuring they are all fitted correctly.
9) Condenser Replacement.
Reclaim the refrigerant.
On satisfactory reclamation of the refrigerant disconnect the pipework from the condenser and tape the ends of the
pipes to avoid moisture ingress into the system.
It is important to note that the compressor manufacturer recommend that the replacement should be completed
within fifteen minutes to avoid contamination of the lubricating oil due to moisture ingress.
With the pipes disconnected remove the four screws securing the condenser to the back of the cabinet and
remove.
Fit the replacement condenser ensuring the nylon spacers are fitted correctly.
Remove the tape from the ends of the pipes and connect the pipe work ensuring that when brazing the flame does
not come into contact with the cabinet exterior.
It is good refrigeration practice to replace the drier when replacing component parts in the refrigeration system.
Evacuate the system and charge with the correct amount of refrigerant as shown in the technical data on page 11.
Once the system has been recharged with refrigerant check for leaks.
10) Door Replacement.
Tilt the cabinet backward and support it against solid surface e.g. brick wall, to expose the base of the cabinet.
Remove the three screws securing the hinge bracket to the base of the cabinet and disengage the door from the
top pivot pin.
Fit the door handle to the replacement door using the two pop rivets provided.
Lay the replacement door on to the cabinet and slide the door into position to engage the top pivot pin.
Fit the bottom bracket into place and secure it to the base of the cabinet with the three screws.
Lower the cabinet to its normal position and check that door locks.
If it has been necessary to lay the cabinet onto its back to change the door do not switch the cabinet on for at least
60 minutes.
10
11) Door Change from Right Hand Hinging to Left Hand Hinging.
Remove the door as in 10.
Drill out the two pop rivets and remove the door handle.
Remove the nylon bush from the right-hand side of the door and insert it into the hole in the left-hand side of the
door.
Refit the handle to the right hand side of the door using 3/16 pop rivets.
Unscrew the top pivot pin from the captive nut in the right hand side of the top plate and screw it firmly into the
captive nut on the left-hand side of the top plate.
Note:- it is recommended that a small amount of Locktite or an alternative is used on the thread to reduce the risk
of the pivot pin becoming unscrewed.
Replace the door as in 10
12) Door Gasket Replacement.
Open the door fully.
Whilst holding the door firmly with one hand pull the gasket from its retainer.
Offer the replacement gasket to the cabinet and force the top right and left-hand portion of the gasket into the
retainer.
Once secured into place use a rubber mallet to knock the gasket firmly into the retainer.
Check the gasket is held securely in place, if not continue with the rubber mallet until it is firmly in place.
11
Technical Specification
Model
Gas
Gas Charge
Compressor
Capillary
Defrost Type
Heat Output
Extraction
Rate
Voltage
Power Consumption
Fuse
Rating
Amps
Watts
Amps
HR 410
R 134A
180grms
GL60TB
Part of evaporator
assembly
Timed Off Cycle
451w
233w
230/50/1
218
1.3
13
HR 410G
R134A
200grms
GL80AA
Part of evaporator
assembly
Timed Off Cycle
546w
285w
230/50/1
261
1.5
13
LR 410
R 134A
200 grms
GL 90AA
Part of evaporator
assembly
Manual Defrost
575w
206w
230/50/1
369
2.8
13
Parts List - HR 410, HR 410G and LR 410
Item
Description
Part number
Model
Compressor
GL60TB
00-555111
HR 410
Compressor
GL80AA
00-555112
HR 410G
Compressor
GL 90AA
00-555113
LR 410
Compressor Vaporiser Tray
Type L
15271007
HR 410
HR410G
Compressor Cooling Fan
00-554830
All
Compressor Fan Guard (2)
00-554832
HR 410
HR 410G
Evaporator Fan (2)
00-554830
HR 410
HR410G
Evaporator Fan Guard (2)
00-554832
HR 410
HR 410G
Air Probe
SN2K2OP
00-554253
All
Controller Display
Bit 12RU
00-554167
All
Controller
BIT20B11E
00-554860
All
Door Lock
SH0072-215
00-554846
All
Keep Insert
15230319
All
Door Gasket
Magnetic 1755x542.6
01-231780-01
HR 410
LR 410
Glass Door Gasket
TBA
HR 410G
Internal Light
00-0-5548393
HR 410G
Internal Light Diffuser
00-0-5548394
HR 410G
Mullion Heater
230V 4505 R
01-231807-01
All
12
High Temperature Controller Wiring Diagram
13
Low Temperature Controller Wiring Diagram
14
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
15
Excessive heat load placed in
cabinet
Advise user not to put in products
that are too hot.
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.
16
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
17
Foster European Operations
France
Foster Refrigerator France SA
Tel: (33) 01 34 30 22 22. Fax: (33) 01 30 37 68 74.
Email: comm[email protected]
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‟
410CAB/BIT20B11E /SM 09/10
/