Foster RBC MK 3 Controller Retarder Prover Service Manual

FOSTER DRP

RBC MK 3 CONTROLLER

Program Version F206

SERVICE MANUAL

Revised 09-02-2009

Contents

Introduction 1 to

2

2

Controller Instructions

3

4

Set ting of Parameters

Configuration

4 to 11

4

Standard Parameter Settings

Time and Date

4

5

5 to 6 Programs

Program

Storage

Fast Chill Parameters

6

6 to 7

Recovery Parameters

Prove Parameters

Oven Contact Parameters

7 to 8

8 to 11

11

11

Factory Test Program

Alarm Cancelation

11 to 13

13 to 14

Controller Reset

Fault

14 to 15

Messages 15

Interrupt 15

Modem Dial Number Missing 15 to 16

Fitting Procedure for F206 Eprom

Probe Resistance Values

Overtemperature Stat Settings

16

17

17

Fault Diagnoses

Wiring Diagrams

17 to19

20 to 29

INTRODUCTION

The cabinet and Modular DRP are designed to retard, recover and prove dough products. When utilised correctly the unit will enable a more consistent product quality to be achieved.

It is therefore important that prior to working on this equipment that this manual is read and understood.

If any point of operation is unclear the engineer should contact Foster Refrigerator (UK) Ltd on (01553) 691122.

The controller contains both ‘User Parameters’ and also ‘Machine Operating Parameters’. Neither of these parameter sets are accessible to the store operators and as such should not be disclosed to any member of store personnel

(including management).

Similarly the parameters are pre-set on commissioning to ensure consistent product quality and as such should not be adjusted under any circumstance without prior consent in writing from Head Office bakery personnel.

Note: Although the controller has 9 programs only program 4 is used.

Upon initiation of a complete cycle the controller will display ‘DO NOT LOAD PRODUCT’ until the chamber temperature reaches -5ºc (fast chill) at this point it will sound an alarm and the display will show ‘LOAD PRODUCT’.

The fast chill program is set for 1hour.

On completion the temperature will be controlled at -5ºc with the controller in the storage mode, there is no fixed time to this section as the controller calculates how long this temperature is maintained based on the bake time and the remaining process times.

The recovery time is set for 6 hours and the prove time is set for 2 hours and 30 minutes

An illustration of this is;

Assuming that the current time is 15:00 and the bake time is 06:00 the following day a total time for the cycle is 15 hours.

The controller calculates back from the bake time, ’06-00’, for the prove time of 2 hours and 30 minutes plus the recovery time of 6 hours

So with the with a fast chill time of 1 hour + recovery of 6 hours + prove of 2 hours and 30 minutes this will leave a storage time of 5 hours and 30 minutes

When the calculated time for the phase is reached the controller will change from the Storage Mode (RETARD) mode to the Recovery mode. During the recovery mode the controller increases the temperature of the chamber linearly

1

from the storage temperature to the recovery temperature over 75% of the given period of time. If other parameters allow it up to 82% humidity may be introduced during this phase.

Upon completion of the Recovery phase the Prove cycle commences. The chamber is then increased to a higher temperature over 75% of given set time period. During this phase 87% humidity may introduced into the chamber as required to maintain the required humidity.

When the Prove phase of the cycle is complete the operator is advised both audibly and visually that the current program is complete and is given an option to either extend the prove time or hold the product. Assuming that these options are not selected the cycle is complete and as such is halted.

If the product is not ready at the bake time then a Extra Prove (10 minutes), for a maximum of 15 minutes, can be selected. Similarly, if the product is ready but there is no oven capacity the product can be held in Hold (10 minutes).

The duration of both Extra Prove and Hold are governed by the machine parameters.

Operator Program

Description:

Each stage of the R etarder Prover cycle is explained as follows:

Figure 1 – Retarder Prover Operating Cycle

28ºC

15ºC

7ºC

-5ºC

P HASE 1 – “Chill”

From ‘Start’ the refrig eration attempts to reduce air temperature to -5ºC.

While air temperature is above 0ºC the display shows “Do not load produ ct”.

Typically after 15 to 20 minutes the chamber has reduced to -5ºC an alarm so unds indicating product can be loaded.

The duration of the Fast Freeze Phase is 1 hour.

P HASE 2 – “Retard”

From the end of Phase 1 the air temperature is maintained at -5ºC for the duration of the Retard Phase.

The length of the Retard Phase will depend on the required bake off time (end of Phase 4).

P HASE 3 – “Recovery”

From the end of Phase 2 t he recovery phase is split into two segments (75% and 25%).

During the first 75% of Phase 3 (4½ hours) the temperature rises from -5ºC to +7ºC.

During the final 25% of Phase 3 (1½ hours) the temperature is maintained at +7ºC.

Through-out this period the humidity is around 82%.

The duration of Recovery Phase is 6 hours.

P HASE 4 – “Prove”

From completion of Ph ase 3 the Prove Phase starts, and it is split into two segments (75% and 25%).

During the first 75% of Phase 4 (1hour 52 minutes 30 seconds) the temperature rises from +8 o

C t o +28ºC. (Tesco

32ºC)

During the second 25% of Phase 4 (37 minutes 30 seconds) the temperature is maintained at +28ºC. (Tesco 32ºC)

Through-out this period the humidity is maintained at 87%.

The duration of Prove Phase is 2 hours 30 minutes. If the pr oduct is not ready at the bake time then an Extra Prove (10 minutes) can be selected for up to a maximum of 15 minutes.

P HASE 5 – “Hold”

On completion of the Prove phase, if th e load is not immediately required for baking off, the product can be placed in the HOLD mode for 10 minutes when the air temperature will be reduced to 15ºC in order to stabilize the product and can be held for up to a maximum of 20 minutes.

2

OPERATING INSTRUCTIONS

1) To start the Operation

Press ‘START’

WEDNESDAY

16:45

SYSTEM OFF

PRESS START

START

4) Enter the Bake Time

14-02-2009

Press ACCEPT or Press EDIT followed by the up or down arrows to change the time

BAKE DAY TODAY

BAKE TIME 18: 34

ENTER BAKE TIME

ACCEPT EDIT EXIT

5)

2) Select the Bake Program from the menu. If Prove only program is selected program will start automatically

Retard & Prove

Timed Prove 1

Prv Brd & French

Prv Soft Rolls

Prv Donuts

SELECT EXIT

Press ACCEPT to Confirm Selected

Cycle

BAKE DAY TODAY

BAKE TIME 09:48

CONFIRM SELECTED CYCLE

ACCEPT EDIT EXIT

WAIT

FOR

AUDIBLE

ALARM

3) Enter the Bake Day for Retard &

BAKE DAY TODAY

ENTER BAKE DAY

6)

Prove. Press ACCEPT or Press the

UP arrow to change the B ake Day

ACCEPT EXIT

An Audible alarm will sou loading temperature.

‘START’

Program 4

7

28

15

-5

-5

Bake Date: Thursday 09 :40

LOAD PRODUCT

PRESS START

nd when the machine is at the correc

Load the product and press t

STOP START

7) When cycle is complete an audible alarm will sound, press ‘STOP’, check the product is fully proved, remove and bak e.

8) Should an extra proving time be required, select ‘EXTRA TIME’ and press ‘START’.

For HELP press the? Button located above the display.

PLEASE NOTE when changing the machine from Prove to Retard Overnight Operation allow 45 minutes for the cabinet to cool down.

In the event of an emergency switch off the machine at the ‘MAIN ISOLATOR SWITCH’.

02/09 Rev 1

Controller Instructions

The display is a yellow back lighted graphic display with a resolution of 320 * 240 dots.

Above the Display the Info-key is located. Press to display help and information at all times.

Under the Display the keys LEFT, MIDDLE and RIGHT

On the right side besides the Display the Arrow Keys UP and DOWN are located. are located .

NOTE:

At any time during a program if the bottom button is pressed and help the display will sho w: Temp Set

Point, Coil Temperature, Winter/Summer Time and the program number.

Setting of Parameters

After switching the auxiliary voltage on the controller carries out a self-test of the program and s how s FLASH TEST

FOR INTEGRITY for a few seconds followed by the program information including version and mod el d etails.

After that the Start Screen is shown:

Start Screen

Monday 14.02.2009

08:11

SYSTEM OFF

Press START

START

C onfiguration Parameters

Af ter pressing the DOWN, RIGHT and LEFT keys together the Configuration Parameters Menu is sh ow n:

Th ese are machine default parameters that are stored in the controller.

Co nfiguration Parameters Menu

CONFIGURATION PARAMETERS

Standard Parameter Setting

Select Standard Parameter Settings usin g the Arro w Key s and then press SELECT.

Tim e / Date

Pr ograms

Ma nual Prove

Ma nual Fast Chill

Ma nual Storage

Ma nual Recovery

Se rvice

Re set Alarms

En d Times

Select Exit

Standard Parameter Setting (Load Set of Parameters)

Once selected the following screen will appear:

It is important that the correct default parameters are selected for the machine e.g. does it have an i nte gral condensing unit or is it remotely sited (pack system), is it constructed using modular panel s or a cab ine t.

DEFAULT PARAMETER SELECT

TESCO/MOD/PACK

TESCO/MOD/INTEGRAL

Select from the listing using the Arrow Keys and then pr ess

SELECT,

The screen will change and display the sele cted model follo wed by

Loading Service Parameter and then Loading Progra

m

TESCO DONUT UPRIGHT

TESCO DONUT BENCH

SAFEWAY/MOD/PACK

SAFEWAY/MOD/HT PACK

SAFEWAY/MOD/INTEGRAL

ASDA/MOD/PACK

ASDA/MOD/INTEGRAL

CRAFT/MOD/PACK

CRAFT/MOD/INTEGRAL

CRAFT UPRIGHT

Parameters.

When the parameters have been loaded the screen will reve rt back to the default parameters.

4

Time and Date

Select Time and Date in the Configuration Parameters Menu and the following screen will appear:

CONFIGURE TIME & DATE

It is impo rtant that the correct time and date are loaded ensuring

Current Time 10 :40 the correct function of the machine.

C urrent Date

14.02.2009

EDIT

TIME

EDIT

DATE

ACCEPT

EXIT

For setting the Clock press EDIT T IME:


The screen to the left will appear with ‘Current Time’ flashing.

Modify Parameter:

Current Time

The first digit of the time will have a

^

symbol beneath it and the value will flash on and off. Modify each Digit with the up or down arrow keys, confirm the sections by pressing SELECT and continue

V alue:

10:45 to change each of the segments in turn. On completion press

^

ACCEPT.

Press EXIT to exit without storing the modified values.

Accept SELECT EXIT

The screen will change to display the first screen to allow the cha nging of the date.

F or setting the Date press EDIT DATE:


The screen to the left will appear with ‘Current Date’ flashin g.

Modify Parameter:

C urrent Date

The first digit of the date will have a

^

symbol beneath it and the value will flash on and of f. Modify Digit with the up or down arrow keys, confirm the sections by pressing SELECT and continue to

Valu e:

14.02.20

09 c hange each of the segments in turn. On completion press

^

ACCEPT.

Press EXIT to exit with out storing the modified values.

Accept SELECT EXIT

T he screen will change to display the first screen press EXIT to return to the Co nfiguration Parameters Menu.

Programs

First select Pro grams in the Configuration Parameters Menu and the following screen will appear:

CONFIGURE PROGRAMS

Program 1

Program 2

Program 3

If the program is ‘On’ then all parameters are then governed by th eir own individual parameters. If the program is ‘Off’ only the program name and prog ram active screen will be visible.

Program 4

Program 5

Program 6

It is important to note that only program 4 is

Program 7

switched ON all other programs are switched OFF.

Prog ram 8

Prog ram 9

Select Exit

Select from the listing usin g the Arrow Keys an d then press SELECT,

Program 4

The screen will change and display the selected program.

It is important to ensure th at program 4 is ON and all other

Program A ctive

programs are switched OFF.

Yes

Modify?

To modify the program press YES

5

The screen will change and display the following.

Access Level

Enter Code for Lev el L3

0000

^

To modify the program it is necessary to enter the a ccess code for le vel 3. The screen will display 0000 with a

^

be neath the first

0

.

Use the up arrow to change the level code to 1122.

Press the up arrow once to change the 0 to 1 and then press sele ct t o move to the next 0. Continue until 1122 is on the display and th en press Confirm

Exit Select Confirm

The screen will ch ange and displ ay the following .

Program 4

Modify Parameter :

Program Acti ve

Value : yes

Program Active and yes will flash on and off to proceed pres s

CONFIRM

The screen will change and display the following screen

CONFIRM CANCEL

CONFIGURE Program

4

This menu allows for the particular program to be giv en a name and the parameters to be adjusted within the d efault parameters.

CONFIGURE Program 4

Program Name

F

S

R

P

M ast Chill Parameters torage ecove

Parameters ry Parameters rove Parameters in. Prove Time

Oven Contact

Param.

Select Exit

P rogram Nam e

The pre-defined name of the program can be changed if required

Configure Program 4

Select Program Name in Program Configuration 4 and the s creen to the left will be displayed.

Program Name

The Name is now displayed in the Start Menu.

To insert a short description for the Operation Mode into the

Program Name e.g. “Ret&Prv Bread”, select EDIT and the first letter will have a symbol

^

under it. Use the up or down arrow to s croll through the alphabet, press SELECT to confirm the change

EDIT

Accept

Exit and the symbol will move to the next letter. On completion pre ss

ACCEPT to store the changes made and the screen will re back to the first screen.

Press EXIT to return to the menu an d EXIT again to return to the Configure Program 4 menu. vert

Fast Chill Parameters

S elect Fast chill from the Configure Program 4 menu, press SELECT and the screen below will appear.

Configure Program 4

S elect YES, the screen will change with Fast Chill Active and yes

Fast Chill A ctive

Yes

M odify

flashing on and off, to proceed press CONFIRM.

To return to the menu press CANCEL.

YES EXIT NO

6

The screen will change and display the following s creen

Configure Program 4

Fast Chill Duration

Fast Chill Tem perature

Modify Exit

Select FAST CHILL D

URA

TION and press MO DIFY and the following screen will be displayed:

Menu: Fast Chill Duration

Co nfigur e Program 4

P ress Modify and the screen will change to show the first digit for

Fast Chill Duration 01:00

m odification.

Fast Chill Duration MAX 02:30

Us e the UP and DOWN arrows to change the value and press

Fast Chill Duration MIN 01:00

S

ELECT to move to the next digit.

Modify

O nce the changes have been made press ACCEPT and proceed to change the other values if required.

NOTE: It is not recom mended to make changes to the values without managerial consent.

P ress EXIT to retu rn to the menu and Select FAST CHILL TEMPERATURE, press Modify, then press YES followed by CONFIRM and the followin g screen will be displayed:

M

enu: Fast Chill Temperature

Configure Program 4

P ress Modify and the screen will change to show the first digit for

Fast Chill Temperature -05°C

m odification.

Fast Chill Temperature MAX +00°

Use the UP and DOWN arrows to change the value and press

Fast Chill Temperature MIN -15°C

SELECT to move to the next digit.

Modify

Once the changes have been made press ACCEPT and proce to change the other values if required. ed

NOTE: It is not recommen ded to make changes to the values without managerial consent.

Press EXIT three times to return to the Configure Program 4 menu.

Storage Paramet ers

Select Storage Par

am

eters from the Configure Program 4 menu, press SELECT and the screen below will appear.

Co nfigure Prog ram 4

Press Modify and the screen will change to show the first digit for

St orage T emperature

-05°C modific ation.

Storage Temperature MAX +00°C


Storage Temperature MIN -10°C


MODIFY

Once the changes have be en made press ACCEPT and proceed to change the other values if required.

NOTE: It is not recomm ended to make changes to the values without managerial consent.

P ress EXIT to ret urn to the menu and EXIT aga in to return to the Configure Program 4 menu.

R ecovery Parameters

S elect Recovery Temperatures from the menu , press YES to modify and then press CONFIRM and the screen b elow will appear.

Co nfigure Program 4

Re covery r

Select Recovery Tempe

Recovery Humidity d isplayed:

R ecovery Duration

SELECT EXIT

rature and the following screen will be

Menu: Recovery Temperatures

Configure Program 4

Recovery Temperature

+07°C

Press SELECT and the screen will change to show the first digit for modification.

Recovery Temperature MAX

Recovery Temperature MIN

+12°C

+05°C

Use the UP and DOWN arrows to change the valu e and press


SELECT EXIT to change the other values if required.

N

OTE: It is not recommen ded to make changes to the values without managerial consent.

P re ss EXI T twice to return to the me nu an d Sele ct Recovery Humidity, press SELECT followed by YES to modify, p ress CONFIRM and the following screen will be displayed:

7

Menu: Recovery Hum idity

Configure Program 4

Press SELECT and the screen will change to show the first digit for

Recovery Humidity

82% modification.

Re covery A 95%


R e covery Humidity MIN 75%


SELECT

Once the changes have been made press ACCE to change the other values if required.

PT and proceed

NOTE: It is not recommended to make cha nges to the values without managerial consent.

Press EXIT to return to

the menu and Select Re

covery Duration, press SELECT followed by YES to modify, press

CONFIRM and the fo llowing screen w ill be d ispl ayed:

Menu : Recovery Duratio n

Co nfigure Program 4

Recovery Duration

Recovery Plateau Time

06:00

25%

Select Recovery Duration and the follo wing screen will be displayed:

SELECT EXIT

Menu: Recovery Duration

Configure Program 4


Recovery Duration 06:00

modification.

Recovery Duration MAX 07:00


04:00


Select

Once the changes have been made press ACCEPT and proceed to change the other values if required.

NOTE: It is not recommended to make changes to the values without managerial consent.

Press EXIT twice to return to the menu and Select Rec. Plateau Time , press SELECT and the following screen will b e displayed:

Menu: Recovery Plateau Time

Configure Program 4

Recovery Plateau Time

Recovery Plateau Time MAX

Recovery Plateau Tim e MIN

25%

50%

10%

Press SELECT and the screen will change to show the first d igit for modification.



Select to change the other values if required.

NOTE: It is not recommende d to ma ke chang es to the values without managerial consent.

P ress EXIT three times to return to t he Con

figu

re Program 4 menu.

Prove Parameters

Select Prove Parameters from the menu, press SELECT followed by YES to modify, press CONFIRM and the screen below will appear.

Menu: Prove

Configure Program 4

Prove Temperatures

Select Prove Temperatures and the following screen will be d isplayed:

Prove Humidity

Prove Duration

Extra Prove

Hold

SELECT EXIT

Menu: Prove / Temperatures

Configure Program 4


Prove Temperature

+35°C modification.

Prove Temperature MAX +35°C


Prove Temperature MIN +25°C


SELECT



Press EXIT to return to the menu and Select Prove Humidity, press SELECT followed by YES to modify, press

CONFIRM and the following screen will be displayed:

8

Menu: Prove Humidity

Configure Program 4


Prove Humidity

87% modification.

Prove Humidity MAX 95%


Prove Humidity MIN 75%


SELECT



Press EXIT twice to return to the menu and Select Prove Duration, press SELECT followed by YES to modify, press CONFIRM and the following screen will be displa yed:

Menu : Prove Duration

Configure Program 4

Prove Duration

Select Prove Duration and the following screen will be displ ayed:

Prove Plateau

SELECT EXIT

Menu: Prove Duration

Configuration Program 4


Prove Duration 02:30

modification.

Prove Duration MAX 03:00


Prove Duration MIN 00:30

SELECT

to move to the next digit.

SELECT



Press EXIT to return to the menu and Select Prove Plateau, press SELECT and the following screen will be d isplayed:

Menu : Prove Plateau



Prove Plateau Time 25%

modification.

Prove Plateau Time MAX 50%


Prove Plateau Time MIN 10%


SELECT


N

OTE: It is not recommended to make changes to the values without managerial consent.

P ress

EXIT

twice to return to the menu and Sele ct Extra Prove, press SELECT followed by YES to modify, press

CONFIRM and the follow ing screen will be displayed:

Menu : Extra Prove


Extra Prove Time

Extra Prove Temperat

Extra Prove Humidity ure

Select Extra Prove Time, press YES to modify, press CONFIRM and the following screen will be displayed:

SELECT Exit

Menu : Extra Pro ve Time


Extea Prove Time 00:10

P ress SELECT and the screen will change to show the first digit for m odification.

Extra Pr. Max Time

Extra Prove Time MAX

Extra Prove Time MIN

Extra Pr. Max Time MA X

Extra Pr. Max Time M IN

00:15

00:20

00:01

00:30

00:10

U se the UP and DOWN arrows to change the value and press


Once the changes have been made press ACCEPT and proceed to change the other value s if required.

SELECT Exit

N OTE

: It is not recommen ded to ma ke chang es to the values without managerial consent.

Press EXIT to return to the menu and Select Extra Prove Temperature, press SELECT an d the following screen w ill be displayed:

9

Menu : Extra Prove Tem perature



Extra Prove Temp. +30°C

modification.

Extra Prove Temp. MAX + 40°C


Extra Prove Temp. M IN + 25°C


SELECT



Press EXIT to return to the menu and Select Extra Prove Humidity, press SELECT followed by YES to modify, press CONFIRM and the following screen will be displayed:

Menu : Extra Prove Hum idity


P ress SELECT and the screen will change to show the first digit for

Extra Prove Humidity 87%

modification.

Extra Prove Humidity MAX 95%


Extra Prove Humidity MIN 75%

S

ELECT to move to the next digit.

SELECT

O nce the changes have been made press ACCEPT and proceed to change the other values if required.

NOTE: It is not recommen ded to make changes to the values without managerial consent.

Press EXIT twice to return to the menu and Sele ct Hold, press YES to modify, press CONFIRM and the following screen will be displaye d:

Menu : Hold

C onfiguratio

Hold Times

n Program

Hold Temperature

Hold Humidity

4

Select Hold Times, press YES to modify, p ress CONFIRM and the following screen will be displayed:

SELECT Exit

Menu: Hold Times


Hold Time 00:10

Press SELECT and the screen will change to show the first digi t for

Hold Maximum Time 00:20 modification.

Hold Time MAX 00:15


Hold Time MIN 00:01


H old Maximum Time MAX 00:30

Once the changes have been made press ACCEPT

H Old Maximum Time MIN 00:01 to change the other values if required.

SELECT Exit

and proceed

N

OTE: It is not recommended to make changes to the values without managerial consent.

Press EXIT to return to the menu and Select Hold Temperature and the following screen will be displayed:

Menu: Hold Temper ature


Hold Temperature

H old Tempe rature MAX

Hold Tempersture MIN

+1 5° C

+20°C

+02°C

Press SELECT and the screen will change to show the first digit for m odification.


SELECT

to move to the next digit.

SELECT to change the other values if required.

NOTE: It is not reco mmended to mak e chan ges to the values without managerial consent.

Press EXIT twice to retu rn to the menu and Sele ct Hold Humidity , press SELECT followed by YES to modify, press CONFIRM and the following sc reen w ill be displayed:

Menu: Hold Humidity


Press SELECT and the screen will change to sh ow the first digit for

H old Humi dity 87%

m odification.

Hold Humidity MAX 95%


H old Humidity MIN 75%


SELECT


NOTE: It is not rec ommended to make changes to the values without managerial consent.

P ress EXIT three times to return to the Configure Program 4 menu.

10

Min. Prove Time Param.

Select Minimum Prove Time Param from the m enu, press SELECT followed by YES to modify, press CONFIRM and the screen below will appear.

Menu: Min. Prove Time P aram.

Configure Program 4

Press SELECT and the screen will change to show the first digit fo

Minimum Prove Time 02:00

modification.

Minimum Prove Time MAX 01:00

Use the UP and DOWN arrows to change t he value and press

Minimum Prove Time MIN 04:00


SELECT EXIT to change th e other values if required. r


Press EXIT to return to the Configure Program 4 menu.

Oven Contact Parame ters

T he Oven Co ra t swi tched on so modification is not required.

P ress EXIT to return to the Configure Program 4 menu, press EXIT twice to return to the

CONFIGURATION

PARAMETER screen.

Configure End Time s

Each of the days when the machines is required the end times can be pre-set to enable the baker to start a program without ha m

T o access t he program select End T imes from the Configure Program 4 menu and the following screen will a ppear.


END TIM ES

Monday

Tuesday

03-00

03-00

Press EDIT SELECT and the following screen will appear.

Wednesday

Thursday

Friday

Saturday

03-00

03-00

03-00

03-00

03-00 S unday

ACCEPT

VALUES

EDIT

SELECT


END TIM ES

Press SELECT and the day and the first segment of the value time

Modify Parameters: will flash on and off.

Monday

Alter the time by using the UP and DOWN arrows to suit the

Min Value :

03-00 individual requirement, press SELECT to move from one segme nt

03-00 to the next and when completed press ACCEPT.

V alue :

Max :

ACCEPT SELECT

03-00

Make the necessary changes to the days required and then press

ACCEPT VALUES to return to the Configu

Menu.

EXIT ration Parameters

O n completion of all change press EXIT to return to the SYSTEM OFF PRESS START screen.

Factory Test Program

r

The Factory Test Pr o gram is designe d to enabl e the engineer to check the various f unctions, outputs and probe eadings as a mean of chine and/ or controller problems.

You can start the factory test program switching off the power supply to the controller and p ress and hold in the UP a nd DOWN Arrow keys during switching on the auxiliary voltage and carrying out the Flash Te st.

Remain holding the buttons until the flash test has been completed and the following screen will be displayed.

11

Factory Test (Ver. F203)

1 – Keyboard Test UP

Factory test ‘1’ allows for the Left, Right, Middle, Up, Down and

RIGHT + LEFT : Continue

Help (?) buttons to be checked.

Press each button once for them to be displayed.

DOWN

T o continue xt

The next screen will display. e RIGH T & LEFT buttons simultaneously.

Fact ory test ’2’ allows for the Display to be tested. Factory Test (Ver. F203)

2 – Display Test


Middle : Start Test

LEFT MIDDLE RIGHT

To continue to the next test press the RIGHT & LEFT buttons simultaneously.

The next screen will display.

Factory Test (Ver. F203)

3 – RS232 / Bus Test


Factory test ’3’ allows for the testing of the Modem connections.

Modem Connections NOT USED.

Modem

- - - - - - - - -

To con tinu e to the next test press th e RIGH E

The next s creen will display.

Factory Tes t (Ver. F20 3)

4 – Relay Test

RIGHT + LEFT : C ontinue

LEFT : Periodic Test

MIDDLE: Static Test

K1 2 3 4 5 6 7 8 9 10

LEFT MIDDLE RIGHT

Factory test ’4’ allows for the testing relay outputs.

When the screen is displayed the Periodic Test is in operation. To change to Static Test press the middle button.

Each of the relay outputs relates to the following.

K1, 7, 8, 9. = Coil Fans. 2 = Interior Light. 3 = Liquid

Solenoid Valve. 4 = Room Heating. 5 = Defrost

Heaters. 6 = Water Solenoid Valve

To contin ue to the next test press th e RIGH T & L EFT buttons simultaneously.

The next scr een will display.

F actory Tes t (Ver.

F203)

5 – Digital Input Test


Inp 1 2 3 4 5 6

Factory test ‘5’ tests the digital inputs.

1 = Overtemperature.

2 = Emergency Switch.

3 = Overpressure.

4 to 6 Not used

LEFT MIDDLE RIGHT


12

T he next screen will display.

Factory Test (Ver. F 203)

6 – Analog Input Test


AN0 AN1 AN2 AN3

0 0 0 0

AN4 AN5 AN6 AN7

4 889 746 640

92 % 65C 45C

LEFT MIDDLE RIGHT

Factory test ‘6’ tests the gives the readings against individual probes.

AN0, AN1, AN2, AN3, Not used.

AN4 = Door contact

AN5 = Humidity Probe reading in ohms and pe

AN6 = Evaporator Probe reading in ohms and rcentage. temperature °C.

AN7 = Air Probe reading on ohms and temperature °C.

Values below AN4, 5, 6, 7 for reference only these will change relative to status

To continue to the next test p ress the RIGHT & LEFT buttons simultaneously.

T he next screen will display.

Factory Test (Ver . F203)

7 – Buzzer Test

F actory test ‘7’ Buzzer Test.

Follow the in struction on the screen


UP: Buzzer ON

DOWN: Buzzer OFF

LEFT MIDDLE RIGHT


The next screen will display.

F actory Test (Ver. F203)

8 – EEPROM Test


LEFT: Start Short Test

RIGHT + MIDDLE: Long Test

MIDDLE: Restart Test 1

LEFT MIDDLE RIGHT

Factory test ‘8’ EEPROM test.

Press the LEF T button for a short test.

Press the RIGHT + MIDDLE button s for a long test.

Press the Middle button to return to factory test 1.

On completion of the selected test press the left and right to return to the ‘SYSTEM OFF PRESS START’ Screen.

A larm Cancelation

Prior to clearing the alarm i t will be ne ce ssary to chan ge the faulty component.

However in the case o f ‘Overtemp Fault’, ‘Over Press ure’ and ‘ Emergency Stop’ these are fault messages relating to situations and not s n etting is all that is required.

e ‘SYSTEM O F PRESS START’ screen as below: n

Monday 14-02-2009

08:11

SYSTEM OFF

Press START

START

With the screen displayed press the DOWN, RIGHT and LEFT keys together.

After pressin g the DO WN, RIGHT a nd LEFT key s together the Configuration Parameters Menu is shown.

Usi ng the DO WN arrow, select ‘Re set Alarm s’ and then press ‘Select’.

13

Configuration Parameters Me nu

CONFIGU RATION PARAMETERS

Standard Parameter Setting

Time / Date

Programs

Manual Prove

Manual Fast Chill

Manual Storage

Manual Recovery

Service

Reset Alarms

End Times

Select Exit

The ‘RESET ALA RM’ Screen, below, will be displaye d. The alarm fault will be displayed, e .g. ‘Over Temperature

Alarm’.

Over Temperature Alarm

Reset Exit

Press ‘Reset’, Res etting A larms will flash on and off o n the display

RESET ALARMS

Resett ing Ala rm s

O nce the reset has taken place the screen below will be displayed.

RESET ALARMS

Reset

No Current Alarms

Exit

P ress ‘Exi t’ to return to the ‘Configuration Parameter Menu’ and then press ‘Exit’ again to return to the ‘SYSTEM

OFF PRESS START’ Screen.

Controller Reset

It may be necess ary to reset the panel if it is felt that the controller has been compromised in any way.

To ca rry out Reset procedure turn the power off to the machine, press and hold the Help button and switch on the power.

Remain holding the button until the flash test has been completed and the following screen will be displaye d.

14

LOAD DEFAULT VALU ES

Clear Datalog Buffer too?

YES Exit No

Press YES to start the reset program and the following program will be displayed and the reset program will start

LOAD DEFAULT VALUES

Cl ear Datalog Buffer too?

Loading Service Parameters

Load ing Program Parameters

Clear Datalog Buffer

Address: xxxxx of 35136

YES

O n completion of reset the display will return to the SYSTEM OFF PRESS START screen.

It will be necessary to install the default parameter settings for the particular model before starting any program.

2 .5 Fault

W rong checksum

after having exchanged the flash EPROM: Press left & right while switching on the auxiliary v oltage to calculate a new checksum. It is strictly necessary to carry out a Reset Procedure after changing the p rogram!

Possible Fault Messages are:

01

02

03

Air Sensor Short Circuit

Air Sensor Break

Coil Sensor Short Circuit

04

07

08

Coil Sensor Break

Humidity Sensor Short Circuit

Humidity Sensor Break

20

22

Defrost Term. Fault (Safety Time 45 Min)

Door Open Fault

51 Steam Tank de-scaling

60

61

63

Modem not ready

Modem Dial Number missing

Bus Read Faul t

P ower Interrupt

If there is a power interrup t, all information is stored and the clock continues running for one day.

After power interrupt the u nit tries to keep the programmed bake- time.

Communication via remote control is not possible during power interrupt.

Modem Dial Number Missing

If the alarm message ‘Modem Dial Number Missing’ is shown on the display it is necessary to reset the ‘Remote

Access Type’ value to ‘SERIAL’.

Press the DOWN, RIGHT and LEFT keys together the Configuration Parameters Menu is shown, see 2.2.1.

Scroll the list and select ‘Service’. Once selected the screen will change, see 3.4 Service Parameters.

Select ‘Remote Access’. After entering select ‘Remote Access Type’, if ‘Modem’ is shown on the right hand side press the middle bottom button, EDIT SELECT.

15

Access c ode will be requested, enter the correc t level acce ss code to continue.

The next screen will di sp lay ‘Remote Access Ty pe ’ flashing’ press the down pointing arrow to change it to display

‘Serial’. P ress ACCEPT. The screen to

Once the screen ha s changed press ‘E XIT’. You will now be back to the ‘Configuration Parameter’ press ‘EXIT’ to store the change made .

NOTE. Leave the unit for ten minutes to allow th e controller to re-set.

Afte r the ten minute s has elapsed acc ess the Configuration Parameters Menu, and reset the alarm.

FITTING PROCEDURE FOR F206 SOFTWARE EPROM

The EPRO M is located on the PCB b ehind the D ispla y Panel and not the Relay Board and is the only one of its type on this board so it can be easily id entified. There may already be a Software revision on the EPROM such as

F203.

Before any work is carried it out is advisable to check the customers settings so that the new EPROM can be set to the correct t emperatures after fittin g.

RE L

Remove the Power supply to the machine and turn off the isolator on the Control Panel. 1)

2)

3)

Remove the front part of the Control Panel by removing the 3 screws on top of the Panel

Disconnect the Interconnect ing cable between the Relay Board and the Display Panel.

The cover over the Display can then be removed exposing the relevant board. The EPROM is located o n

4) the top board.

Ma ke a note of the orientation of the EPROM in the holder by way of the circular indentation on one edge.

(See fig 1) Remove the EPROM from the holder using the correct lifting tool.

Removal has to be don e carefully as the holder can easily be damaged.

Fig 1

Direction Marks

5)

6 )

REPLA CEMENT

1) Locate the EPROM onto the holder and ensure it is perfectly square and carefully push fully home into the sock et.

2) Rep lace all panels and replace the Inte rconnecting cable

3 )

4)

Re – as semble Control P anel

The Controller w ill now need to be Reset :

Whilst restoring p ower hold down the Left & Right keys and allow the Flash Test to be carried out.

Then follow the on screen prompt.

When asked to ‘Clear Data Log Buffer’ select ‘YES’ to continue .

On completion the controller display will return to the Start Screen .

Check that the time and date are set

Reset all other parameters to custom

correctly using the procedure in the Service Manual. er requirements.

Probe Resistance Values

16

Air and Coil Probe PTC type.

Resistance values against temperature

+25°C Ohm

+30°C Ohm

+40°C Ohm

+50°C Ohm

+60°C Ohm

+70°C Ohm

815Ohm +80°C Ohm

+90°C Ohm

T ec hnic al Detail

IP R atin g:

Range:

Toleran ce:

IP65

-30°c to +90°c

+1.25 a t 25°c.

+2°c at -10°c and +50°c.

+3°c at -50°c and +80°c

O vertemperature Thermostat Setting

T he overtemperature setting is 60°c with a 10°c differential.

F AULT DIAGNOSIS

T he following section details a number of faults which may occur and their possible c auses. This list is not exhaustive.

T EMPERATURE

PROVING

Possible causes are prove heater failure or fan failure. The most likely would be heater related as a fan failure would also cause problems related to low humidity uneven proving and/or an over temperature fault.

TEMPERATURE FAULT ACTIVATED

There are a number of possible causes for this fault. The easiest method of diagnosis is to ascertain the time that the error o ccurred. It should also be determined the exact condition which causes the fault (see paragraph 3.4.2). From the time of occurrence it can be determined via the operating prog ram parameters which condition the machine was in at the time. For example if the machine was in storage mode at the time the fault occurred the likely (although n ot certain) cause would refrigeration related. Similarly if the machine was in recovery, heate rs would probably be a good place to start.

OVER TEMPERATURE TE MPERATURE FAULT ACTIVATED

In all probability it is almost certain that this fault would be caused by one or all of the fans being rendered inoperative. The cause would most probably be controller output or solid state relay fa ilure.

Another cause may be a contac tor ‘sticking’ on thus causing the heaters to operate continuously.

HUMID ITY

LOW OR NO HUMIDITY

This can be caused by a number of faults. First ch eck that the water supply to the steam tank is operating. By energising the solenoid valve and en suring that water is entering the tank (the later can usually be done audibly).

Confirm correct operation of the humidity sensor. As an initial indication use the display on the controller. For example if the room is obviously ‘dry’ but the display is showing 90% humidity the likely cause would be a hum idity sensor failure. If everything appears normal use a calibrated hand held

17

humidity device to compare the value indicated on the display with that on your meter. Small differences

±15% can be expected although more should be viewed with suspicion.

case check that the level controll is operating. Malfunction of the level controller is not necessarily an indication if a level controller failure (see water overfilling below ) alt hough failure to fill usually is.

Check the heater is operating correctly.

In all of the above prove negative ensure that the steam delivery pipes have not become scaled or the inside of the tank itself is not full of scale therefore preventing sufficient steam production.

WATER

WA

TER OVERFILLING

The water system is controlled by the level controller situated in the control panel. The first check to make however is to ensure that no debris from the water supply has passed through th e water strainer and become lodged in the solenoid valve, thus preventing the valve from closing comp letely.

If the valve is permanently energised this can only be caused by the level controller. However this does not necessarily indicate a level controller fault. The level controller uses conduct ivity between the pro bes and the tank case to determine water level. If the probes have become s caled due to water soften ing being inoperative this will prevent conductivity causing the controller to assume low level thus causin g the solenoid valve to remain open. It should also be ensured that the earth connection betw een t he level controller and tank has not been disrupted in any way as this will cause the same sce nario.

WA TER OVERFLOWING DR

AIN PAN

Mos t likely caused by a drain pipe blockage although this could be a symptom of the steam tank overfilling.

PRODUCT

DOUGH SKINNING

Rack Badly

Positioned

Slow Pull

Down

Check

Humidity

In Chamber

Bakery

Operation

•Is rack positioned centrally between guide rails ?

•Check pull down performance - should be +20°C to -5°C in 40

minutes with an empty chamber

•Are evaporator fans running ?

•Is refrigeration system evaporating at -12°C to -15°C ?

•Check machine humidity parameters - should be 80% - 85%

•Is water supply to steam tank working ?

Check -

•Solenoid valve operation

•Water level

•Water control system

•Is the steam element heavily scaled ?

•Is the steam tank heater working correctly ?

•Is the humidity displayed by the controller correct with that inside

the chamber ?

•Is there any delay between product production and loading into the

retarder prover ?

18

UNEVEN PRODUCT DEVL OPMENT

One Part Of The Rack

Is More Or Less

Proved Than Another

Product Is Not Ready

On Time

Product Is Ready To

Early

•Is rack positioned centrally between guide rails ?

•Are all the evaporator fans running ?

•Has the controller end time been set correctly ?

•Is the refrigeration solenoid ‘leaking’ when closed ?

•Are all the heaters operating correctly ?

•Are the fan speeds set correctly ?

•Are the controller parameters set correctly ?

•Is the temperature displayed on the controller correct with that

inside the chamber ?

•Has the controller end time been set correctly ?

•Is the refrigeration system operating correctly ?

•Are the

heaters operating at the correct time or is one or more on all the time ?

•Is there any delay between product production and loading into the

retarder prover ?

•Are the controller parameters set correctly ?

•Is the temperature displayed on the controller correct with that

inside the chamber ?

19

20

27

29

Foster Refrigerator

Oldmedow Road

Kings Lynn

Norfolk

PE30 4JU

Tel: 01553 691122

Fax: 01553 691447

Website: www.fosterrefrigerator.co.uk

Email: [email protected]

a Division of ‘ITW (UK) Ltd’

DRP MK3 P V F206 /SM/19/09

Foster RBC MK 3 Controller Retarder Prover Service Manual

Assistant Bot

FOSTER DRP

RBC MK 3 CONTROLLER

Program Version F206

SERVICE MANUAL

Contents

INTRODUCTION

Operator Program

OPERATING INSTRUCTIONS

1) To start the Operation

Press ‘START’

4) Enter the Bake Time

Press ACCEPT or Press EDIT followed by the up or down arrows to change the time

5)

2) Select the Bake Program from the menu. If Prove only program is selected program will start automatically

AUDIBLE

ALARM

3) Enter the Bake Day for Retard &

6)

Prove. Press ACCEPT or Press the

UP arrow to change the B ake Day

An Audible alarm will sou loading temperature.

‘START’

nd when the machine is at the correc

Load the product and press t

7) When cycle is complete an audible alarm will sound, press ‘STOP’, check the product is fully proved, remove and bak e.

8) Should an extra proving time be required, select ‘EXTRA TIME’ and press ‘START’.

For HELP press the? Button located above the display.

In the event of an emergency switch off the machine at the ‘MAIN ISOLATOR SWITCH’.

Controller Instructions

NOTE:

Setting of Parameters

C onfiguration Parameters

Standard Parameter Setting (Load Set of Parameters)

Time and Date

^

^

^

Programs

It is important to note that only program 4 is

switched ON all other programs are switched OFF.

^

^

P rogram Nam e

^

Fast Chill Parameters

Storage Paramet ers

R ecovery Parameters

Prove Parameters

Min. Prove Time Param.

Oven Contact Parame ters

Configure End Time s

Factory Test Program

A larm Cancelation

Controller Reset

2 .5 Fault

P ower Interrupt

Modem Dial Number Missing

Probe Resistance Values

O vertemperature Thermostat Setting

F AULT DIAGNOSIS

T he following section details a number of faults which may occur and their possible c auses. This list is not exhaustive.

HUMID ITY

WATER

PRODUCT

DOUGH SKINNING

UNEVEN PRODUCT DEVL OPMENT

Key Features

Frequently Answers and Questions

How do I start a program on the Foster RBC MK 3 Controller?

What are the different phases of a retarder prover cycle controlled by the Foster RBC MK 3 Controller?

How do I change the bake time for a program using the Foster RBC MK 3 Controller?

Can I extend the prove time on the Foster RBC MK 3 Controller?

What should I do if I encounter an alarm on the Foster RBC MK 3 Controller?

Related manuals

Foster

DRP MK 3

Foster

RBC MKII