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Norcold N500 Service manual

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1. L Absorber retaining screws Inline fuses for ac and dc heaters Terminal block FI Manual shutoff Burner Burner tube assembly Relighter Liquid heat exchanger Drip cup Upper shroud lt _1 Canister door Heater well Burner box cover Front View Ww o D Breaker retaining screws Freezer plate screws Fin assembly screws TN Breaker we retaining screws Figure 32 N500 front and back views 7 Remove refrigerator from enclosure a Remove rear mounting flange screws b Remove the breaker retaining screws c Pull refrigerator from enclosure Removal of Cooling Unit Units with fan a Remove fan from bracket b Remove bracket c d Remove fan wiring Remove thermostat from the first condenser fin 1 Remove the drip cup retaining screw then remove the drip cup Remove the burner box cover retaining screw slide the burner box cover to the left Remove the spark sense electrode assembly a then remove the spark sense electrode assembly from burner box with a twisting motion then Remove spark sense electrode retaining screw
2. Remove spark sense electrode assembly and burner box cover from refrigerator and burner box 4 5 Disconnect the burner tube from the gas valve Remove the burner assembly retaining screw then remove the burner assembly from the burner box Disconnect the spark sense electrode wire N500 reilghter N510 power board e 9 5 9 _ N300 units Remove upper shroud Cut wire ties surrounding split loom cover Disconnect ground wire Disconnect gas supply to burner Disconnect and remove gas supply to gas safety valve thermostat assembly Remove manual shutoff Disconnect thermocouple See Figure 20 page 24 Disconnect capillary tube from the condenser fins and thread through refrigerator cabinet Refrigerator Service Manual NORCOALD man vv www norcold com cda 37 N500 N510 Models Front View Back View Breaker retaining screws Condenser Split loom A tubing n Freezer plate i screws if Foam plug Ai 7 Thermistor Fin assembly i BH H screws Absorber retaining screws
3. 33 N Fault Code No cooling detected by the controls 20 First n Fault Code 33 no Refrigerant Leakage All Modeles 33 Ventilation 21 Disposal of Cooling Unit All Models s1 11551110511121111 33 Roof Exhaust Venting sua 21 Cooling System Diagnostic Flowchar 34 Alrdnlake Vent miss aS ae d bn 21 Removing the Refrigerator from the Enclosure 36 Roof Exhaust Vent sets ments 21 Replacing the Cooling Unit 36 DATES nee sr nn N aa 21 Removal of Cooling Unit 37 Vertical Angled Baffles eee eeeeeeeeeeeeeeeeeeeeeeeneeeeeeees 21 Installation of Replacement Cooling Unit 2 222212 39 Double Sidewall Venting ke 22 Installation of Refrigerator into Enclosure 40 Sidewall Exhaust Vent EEE 22 Electronic Components All Models at CoOmMp n NTS seu kaniya r s dide eel T 23 Spark sense Electrode All Models 41 Manual Shutoff Valve u uy n wnun uzun awae awara 23 Replacing Spark sense Electrode 41 OMMICO sus c ley kas leatazin icone re l ete 23 Electronic Components N500 Models 42 LP Gas System a N500 E n 23 Relighter N500 Models KE kek 43 Gas Safety Valve mm 2
4. Flame not touching flue wall 2 UZZZZZLL LLL ALLELE LIT IT D TP III III TI TL Light blue outer mantle 3 16 in electrode to burner gap Dark blue inner cones Figure 24 LP gas flame appearance Flue Tube The flue tube channels hot exhaust gases towards the exhaust vent It should be cleaned annually to maintain the combustion system at peak performance Flue Cap The flue cap maintains a slight back pressure of hot combustion exhaust gases in the flue tube This slight back pressure helps to establish and maintain a good draft of ventilation air through the cooling unit Flue Baffle The flue baffle is located inside the flue tube and helps distribute the heat to the generator section of the cooling unit The flue baffle must never be permanently removed The flue baffle should be cleaned annually to maintain the combustion system at peak performance Flue cap Flue tube flue baffle not shown Canister Canister door Figure 25 Flue and components Acs UTION Flue and components may be hot Allow flue to cool before servicing To remove the flue baffle for cleaning 1 Remove the flue cap see Figure 25 2 Unclip the baffle retaining wire from the rim of the flue tube 3 Pull the baffle out of the flue tube Handling of LP Gas Lines and Fittings Loosen and tighten all connections using two wrenches Insufficient or excessive force when tightening fittings ca
5. systems and ac dc electrical systems as installed ina variety of recreational vehicles RV All information illustrations and specifications contained in this publication are based on the latest product information available at the time of publication NORCOLD reserves the right to make changes at any time without notice Model Identification Models N500 and N510 are 2 way refrigerators that can operate on ac power or LP gas The electronic controls operate on 12 Vdc Models N500 3 and N510 3 are 3 way refrigerators that can operate on ac power LP gas or dc power The electronic controls operate on 12 Vdc Information Label The information label is located in the upper right corner of the fresh food compartment just below the freezer compartment See Figure 1 page 2 The label provides the following information m Serial number Model number LP gas propane pressure Btu hr AC voltage and amperage DC voltage and amperage Design certification Vent kit requirement Cooling Unit Serial Number The cooling unit has a separate serial number that appears on the cooling unit bar code label The label is affixed to the surface of the cooling unit leveling chamber See Figure 2 page 2 INTRODUCTION Certification and Code Requirements NORCOLD N500 N510 gas electric absorption refrigerators are certified under the latest edition of ANS Z21 19B standards for installation in mobile homes or recreational vehic
6. AC heater resistance 58 to 64 Q Figure 9 Measuring ac heater resistance r Fault Code AC relay stuck closed N510 Fault indicator displayed ac LP GAS AUTO Flame sense circuit failure Replace power board See page 43 18 N500 N510 Models www norcold com cda Refrigerator Service Manual Thermistor Failure Fault Controls in Backup Operating System Mode N510 Before beginning this procedure m Make sure thermistor assembly is connected to the wire harness Fault indicator displayed K A AC Teme LP GAS Setting AUTO Flashing FON Check thermistor wire assembly and connector for dirty broken connections Thermistor connectors are located in P1 connector terminals 8 and 13 Wires and connector good Clean repair terminals or connector as required Check thermistor resistance See Figures 10 and 11 If resistance is not within specified ranges replace thermistor Temperature Resistance F kQ 85 8 1 9 0 80 9 1 10 0 16 pin connector 75 10 1 11 0 70 11 1 12 0 a 60 12 1 13 0 50 15 5 16 5 40 22 5 23 5 35 24 5 25 5 33 28 5 29 5 32 30 0 32 0 Thermistor Approximate Values packed in ice bath NN NN Thermistor wiring to 16 pin connector Figure 10 Thermistor assembly Backup Operating System N510 Models The backup operating system BOS is an electronically controlled duty cycle
7. Make sure the combustion seal seats fully against the rim of the enclosure 3 Install breaker retaining screws Install mounting flange retaining screws Connect RV LP gas supply line to gas valve inlet fitting Open the manual gas valve shutoff Plug the ac power cord into the RV ac receptacle Open the RV LP gas tank valve s Leak test all LP gas connections manipulated throughout this procedure 10 Place refrigerator in service AE N Refrigerator Service Manual ELECTRONIC COMPONENTS ALL MODELS Spark sense Electrode All Models The spark sense electrode assembly provides a spark to light the burner and monitors the presence of the Spark sense electrode flame In N500 models the spark sense electrode assembly is routed through the relighter in N510 models it is routed through the power board See Figure 36 Replacing Spark sense Electrode 1 Turn OFF refrigerator 2 Unplug ac power cord gt Orange wire 3 Disconnect 12 Vdc supply 4 Close manual shutoff to LP gas supply A WARNING Burn hazard Allow the burner box and burner Figure 36 Spark sense electrode components to cool before attempting to service the burner assembly or components 5 Remove burner box cover retaining screw then slide burner box cover to the left 6 Remove electrode retaining screw then remove electrode 7 Thread replacement spark sense electrode wire through burner box cover 8 Install
8. N500 3 N510 3 3 way models For 3 way models the controls and ignition circuit operate at 12 to 15 Vdc The dc heater operates at 13 5 to 15 4 Vde DC Heater N500 3 N510 3 The dc heater which has yellow leads is shown in Figure 27 page 30 The heater is rated for 225 watts 16 amps and requires 12 to 15 Vdc for operation Heater resistance is 0 87 ohms Relighter N500 N500 3 The relighter is a potted modular 12 Vdc circuit protected by a 1 amp 1 4 in x 1 1 4in AGC type fast acting fuse housed in an in line fuse holder To replace the relighter see the procedure on page 42 by Refrigerator Service Manual www norcold com cda N500 N510 Models 29 A WARNING Never use undersized wires to supply dc power to the power board The use of undersized wires can cause low voltage and high amp draw conditions The high amp draw caused by a circuit using undersized wires will cause the wire to overheat and creates an electrical fire hazard 2 Way Model Wiring 18 AWG is the minimum AWG size wire that can be used for connecting dc power to 2 way models The size fuse for overload protection must not exceed 6 amps 3 Way Model Wiring The distance between the RV dc power source and the power board dc power connection terminals dictates the AWG size wire that must be used If the distance from the dc power source is m 20 feet or less 10 AWG or a larger gauge wire must be used The size fuse for circuit ove
9. OQOOOO DC heater 3 ways 1 amp fuse 17 Thermostat Gas safety valve Thermocouple interrupter Spark gap 120 Vac 12 Vdc power supply Power board 019010 5 amp fuse amp by Refrigerator Service Manual 6 30 amp fuse 3 ways Q AC heater 12 Vdc power supply DC heater 3 ways Gas safety valve Spark electrode Display overlay Optical control circuit board 3 Temperature sensor Fan optional 5 Thermostat optional Figure 48 N510 wiring pictorial www norcold com cda N500 N510 Models 55 Publication No 626800A 06 08 04 Publication No 626800A 06 08 04 NORCOLD CUSTOMER SERVICE NORCOLD 1 800 444 7210 P O Box 4248 937 497 3183 Sidney OH 45365 4248 www norcold com cda
10. SERIAL N de serie REFRIGERANT frigorigene 120VAC R707 z 2 Amps 240 Watts XXXXXXX 0 42 LBS 60H p MODEL N de modele 12VD N510 3 TEST PRESSURE 14 10 Amps 170 Watts D ESSAI 800 PSI GROUP CODE code de e mi n INPUT puissance 1200 BTUH For recreational vehicle installation Min Installation clearance 0 sides top bottom back Install only with Kit 5 See installation instructions Pour installation vehicule de plaisance Degagement minimum pour l installation CERTIFIED 0 cotes haut bas arriere Installer uniquement avec latrousse n_5 Voir les instructions d installation 618860 CSA 1 10 2003 ANZI Z221 19 2003 REFRIGERATORS REFRIGERATORS Figure 1 Information label location Figure 2 Cooling unit label location N500 N510 Models www norcold com cda Refrigerator Service Manual SAFETY AWARENESS Safety Notice It is not possible to anticipate all of the conceivable ways or conditions under which the refrigerator may be serviced or to provide cautions as to all of the possible hazards that may result Standard and The safety alert symbol with the appropriate heading appears on all safety labels posted on the refrigerator and safety awareness notices presented throughout this manual accepted safety precautions and equipment should be used when working on electrical circuits and handling toxic or flammable materials Safety goggles and other required protection
11. Setting No cooling detected by the controls See pages 20 and 32 We by Refrigerator Service Manual www norcold com cda N500 N510 Models 7 TROUBLESHOOTING FLOWCHARTS N3500 UNITS Burner Will Not Maintain Flame N500 Units Check burner and thermocouple for carbon deposits Burner and thermocouple clean Clean and service burner and thermocouple See page 28 Check that thermocouple is centered on burner slots Center thermocouple over center of burner slots Thermocouple centered Connection Tighten connection Do not overtighen Check thermocouple i i tight connection connection at interrupter Jump interrupter terminals Does flame and light unit holding gas stay lit safety valve in See Figure 3 See procedure on page 12 Check selector switch wiring Repair or replace selector switch wiring Check continuity across red switch lead and blue swtich lead terminals 2a and 2b Replace selector switch See page 45 Interrupter terminals Figure 3 Jumping interrupter terminals Interrupter 8 N500 N510 Models www norcold com cda Refrigerator Service Manual Ne n No AC Operation N500 Units Before beginning this procedure make sure m The refrigerator is receiving 108 minimum to 132 maximum Vac from a grounded receptacle m Fuse holder and 3 amp fuse are in good condition m Selector knob is set to AC m Thermostat knob is set
12. a 3 16 in double spiral wire brush Do not damage the threads when cleaning the inner bore of the burner A WARNING Do not insert any type of cleaning tool or wire into the orifice Do not drill or ream the orifice opening to clean it Insertion of any type of cleaning tools reaming or drilling through the opening will alter the volume of LP gas flow to the burner and create a fire hazard potential 11 Visually inspect the orifice If dirty wash the 12 13 14 17 18 19 20 21 assembly with alcohol then allow to air dry If cleaning fails to remove dirt or if the condition of the orifice assembly is questionable replace the orifice assembly Clean dirt or debris from the burner box base Reinstall the burner Do not overtighten the retaining screw A CAUTION To avoid gas leaks and prevent damage to connections piping and components always use two wrenches to tighten the burner tube Adamaged burner tube creates a potential for gas leaks Install the orifice assembly Thread the orifice assembly into the burner finger tight then finish tightening using two wrenches Connect the burner tube Thread the fitting finger tight then finish tightening using two wrenches Install the burner box cover Do not overtighten the retaining screw Install the drip cup Open the LP gas tank valve Open the gas valve manual shutoff Turn ON the refrigerator and select the GAS mode N500
13. supply dc power the refrigerator circuit must be connected to the appliance output terminals of the converter filtered side If the refrigerator circuit is connected to the unfiltered side the ac ripple generated by the converter may cause a E or C fault code to display To troubleshoot an E or C fault connect a charged 12 volt automotive battery to the power board If the E or C code clears the fault was caused by unfiltered dc power If the E or C code does not clear replace the power board see page 43 C Fault Code DC voltage low N510 Before beginning this procedure m Make sure RV dc voltage to refrigerator is 10 5 to 15 4 volts Determine if the C fault code displays when the converter is the source of dc power Fault indicator displayed AC LP GAS AUTO Check for dc voltage input to power board terminals 12VDC and GND1 Voltage lower than 10 5 Vdc See NOTE above to determine and correct a C fault Correct incoming dc power distribution to refrigerator Power distribution must be 10 5 15 4 Vdc 16 N500 N510 Models www norcold com cda Refrigerator Service Manual A Fault Code No ac power available N510 Before beginning this procedure make sure m No other problem exist with the RV ac power supply m No other appliances or lighting circuits are connected to the refrigerator ac circuit m Extension cords are not being used to
14. 1 2 in bead of sealant NOTE Ensure the burner box is in position at the base of the cabinet before installing the cooling unit Figure 35 Application of sealant D L DAN Refrigerator Service Manual www norcold com cda 39 N500 N510 Models amp CAUTION To prevent damage to connections piping and components always use two wrenches to loosen and tighten LP gas connections Damaged connections create a potential for gas leaks 10 Install burner tube and burner assembly then install burner tube and burner assembly retaining screw N500 units a Connect gas supply to gas valve thermostat assembly b Connect gas supply to burner N510 units a Reconnect solenoid gas valve wiring to power board terminals GV and GV_GND 11 Connect the burner tube to the solenoid manual shutoff gas valve 12 Install the spark sense electrode assembly then install assembly retaining screw 13 Set electrode to burner gap to 3 16 14 Align canister to install the burner box cover then install the burner box cover retaining screw N500 units a Connect one ac heater wire to ac heater inline fuse b Connect other ac heater wire to terminal block terminal 5 See Figure 30 page 31 c Install ac heater d For 3 way units connect one dc heater wire to dc heater inline fuse e For 3 way units connect other dc heater wire to terminal block f For 3 way units install dc heater g
15. 108 to 132 Vac AC heater circuit fuse 5A 1 4in x 1 1 4 in AGC type fast acting inline AC heater rating 200 W 110 Vac resistance of 61 3 ohms LP gas propane Operating pressure 10 5 to 11 5 in w c Heat input 1200 Btu h 11 in w c Orifice Gas ignition 12 Vdc ignition module Electrode to burner air gap 4 N500 N510 Models www norcold com cda Refrigerator Service Manual N510 Models Storage volume Rough opening dimensions H x W x D Decorative panels dimensions Thickness Door panel dimensions H x W Controls Temperature settings Temperature sensor Off level operating limits Side to side Front to back DC power Controls operating voltage Controls DC fuse F2 in power board DC operation voltage 3 way models only DC heater rating 3 way models only DC amp draws at nominal 12 Vdc Automatic ignition Gas valve AC power AC heater operating voltage requirements Fuse ac heater circuit F3 in power board AC heater rating LP gas propane Operating pressure Heat input Orifice Gas ignition Electrode to burner air gap 3 16 in 31 in x 21 5 16 in Electronic with built in diagnostic function Flush pushbutton style 1 cold 5 coldest Thermistor fin mounted on 5 fin 3 degrees maximum 6 degrees maximum 10 5 to 15 4 Vde 3A type 3AG 12 Vdc to 15 Vdc 10 7 amps 12 Vdc resistance is 1 3 ohms 108 to 132 Vac 5A 1 4in x 1 1 4 in AGC type fast acting 2
16. 48 AUTO DC Operation 3 Way Units Only ween 49 AG Manual Mode g J x inn bas siniya ea nana hist 49 No AC Power or Loss Of AC Power 49 Troubleshooting an A Fault gt zi ia ih nae kb n k na li 49 AC Power Restored 32 2eme 49 LP Gas Manual Mode y i si ssskes a san ka Mina e lane ada yan 50 Flame Fails to Ignite or Flame Goes Out aeanaaeaaaaaae 50 Clearing Gas Lock Out 50 Troubleshooting an F Fault cccccccescccceeesseeeeeeteetseeees 50 DC Manual Mode 3 Way Units Only 50 Troubleshooting a DC Faull c cscccccscsceessescesseeeesseeeeees 50 N510 Diagnostic Mode 51 Diagnostic MOGAE ifene aid ma z ka ni birini ye ess 51 Accessing the Diagnostic Mode ll llliEE E 51 Changing Sorens arriere al ney n zina 51 Exiting the Diagnostic Mode 51 Screens and Diagnostic Segments Information 52 Wiring Pictorials and Diagrams 54 NORO Refrigerator Service Manual www norcold com cda N500 N510 Models S About this Manual This service manual provides maintenance diagnostic and repair information for NORCOLD model N500 N510 gas absorption refrigerators It is a reference tool designed for technicians who are knowledgeable in the theory and operation of gas electric absorption refrigerators liquefied petroleum LP gas propane
17. Canister door Power l board Te me 177 TT Heater well i AC power A Burner box Ue cord cover a 1 Breaker Solenoid Liquid heat Burner Burner Drip retaining gas valve exchanger tube assembly cup screws Figure 33 N510 front and back views N510 units N510 units a Disconnect ac power cord from power board a Disconnect the ac heater wires from power b Remove power board cover retaining board terminals AC_HT LO1 and screws then remove power board cover AC_HT_HI c Disconnect the gas valve wires from the power b Open canister door board c Remove ac heater d Cut wire tie restraining gas valve wires and d Disconnect the thermistor wires from the P1 spark sense electrode wire connector 7 Remove the burner box retaining screws 2 then let 1 Unplug the P1 connector from the power burner box drop board 2 Insert a pin extractor tool Figure 34 page 39 3 way units shows a Molex 11 03 0044 REV D into the a Disconnect the dc heater wire leads N500 units terminal side of connector in terminal 8 See terminal block and inline fuse N510 power Figure 34 page 39 Terminals are labeled on board connector and thermistor wires are solid white b Open canister door c Remove de heater 3 Remove wire from connector 4 Repeat steps 2 and 3 for terminal 13 N500 units i e Remove tape securing thermistor wiring to foam a Disconnect ac power cord from terminal block plug b Disconnect ac heater wire from
18. It maintains the refrigerator in operation if the thermistor is disconnected or fails The BOS maintains cooling by controlling the heat source selected When the refrigerator is operating in BOS the length of the cooling cycle is regulated not by temperature but by time To accomplish this the BOS adjusts the length of the cooling cycle according to the temperature setting selected by the user the higher the temperature setting the longer the cooling cycle For example if the Figure 11 Checking thermistor resistance temperature setting is set to 4 raising the setting to 5 will lengthen the cooling cycle making the cabinet colder When a warmer temperature is desired changing the temperature setting to a lower number shortens the cooling cycle For example if the temperature setting is set to 5 lowering the setting to 4 will shorten the cooling cycle When the N510 controls shift to BOS operation the temperature setting flashes for ten seconds when the TEMP button is pressed After ten seconds the selected operation mode indicator displays Refrigerator Service Manual D L DAN www norcold com cda 19 N500 N510 Models N Fault Code No cooling detected by the controls N510 Fault indicator displayed AC LP GAS AUTO Check for cooling at fin assembly 1 Check for ventilation obstructions and Cooling leveled operation detected 2 Reset power board as shown in Figure 12 and described in
19. It takes an average of four hours for the refrigerant to reach peak efficiency This time frame depends on ambient air temperature Additionally ambient air temperature plays a significant role if the unit was not installed correctly Incorrect installation leads to poor ventilation which in turn relates to poor cooling performance The unit s service and maintenance history should also be considered when checking a cooling unit for poor cooling performance The service history and the scope of service work performed may lead directly to the cause and resolution of a cooling problem Cooling Monitoring N510 Units Only Cooling Monitoring monitors the fin assembly temperature through the thermistor This control is activated when the refrigerator is turned on and when the fin assembly temperature has rises above 40 F When the fin temperature is above 40 F and a change in cooling is not detected in a specific amount of time the refrigeration heat sources are turned off Cooling Monitoring will not activate if m The fin assembly temperature stays below 40 F MB If the thermistor is disconnected open or shorted MB If the fresh food compartment door is sensed open resampling starts when door closes m The ac heater is open AC voltage is low E Frost management is active 32 N500 N510 Models www norcold com cda Refrigerator Service Manual Cooling Monitoring Control Operation Cooling Monitoring opera
20. LED aside AC displayed AUTO mode operation LED aside AUTO and LED aside available energy source segment AC LP GAS or DC displayed DC manual mode operation selected 3 ways LED aside DC displayed Figure 41 N510 Controls 46 N500 N510 Models www norcold com cda Refrigerator Service Manual Replacing Optical Control Circuit Board N510 4003N01234 ne LL MMN 2 Unplug ac power ie 3 Disconnect 12 Vdc supply a 4 Disconnect LP gas supply o 5 Remove screws from back mounting flange if present il O 6 Remove retaining screws located on the front of Ex r breaker will need to open door to remove Y J 7 Remove refrigerator from enclosure 8 Disconnect wire harness Display overlay 9 Remove the board bracket retaining screws 2 kawan Land 10 Remove board retaining screws then remove Figure 42 Connecting disconnecting connector optical control circuit board 11 Disconnect display overlay ribbon connector from optical control circuit board See Figure 42 and 19 Install breaker retaining screws Figure 43 20 Install back mounting flange screws if present 12 Remove metal brackets from circuit board 21 Reconnect dc power supply 13 Transfer brackets onto new optical control circuit 22 Plug in ac power cord board 23 Place refrigerator in service 14 Connect display
21. be made from a six inch long insulated 22 AWG wire with a 1 2 inch of insulation stripped from each end 8 Turn OFF the refrigerator 2 4 a 9 Turn ON refrigerator If n code displays repeat steps 7 9 N Insulated wire jumper 2 Ground Lug White violet wire 22 AWG with 1 2 long stripped ends Figure 12 Resetting the power board 20 N500 N510 Models www norcold com cda Refrigerator Service Manual VENTILATION Roof Exhaust Venting The general guidelines for intake vents and roof exhaust vents presented in this section do not replace the instructions and or guidelines provided in the N500 N510 Installation Manual and the Ventilation Guidelines for Gas Electric Refrigerators part number 622090A 3 01 Refer to the N500 N510 Installation Manual and Ventilation Guidelines for Gas Electric Refrigerators for the latest information on approved vents installation instructions and special construction exceptions Illustrations of different venting applications are shown in Figure 13 and Figure 14 Air Intake Vent The ventilation and combustion air flows into the enclosure through the air intake vent The space between the air intake vent and the rear of the refrigerator must be kept clear at all times Any obstruction in this area may cause serious ventilation problems The air intake vent opening also provides access for servicing cooling unit components Roof Exhaust Vent The heat absorbed by
22. gas piping be proven leak free by testing after the refrigerator is connected to the LP gas system The LP gas connection to the refrigerator can be leak tested using commercially available bubble leak test solution soap and water or by performing a pressure drop test explained at below A CAUTION Do not use any liquid detergents that contain ammonia or chlorine for testing These substances can corrode brass components Bubble leak test solution soap and water leak test To test the LP gas connections for gas leakage using a commercially available leak test solution or soap and water solution 1 Pressurize the LP gas system between 10 5 in water column and 11 5 in water column 2 Apply the bubble leak detection solution using a small brush or spray applicator 3 Repair all gas leaks observed and retest for gas leakage after completion of repairs Pressure drop test A pressure drop test requires the use of a manometer or calibrated gauge to indicate any drop of system pressure due to leakage In order to pass the pressure drop test the system must maintain pressure over a period of 3 minutes The guidelines to perform a pressure drop test are below 1 Connect a manometer or pressure gauge to the refrigerator LP gas system pressure tap 2 Pressurize the LP gas system between 10 5 in water column and 11 5 in water column 3 Make sure the temperature of the piping system is approximately the same through
23. outlet ADo not over fuse electrical circuits Use specified fuses and AWG wire sizes The Specifications section of this manual provides fuse size information Refer to the N500 N510 Installation Manual for the correct AWG wire size specifications APrevent child entrapment Before disposing of the refrigerator remove all doors and fasten all shelves with retainers ASome of the refrigerator s metal components have sharp corners and edges Wear hand protection such as cut resistant gloves and exercise extreme care when handling the refrigerator AMake sure all hardware such as hinges and fasteners retaining screws etc is properly fastened We by Refrigerator Service Manual www norcold com cda N500 N510 Models 3 SPECIFICATIONS N500 Models Storage volume Rough opening dimensions H x W x D Decorative panels dimensions Thickness 3 16 in Door panel dimensions H x W 31 in x 21 5 16 in Controls Top mounted Temperature settings 1 cold 5 coldest Temperature sensor Capillary tube Off level operating limits Side to side 3 degrees maximum Front to back 6 degrees maximum DC power Ignition circuit operating voltage 10 5 to 15 4 Vdc Relighter 1 3 amp type 3AG DC operation voltage 3 way models only 12 Vdc to 15 Vdc DC heater rating 3 way models only 10 7 amps 12 Vdc resistance is 1 3 ohms DC amp draws at nominal 12 Vdc Automatic ignition AC power AC heater operating voltage
24. procedure below Check for completion of n code Cooling unit is good Recheck for cooling cycle after resetting shows before ventilation obstructions and leveled power board cycle end operation See pages 21 22 and page 32 1 Replace cooling unit if n shows before completing a full cooling cycle 2 Reset power board as shown in figure and described in procedure Power Board Resetting Procedure 1 Turn OFF the refrigerator 10 Turn OFF the refrigerator 2 Disconnect the following from power board 11 Disconnect the 12 Vdc power positive and negative a 12 Vdc positive and negative wires wires from the power board b AC power cord 12 Install the power board cover c Solenoid gas valve wires 13 Reconnect the following to the power board d Spark sense electrode assembly wires a Spark sense electrode assembly wire Remove the power board cover b Solenoid gas valve wires Reconnect 12 Vdc positive and negative wires c AC power cord Turn ON the refrigerator d 12 Vdc positive and negative wires from the Locate Pin 15 on 16 pin connector P1 Pin 15 is the power Ben empty socket to the right of the white violet wire on 14 Place refrigerator in service the top row See Figure 12 7 Using an insulated jumper wire short Pin 15 to the power board ground lug for 10 15 seconds A click sound will indicate when the controls are reset See Figure 12 oar Ww A jumper wire to short Pin 15 to ground can
25. replacement electrode then install electrode retaining screw 9 Install burner box cover then install burner box cover retaining screw 10 Connect orange spark sense electrode wire N500 relighter N510 power board 11 Open manual shutoff to LP gas supply 12 Reconnect 12 Vdc power supply 13 Plug in ac power cord 14 Place refrigerator in service Refrigerator Service Manual www norcold com cda N500 N510 Models 41 ELECTRONIC COMPONENTS N500 MODELS Relighter N500 Models The relighter relays signals from the gas safety valve to the spark sense electrode and to the flame indicator It operates on 12 Vdc See Figure 37 Replacing Relighter Refer to Figure 37 for component locations Turn OFF refrigerator Unplug ac power cord Disconnect RV 12 Vdc supply at terminal block Close manual shutoff to LP gas supply Disconnect orange spark sense electrode wire Disconnect 12 Vdc from relighter Disconnect ground wire Disconnect flame indicator wire 9 Disconnect selector switch wire 10 Remove retaining screws 2 11 Install replacement relighter 12 Install retaining screws 2 13 Reconnect selector switch wire 14 Reconnect flame indicator wire 15 Reconnect ground wire 16 Reconnect 12 Vdc to relighter 17 Reconnect spark sense electrode wire 18 Open LP gas manual shutoff 19 Reconnect RV 12 Vdc supply at terminal block 20 Plug in ac power cord 21 Place refrigerator in
26. service 9 N 9 O1 N gt Flame Indicator N500 Models The flame indicator allows the user to monitor the LP gas flame when the refrigerator is in LP Mode The flame indicator lights indicates the existence of a flame through the relighter Flame Indicator Replacement 1 Turn OFF refrigerator Unplug ac power cord Disconnect 12 Vdc supply Disconnect LP gas supply Remove screws from back mounting flange if present Remove retaining screws located on the front of breaker will need to open door to remove 7 Remove refrigerator from enclosure 8 Remove wiring shroud four screws 9 Disconnect black indicator wire from power supply 10 Disconnect red indicator wire from relighter 11 Remove flame indicator ar D D Spark sense electrode orange Relighter AL Retaining bd screw DC power supply white o O O o 9 9 Ground reen i H green Retaining Flame Selector screw indicator switch red black 13 14 15 16 17 18 19 20 21 Figure 37 Relighter and connections Install replacement flame indicator through the front of the control panel until it clicks into place Reconnect red and black flame indicator wires Replace wiring shroud Install refrigerator in enclosure Install front breaker retaining screws Install back mounting flange screws Discon
27. terminal block f Pull thermistor wiring through split loom tubing terminal 5 and into the refrigerator cabinet c Disconnect ac heater wire from inline fuse g Remove thermistor d Open canister door h Clip wire ties along split loom tubing e Remove ac heater 38 N500 N510 Models www norcold com cda Refrigerator Service Manual 10 11 12 P1 Connector 3 Terminal 8 Pin extractor Figure 34 Disconnecting thermistor from P1 connector Remove the four retaining screws and washers from the freezer plate Remove the four retaining screws from the fin assembly Cut or remove the tape around the edge of the foam plug Remove the two absorber bracket retaining screws Separate the cooling unit from the refrigerator cabinet a Grab the cooling unit by the liquid heat exchanger b Pull the cooling unit upward at a slight angle to unseat the foam plug then pull the cooling unit from the refrigerator A CAUTION Do not overtighten retaining screws and gas fittings throughout this procedure Overtightening screws and fittings may strip screws and fittings Installation of Replacement Cooling Unit 1 2 Clean old sealant from back of evaporator plate fin assembly and cabinet step Apply a 1 2 bead of sealant to the replacement cooling unit s low and high temperature evaporators and to the foam plug See Figure 35 tool 8 9 Foam plug step 1 2 in bead In
28. the screen number is displayed If an LED segment displays the fault is in the optical control assembly Replacing the optical control assembly should resolve this fault Press the O button to bring up screen 3 52 N500 N510 Models www norcold com cda Screen 4 Thermistor Fin Temperature Screen 3 shows the actual fin temperature being sensed by the thermistor This is not the fresh food cabinet air temperature The example illustration below shows 30 F fin temperature as displayed in screen 3 m az Sent FTS S 30 F 7 e G J Screen Blank Screen 2 second Number pause Press the button to bring up screen 4 Screen Stored Fault History Screen 4 displays stored fault history using lighted LED segments The illustration provides fault history information and assigned LED segments If a fault occurred its assigned LED will light Ignition fault DC voltage low DC voltage high AC relay stuck closed AC mode selected but not available AC heater failed open Press the O button to bring up screen 5 Screen S Stored Fault History Screen 5 also displays stored fault history using lighted LED segments The illustration provides fault history information and assigned LED segments If a fault occurred its assigned LED will light Thermistor failure Flame sense failure AC voltage lo
29. to 5 Measure voltage across terminal block terminals 5 and 6 AC voltage present Check wiring connections and terminal block and replace or repair if necessary Check connections to and Connections from 3 amp fuse good Repair or replace connections Repair or replace connections Replace tions tight and ac heater if resistance is below 58 or above 64 See page 30 Check heater wire connections and heater resistance Check continuity of black wire connected Check voltage to selector voltage to 3 amp fuse If no continuity repair or switch terminal 1a present replace wire AC voltage Replace selector switch See page 45 present Set selector switch to AC Check voltage out of selector switch terminal 1b Set Thermostat to 5 Check voltage input to Thermostat and voltage output from Thermostat to heater E No voltage to input Check blue wire for continuity E No voltage from output Replace Thermostat assembly kan Al Refrigerator Service Manual www norcold com cda N500 N510 Models No DC Operation N500 3 3 Way Units Only Before beginning this procedure make sure m The refrigerator is receiving dc power from the RV dc power system m Voltage across terminal block connections 7 and 8 is at least 12 Vdc m Fuse holder and 25 amp fuse are in good condition m Selector switch is set to DC Check dc voltage input at selector switch t
30. 00 W 110 Vac resistance of 61 3 ohms 10 5 to 11 5 in w c 1200 Btu h 11 in w c Automatic with flame sensing circuit tng Refrigerator Service Manual www norcold com cda N500 N510 Models TROUBLESHOOTING QUICK REFERENCE GUIDE Problem Possible Cause Checks Reference No 12 Vdc power to refrigerator Faulty loose 12 Vdc connections F1 fuse in power board open No ac power to refrigerator See page 9 N500 F3 fuse or ac heater inline fuse open Check fuse P AC heater failed open Check heater resistance and continuity The refrigerator does not cool Ventilation obstructed Check enclosure for air flow obstructions efficiently on ac power AC voltage low Check ac voltage input 3 Way Units Only The refrigerator does not cool on dc power 3 Way Units Only The refrigerator does not cool efficiently on dc power See page 13 N510 Check 12 Vdc connections Check fuse N510 F2 fuse or dc heater inline fuse open Check fuse DC heater failed open Check heater resistance and continuity Check enclosure for obstructed air flow Check dc power input Ventilation obstructed DC voltage below 12 volts No LP gas Check LP gas supply and valves The refrigerator does not operate Incorrect electrode to burner gap Set electrode to 3 16 in on LP gas Faulty spark sense electrode assembly Replace spark sense electrode See page 41 Flame sensing circuit failure Replace po
31. 2 The AUTO and AC indicators display as the controls search for ac power 4 Ifa flame is not sensed the controls shift to AUTO DC Mode The AUTO AC LP GAS and DC indicators display as the AUTO pc controls search for DC power AC LP GAS AUTO DC 5 Once dc power is detected the AUTO LED displays The auto sequence described in steps 1 through 5 is repeated after the completion of each cooling cycle to enable the controls to select a higher priority heat energy source if available The controls priorities for selecting a heat energy source are E Firstpriority AC power m Second priority LP gas Third priority DC power 3 way units only NOTE AUTO DC and DC Manual Mode maintain cooling only by Refrigerator Service Manual www norcold com cda AC Manual Mode When the AC Manual Mode is selected ac power is the only heat energy source selected by the controls When the AC Manual Mode is selected 1 Mode of operation selected is AC LPGAS indicated by the AC LED AUTO 2 The AC LED stays on as long as the AC Manual Mode is selected No AC Power or Loss of AC Power When no ac power is available or ac power is lost the controls 1 Provide a visual warning by flashing acl I Lucas the A no ac fault code AUTO 2 Record and store the no ac fault in diagnostics nonvolatile memory fault history Troubleshooting an A Fault Use the following references to identify troublesh
32. 3 Replace thermostat knob 6 Remove refrigerator from enclosure 24 Replace wiring shroud A Remove wining shroud MoUs Screws 25 Install refrigerator in enclosure 8 Remove thermostat knob N 26 Install front breaker retaining screws 9 Remove gas valve thermostat retaining screws 2 27 Install back mounting flange screws 10 Mark interrupter wiring for ease of reinstallation 28 Reconnect RVILP gas sunply a ai dre blue a leads 29 Reconnect 12 Vdc power supply Disconnect thermocouple 30 Plug in ac power cord 31 Place refrigerator in service Thermostat knob shaft Capillary Thermostat tube Valve control switch button Brown wire to ac heater a safety EDE valve Black wire from switch BA le N d Gas inlet Eni O i A BS X 1 By ji rm o j m Gas outlet c D lt Herim U SON ER Rea yo rom switc L TT to interruptor D N Interruptor Bracket N Thermocouple retaining Ground Blue wire SOTOWS wire green from interruptor to switch Figure 20 Gas valve thermostat assembly 24 N500 N510 Models www norcold com cda Refrigerator Service Manual LP GAS SYSTEM N510 Canister Flue tube DC connections Gas valve Flue baffle Burner tube Gas inlet fitting Electrode H Burner LP10 orifice assembly Gas outlet fitting kur P
33. 4 Replacing Relighter 43 Gas Safety Valve Replacement ne 24 Flame Indicator N500 Models EEEE 43 LP Gas Svetem NEJO NE 25 Flame Indicator Replacement E keeuE 43 aan YN A evan icant e a a fe cn deetocetimeeste 25 Electronic Components N510 Models 43 Solenoid Gas Valve ececcccesesecesescssesesescsessesescsestisesesesssseees 25 Power Board N510 Models 43 D 6 SR RER IN El 25 Removal Power Board 43 Installation Power Board 43 LP Gas System ALL MODELS 26 Components Continued All Models ceceeeeeereeee 26 ae ea aa a a KAREN 44 B te ER Rx ded Da a na nr 26 N500 Controls emr ne 44 Flie a DN N eects A e O Ds 26 Replacing Selector Switch N500 s 1s 12s115115111112111 45 FU E o EEE neti bie salla mandin dinal a tanl uk n alen 26 N510 Controls EEmmmmmmmmmmnnmrrreemmrreeeere 46 WEL by Refrigerator Service Manual www norcold com cda N500 N510 Models Replacing Optical Control Circuit Board N510 47 AUTO Mode All N510 Units 48 AUTO Mode N510 3 3 way units 48 AUTO AC Operation 48 AUTO LP Gas Operation 48 N510 Modes of Operation 48 Troubleshooting a F and A Faults cscccccceseeeseees 48 Shift from AUTO LP Gas to AUTO AC 2 wayS 48 No AC Power and No Flame
34. Close canister door h Thread capillary tube through cabinet and reconnect to fin assemby i Reconnect thermocouple to interrupter j Reconnect ground wire k Install wire ties around split loom cover Install upper shroud m Reconnect ac power cord to terminal block N510 units a Connect ac heater wires to power board terminals AC_HT LO1 and AC HT HI b Install ac heater c For 3 way units connect dc heater wires to the power board d For 3 way units install de heater 40 N500 N510 Models www norcold com cda e Close canister door f Install power board cover then install power board cover retaining screws g Install power board cover retaining screws h Connect ac power cord to power board i Reconnect spark sense electrode wire to power board j Install wire ties along split loom tubing A WARNING Do not install the refrigerator if the combustion seal has been damaged Adamaged combustion seal must be replace The seal isolates the living area of the vehicle from the exhaust gases generated by LP gas combustion LP gas exhaust gases contain carbon monoxide which is an odorless colorless gas that can cause dizziness nausea or in extreme concentrations death 15 Install drip cup then install the drip cup retaining screw Installation of Refrigerator into Enclosure 1 Check condition of combustion seal Replace seal if damaged 2 Install refrigerator in enclosure
35. Figure 26 has black leads and is a cartridge type heater The heater is rated for 200 watts 2 5 amps at 110 Vac Heater resistance is 61 3 ohms The ac heater replacement procedure is located on page 30 AC Fuse N500 Models The N500 ac circuit is protected by a 5A 1 4 in x 11 4 in AGC type fast acting fuse housed in an in line type fuse holder N510 Models The N510 ac circuit is protected by a 5 amp fuse located on the left side of the power board The power board cover must be removed to gain access to the fuse When the refrigerator operates with poor or no cooling in ac operation but operation is present a Measure ac voltage input to the power board b Measure heater amp draw c If amp draw is not as specified measure the heater s resistance at ambient temperature Heater data Stop bead Figure 26 AC heater in heater well When replacing an ac heater make sure the stop bead rests fully against heater tube rim See Figure 26 DC Power DC Power Requirements N500 2 way models DC operation requires 12 to 15 Vdc power for relighter and ignition circuit The ignition circuit requires 10 5 to 15 4 Vdc N510 2 way models Electronic controls operate on 10 5 and 15 4 Vdc A voltage drop below 10 5 Vdc or rise above 15 4 Vdc will cause the controls to set fault codes on the display The control circuit is protected with a 5 amp automotive type fuse located on the right side of the power board
36. K 1 Burner Cleaning Procedure EiuEkmkkkke e 28 Safety Awareness 0 0 0 00 00 0 3 Electrical Requirements and Components 29 Safety Notice go m m 3 AC Heale sein nalan oiaren a rte 29 Attention Statements s i iss aii areye kiwel se k ke b nan ta e d nette 3 reda r n E NN Dr 29 Saf ty Statements cenone rrr 3 eray T rrr a a are a ede 29 Speca GS eisirean iaaiiai 4 Ten Did Requirements All Models a N500 Models 4 DC Power Requirements csccccsescesesessessssestesecessecsesees 29 N510 Models 5 N500 2 Way models russe 29 Troubleshooting Quick Reference Guide 6 Nea ec Hara pang I E ea LL ET j E way Models N510 Displayed Fault Codes 7 DC Heater N500 3 N510 3 eccsesccccssssssssssesssseessssstessseeeee 29 Troubleshooting Flowcharts N500 Units n ka len PRES 8 Relighter N500 N500 3 RO akp 2u n Ak Ak En DN ENA 2 AKS Wa e W y aa naba ene 29 Burner Will Not Maintain Flame N500 Units 8 DC Heater 8 Way Refrigerators Only 30 No AC Operation N500 UNIS MALL 9 2 Way Model Wiring rrr rrr 30 No DC Operation N500 3 3 Way Units Only RY NA 10 3 Way Model Wiring We Edal k a S w R w W k AW Sc AE di ah ba W 30 No LP Operation N500 Units ns 11 ww an cn SEG k N SOU 7 Li ARE E o MAOTA E tre kk L AG Power Cordi eer
37. NORCOLD Service Manual Gas Electric Refrigerators MODELS A WARNING DO NOT install this refrigerator in below deck marine applications Do not install this refrigerator in fixed indoor cabin or other dwelling applications This refrigerator must use only NORCOLD designed and approved outside air in take and exhaust ventilation for correct and safe operation Any other ventila tion could cause lethal combustion exhaust fumes and or explosive propane gas fumes to be in the living area and or below deck 2004 THETFORD NORCOLD All rights reserved Publication No 626800A 06 08 04 TABLE OF CONTENTS Introduction 1 Fle Baffle sin Ain en An bnn Witte eared fos ede ats 26 About this Manual 1 Handling of LP Gas Lines and Fittinge 26 Model Identification s sisien 1 LP Gas Pressure Sill yy l irkin sae irii 27 Information Label k 1 Testing for Gas Leakage hEiii ee 27 Cooling Unit Serial Number i rez 1 WOTE Ea EERE 522s odes e e e lel mm 27 Certification and Code Requirements eeseeeeeeeeeeee 1 About Installation LE Eke kk k 1 Bubble leak test solution soap and water leak test 27 Replacement Parts sieste cic zina al k ba ei enr 1 Pressure drop Test jis iiin keskin ylnieyatinil aiiai 27 Technical Assistance EELLLE EEE k
38. OLD warranty procedure must be returned to NORCOLD per the instructions included with the replacement system N500 N510 Models 33 Cooling System Diagnostic Flowchart A WARNING Do not bypass or modify the refrigerator s controls or components to diagnose the cooling system Do not wire the heater s direct The heater is supplied power through a fused circuit warnine Check eg l ng unit Do not operate the refrigerator if the cooling unit is leaking or a leak is suspected Signs of leak s E Yellow residue inside or at the rear of the refrigerator E Ammonia smell YES Replace cooling unit Any signs of leak NO Ventilation as per installation instructions Correct ventilation to meet installation requirements Check heat input zZ O Heat input device operating within specification Correct heat input device to NO meet specifications Check as required m AC heater voltage and amp draw m DC heater voltage and amp draw YES 3 way units only m Burner orifice flue deflector cap flue baffle E LP gas pressure Level refrigerator as outlined NO Refrigerator in Owner s Manual and operating leveled specifications Maximum off level limits E 3 degrees side to side m 6 degrees front to back YES Continued on page 35 34 N500 N510 Models www norcold com cda Refrigerator Service Manual A WARNING From page 34 Do
39. al components Leak detecting solutions are electrically conductive and can create a potential shock hazard electrical shorts and or fire Before connecting the refrigerator to the RV LP gas supply line The ANSI 119 2 Standard on Recreational Vehicles requires that the gas piping be proven leak free by testing before the refrigerator is connected to the LP gas system This standard requires that the system maintains at least 3 psi for a period of 10 minutes Before this test is administered the temperature of the piping system must be approximately the same throughout the system and a uniform temperature shall be maintained throughout the test period The test can be conducted using air pressure and one of the following methods Method A 1 Connect a mercury manometer slope gauge or equivalent measuring device to the LP gas system NOTE The measuring device used must be calibrated so it can be read in increments no greater than 1 10 psi 2 Pressurize the system to 3 psi then shut off the air supply valve The system must maintain 3 psi for 10 minutes Method B 1 Apply a bubble type leak detector solution between the source of air pressure and the piping system 2 Pressurize the system to 3 psi then shut off the air supply valve 3 Check for air bubbles indicating leaks After refrigerator has been connected to the RV LP gas supply line The ANSI 119 2 Standard on Recreational Vehicles requires that the
40. cated by the ac LP GAS AUTO LED AUTO 2 The AC LED comes on as the AC LP GAS controls search for ac power AUTO availability 3 The AC LED turns off when ac power is detected by the controls AC LP GAS Mode operation is indicated by the AUTO AUTO LED See NOTE 1 In AUTO mode pressing the MODE pushbutton momentarily displays the heat energy source in use For example in AUTO AC the AC LED will come on and stay on for approximately 10 seconds AUTO LP Gas Operation In AUTO mode the controls shift to LP gas when ac power is not available or interrupted The shift to AUTO LP proceeds as follows 1 The AUTO LED indicates the unit is AC LP GAS on and operating in AUTO mode AUTO 2 The AC LED comes on as the controls ac verify ac power availability AUTO LP GAS a 3 Since AC power is not detected the controls shift to LP gas The LPLED ac Pas comes on to signal the startofa30 hurto second trial for ignition 4 Once the controls sense the flame the LP GAS LED turns off leaving the Ac LPGA AUTO LED on to indicate AUTO mode AUTO operation Shift from AUTO LP Gas to AUTO AC 2 ways In AUTO mode the controls shift automatically from AUTO LP Gas back to AUTO AC when the controls detect that ac power has become available No AC Power and No Flame When AC power is not present and a flame is not sensed the controls 1 Acknowledge both faults after the 30 sec
41. ctor switch terminal 3b present Check dc voltage at relighter DC voltage See Figure 37 page 42 present Repair replace orange wire Replace relighter See page 42 www norcold com cda N500 N510 Models Thermocouple and Interrupter Malfunctioning N500 Units The following procedure and troubleshooting chart check the operation of the thermocouple and the interrupter Interrupter Voltage Output Check 1 Remove refrigerator from enclosure 2 Remove upper shroud four screws 3 Connect an alternate LP gas supply Gas pressure must be between 10 5 and 11 5 in water column Set selector knob to LP gas operation Set temperature control knob to 5 6 Connect voltmeter as shown in Figure 4 Do not disconnect wires from interrupter 7 Press and hold gas safety valve and turn selector knob to LP to ignite burner Hold the valve open to maintain the flame lit while following procedure e gt Insulator Thermocouple Figure 4 Checking thermocouple voltage output to interrupter NO Replace thermocouple below Check thermocouple voltage output See Figure 4 Voltage 10 to 30 mlV YES Check thermocouple voltage output to interrupter Angled terminal Straight terminal Straight N i terminal No voltage 0 reading from angled interrupter terminal to ground See Figure 5 10 30 mIV across in
42. dc power is the only heat energy source selected by the controls When the DC Manual Mode is selected 1 Mode of operation is indicated by AC LP GAS the DC LED display AUTO DC 2 The DC LED stays on as the DC Manual Mode is selected NOTE AUTO DC and DC Manual Mode Maintain cooling only 50 N500 N510 Models www norcold com cda Troubleshooting a DC Fault Use the following references to identify troubleshoot and correct an ignition failure fault Page 16 C fault code troubleshooting flowchart Page 16 E fault code troubleshooting flowchart Page 52 Diagnostic Mode N510 Mode Screen 4 Refrigerator Service Manual N510 DIAGNOSTIC MODE CF 2 O00 1 COLD 9 COLDEST TEMP SET MODE ON OFF Figure 44 N510 Optical Control Assembly Diagnostic Mode The Diagnostic Mode uses nine diagnostic channels Accessing the Diagnostic Mode commonly known as screens to display live inputs To access the Diagnostic Mode outputs and fault history Each screen is identified by a number which shows in the optical control assembly 1 Press and hold both the O and O buttons display See Figure 44 at the same time Lal Te SK The N510 optical control display uses a single 7 segment LED module to display diagnostic information 2 Release the O and Oas soon as screen Information made up of two letters or numbers displays Ei displays in an alternating sequence Fault history information l
43. e 18 N500 manual shutoff valve MB Figure 19 LP10 orifice i h Refrigerator Service Manual www norcold com cda N500 N510 Models 23 Gas Safety Valve The gas safety valve is mounted on the control panel in the gas valve thermostat assembly This valve is designed to stop the flow of LP gas to the burner when a flame failure occurs Its operation is controlled by the thermocouple which connects directly to the gas valve s interrupter During the ignition process the valve button must be held in open until a flame is established at the burner See Figure 20 Gas Safety Valve Replacement Refer to Figure 20 for locations of components 1 Turn OFF refrigerator 13 14 15 16 Remove interrupter Remove adapter Disconnect gas outlet Disconnect gas safety valve from thermostat assembly Apply sealant to switch outlet threads NOTE Make sure sealant does not extend beyond the threads and onto the valve nipple gt Unni d 18 Install adapter np L AS RO SOR 19 Reconnect interrupter a Disconnect te Vacsuppiy 20 Reconnect thermocouple 3 Disconnect LP gas supply 21 Reconnect red and blue switch leads and blue flame 4 Remove screws from back mounting flange if indicator lead to interrupter present N 22 Install gas valve thermostat assembly and retaining 5 Remove retaining screws located on the front of Screws breaker will need to open door to remove 2
44. e e Rennes 31 Troubleshooting Flowchart N510 Units 13 N500 AC Power Cord uuyyyyyyyeyeeeeexeececen 31 Blank Display Refrigerator does not turn on N510 13 N510 AC Power Cord 31 Optical Display Does Not Turn On Power is available 14 N500 Terminal Block i ne nn 31 F Fault Code Burner failed to ignite or reignite N510 15 AC DC Converter as Power Source Jh F Fk F kh jEiEEiEEEeeee 31 E Fault Code DC voltage high N510 16 NSIO ONY sca DD 31 C Fault Code DC voltage low N510 16 S Fault Code Flame sense circuit failure N510 17 Cooling Unit RE DS NE 32 A Fault Code No ac power available N510 uw 17 Description Pertes 32 H Fault Code AC heater failed open N510 18 Heat Absorption rrr rrr 32 r Fault Code AC relay stuck closed N510 18 Leveled Operation ess mener rnin 32 Backup Operating System N510 Models ccsscsesseeeseees 19 Gradual Decrease in Cooling Efficiency es ae SS A 32 Thermistor Failure Fault Controls in Backup Operating Cooling Monitoring N510 Units Only 32 System Mode N510 su 1 Second n Fault Code ee ae 33 Power Board Resetting Procedure 20 Cooling Monitoring Control Operation
45. eater well rim Stop bead is shown in Figure 26 page 29 and Figure 27 Connect heater leads Reconnect 12 Vdc power source Plug in ac power cord Place refrigerator in service g N 9 30 N500 N510 Models www norcold com cda Refrigerator Service Manual AC Power Cord N500 AC Power Cord N500 models are supplied ac power through the ac power cord which connects to the terminal block see Figure 28 The cord s grounding prong on the ac outlet connector must be left intact and never be modified or cut The cord s ground wire green wire must always be fastened to the refrigerator cabinet metal plate N510 AC Power Cord N510 models are supplied ac power through the ac power cord See Figure 29 Do not modify or cut the cord s grounding prong Always make sure that ground wire green wire is tightly fastened to the refrigerator cabinet metal plate The rounded side of the ac cord s power board connection must be connected to the power board with the rounded side facing left N500 Terminal Block The terminal block is located on the back of the refrigerator in the lower left corner See Figure 30 The terminal block receives ac power from the RV s ac outlet and dc power from the RV s dc power supply and distributes the power to the refrigerator s electrical components AC DC Converter as Power Source N510 Only The power board must be supplied 12 Vdc only from the filtered output battery side o
46. erminal 4a Check voltage output from selector switch terminal 4b Check dc heater wiring connections Check dc heater resistance DC voltage present YES DC voltage present YES Connections good YES Resistance 1 2 to 1 4 NO NO NO NO Check for loose or damaged wiring Repair or replace as necessary Replace selector switch See page 45 Repair or replace wiring Replace dc heater See page 30 10 N500 N510 Models www norcold com cda Refrigerator Service Manual KK LAS No LP Operation N500 Units Before beginning this procedure make sure The refrigerator is receiving dc power from the RV dc power system All ground connections are clean and making full contact LP gas is available LP gas tank valve s is open Refrigerator gas valve is open LP gas pressure is between 10 5 and 11 5 in water column Check burner and orifice assembly Burner NO and orifice Clean burner and orifice See page 28 clean YES NO Check electrode spark Set electrode air gap to 3 16 inch YES Check spark sense electrode NO Replace spark sense electrode assembly assembly for continuity See page 41 YES NO Check voltage input at DC voltage present Check 1 amp fuse and fuse holder selector switch terminal 3a YES Check dc voltage output from DC voltage Replace selector switch See page 45 sele
47. f a converter Unfiltered voltage commonly referred to as ac ripple output of ac dc converters can cause the electronic controls to set false fault codes It can also turn off the refrigerator or prevent the refrigerator from turning off Do not use a 12 volt converter to supply power to an N500 3 or N510 3 model refrigerator A 12 volt converter cannot supply enough power to operate the dc heater Wire leads identification Smooth Line hot lead to terminal block terminal 2 Ribbed Neutral lead to terminal block terminal 1 Green Ground to metal plate Figure 28 N500 ac power cord Wire leads identification Smooth Line hot lead to power board connector Ribbed Neutral lead to power board connector Green Ground to metal plate Figure 29 N510 ac power cord Smooth ac power supply hein ed n DC power supply from RV Ribbed ac power supply Terminal block AC heater lead to ac heater DC heater leads AC heater 3 ways only lead to inline fuse and selector switch i j We Agha Figure 30 Terminal block and connections im Refrigerator Service Manual www norcold com cda N500 N510 Models 31 COOLING UNIT Description The cooling unit is a self contained gravity flow absorption refrigeration system The refrigerant charge is a solution of water ammonia sodium hydroxide and sodium chromate a corrosion i
48. g screws Install back mounting flange screws Reconnect RV LP gas supply Reconnect 12 Vdc power supply Plug in ac power cord Place refrigerator in service 1a 1b 110 250 Vac 2a 2b Thermocouple 3a 3b Relighter 4al4b 12 Vdc Li tir Figure 40 Selector switch wiring Terminals Wiring Assignment 1a 1b 110 250 Vac 2a 2b Thermocouple 3a 3b Relighter 4a 4b 12 Vdc at 20 amps 3 ways Table 2 Selector switch wiring chart Refrigerator Service Manual www norcold com cda N500 N510 Models 45 N510 Controls All N510 model controls operate on 12 Vdc The controls and their functions are shown in Figure 41 TEMP SET Switch MODE Switch E Press and release to verify food cabinet E Press and hold to change operation mode temperature setting 1 cold 5 coldest AUTO AC LP and DC 3 way models only M Press and hold to set or change temperature M Operation mode verified by the 7 segment setting in food cabinet LED NORCA 5 DEN 7 Segment LED Display ON OFF Switch M Provides visual verification of operation mode M Press and hold for two seconds to turn food cabinet temperature setting fault code refrigerator ON verification and operational and diagnostic E Press and hold for two seconds to turn information refrigerator OFF LP manual mode operation LED aside LP GAS displayed AC manual mode operation
49. ighted LED segments The illustration below provides dc voltage status and assigned LED segments If dc voltage at the power board within normal range 10 5 to 15 4 Vdc LED segment 4 will be on DC voltage higher than 15 4 volts DC voltage normal DC voltage lower than 10 5 volts Press the O button to return to screen 1 MODE N500 N510 Models 53 WIRING PICTORIALS AND DIAGRAMS O 120 Vac power cord Thermocouple interrupter 25 amp fuse 3 ways Terminal block Flame indicator Spark electrode AC heater Relighter VO 3 amp fuse Selector switch 12 Vdc power supply DC heater 3 ways Thermocouple 12 Vdc power supply 1 amp fuse Thermostat gas safety valve 91010 9109 Figure 46 N500 wiring pictorial 54 N500 N510 Models www norcold com cda Refrigerator Service Manual 1a ACICA O TB 2 TB 1 TB 3 B i O 1b o o i oOff Arret Ra i i DC CC ee NM loo I I 3a r kem o 1 1 3b 1 1 2a J Gas Gaz Sa o l Iq X 12 Vdc com 12 Vdc 25 amp fuse 3 ways Relighter
50. ires from terminal FLP DC HEAT and DC_HT GND 4 Unplug the ac power cord from the RV ac receptacle 5 Disconnect the ac cord from the power board 6 Disconnect the gas valve wires from power board terminals GV and GV_GND 7 Disconnect the spark sense electrode wire 8 Remove the three 1 4 inch self tapping hex head screws from the power board cover 9 Remove the power board cover 10 Disconnect the ac heater wires from power board terminals AC_HI and AC_LO 11 Disconnect the wire harness connector from power board terminal P1 12 Remove the two 1 4 hex head screws attaching the board to the base then remove the power board along with its base by Refrigerator Service Manual Installation Power Board 1 2 www norcold com cda Seat the power board in the base Attach the power board and base assembly to the refrigerator using two 1 4 in self tapping hex head screws Do not overtighten screws Connect the wire harness connector to the power board terminal P1 Connect the ac heater wires to terminals AC_HI and AC_LO Position and align the power board cover over the power board Attach the cover using three 1 4 in self tapping hex head screws Do not overtighten screws Connect the solenoid gas valve wires to terminals GV and GV_GND Connect the spark sense electrode wire to the power board high tension terminal 3 way refrigerators AC LP DC a Connect the DC heater wires to powe
51. ister E Corners and structural pockets where heated air may stagnate must be reduced in size or completely eliminated M N500 N510 refrigerators must have a at least 47 3 4 inches distance between the upper exhaust vent and the lower intake vent Refer to the N500 N510 Installation Manual for more information Two baffles are required for the N500 N510 model in double sidewall venting applications Double sidewall venting examples are shown in Figures 15 and 16 Air Intake Vent The ventilation and combustion air flow into the enclosure is through the air intake vent Sidewall Exhaust Vent The heat absorbed by ventilation air and combustion gases flow out of the enclosure through the sidewall exhaust vent Exhaust vent Condenser Absorber coils Air intake vent Figure 15 Double sidewall ventilation arrangement Exhaust vent Angled baffle 1 4 inch or less Condenser Horizontal baffles required only when opening between outside wall and cooling unit is over 1 inch Absorber coils Air intake vent Figure 16 Baffles required for sidewall venting 22 N500 N510 Models www norcold com cda Refrigerator Service Manual LP GAS SYSTEM N500 Capillary Thermostat tube control switch valve Mounting bracket WN Mounting bracket iM T Gas inlet from RV LP suppl
52. ive inputs and outputs are presented using lighted 3 A few seconds later H displays LED segments The diagnostic LED segments if present display after the screen number turns off The diagnostic LED segment s identification numbers are Changing Screens shown in Figure 45 To change screens press the O button until the next MODE screen displays Exiting the Diagnostic Mode To exit the Diagnostic Mode 1 Press and hold the O and Opbuttons at the MODE TEMP SET same time m 2 Release the Q and O buttons as soon as TEMP SET the LED segment that represents the selected operation mode appears on the display AUTO ee AC or LP GAS Turning the refrigerator OFF then back ON also exits the Diagnostic Mode Figure 45 Diagnostic LEDs segments identification i A by Refrigerator Service Manual www norcold com cda N500 N510 Models 51 Screens and Diagnostic Segments Information Screen Diagnostic Mode Active Screen 1 confirms that the Diagnostic Mode is active A few seconds after the number displays all LED segments light See illustration If the LED segments do not match the illustration the fault is in the optical control display Replacing the optical control assembly should resolve this fault Press the O button to bring up screen 2 Screen LED Segments Reliability Check Screen 2 confirms the reliability of the display The screen should go completely blank after
53. k for control voltage across power board terminals 12VDC and GND 1 12 Vdc Correct 12 Vdc voltage input to present power board Check for control voltage across optical control wire 12 Vdc harness connector white red present wire and white violet wire Check condition of power board fuse F1 Replace fuse if open blown Check for control voltage across power board wire 12 Vdc harness connector white red present wire and white violet wire Replace power board See page 43 Push and hold OFF ON switch then check voltage 12 Vdc across wire harness optical present control connector blue and white violet wire NO Replace optical control display circuit board See page 47 YES Release the OFF ON switch then check voltage across 12 Vdc uc Replace power board See page 43 wire harness optical control present connector green and white violet wire YES Check optical control LED NO Replace optical control display circuit display operation illuminated board See page 47 YES f f Refrigerator operating as designed 14 N500 N510 Models www norcold com cda Refrigerator Service Manual n F Fault Code Burner failed to ignite or reignite N510 Before beginning this procedure make sure m RV LP gas tank valve s is open m Refrigerator solenoid gas valve manual shutoff is open m LP gas pressure at the solenoid gas valve pressure tap is 10 5 to 11 5 inches
54. les NORCOLD N500 N510 gas electric absorption refrigerators are also certified with the Canadian Standards Association CAN CGA 1 4 M94 Electrical components are compliant About Installation Refrigerator installation must conform with the N500 N510 Installation Manual part number 622265 for the NORCOLD limited warranty to be in effect Installation must also comply with applicable local codes and standards set by the cognizant certification agency Replacement Parts Use only authorized NORCOLD replacement parts Generic parts do not meet NORCOLD specifications for safety reliability and performance The use of unauthorized aftermarket or generic replacement parts voids the refrigerator s limited warranty coverage Technical Assistance If technical issues are unable to be resolved using the information provided in this manual technical support for service technicians is available through the NORCOLD Customer Service Center PY Telephone sssini 1 800 444 7210 FAX DD ne ne 1 937 497 3183 Yj World Wide Web www norcold com cda The following information is required to process technical support requests E Model number E Serial number E Make model and year of recreational vehicle i h Refrigerator Service Manual www norcold com cda N500 N510 Models 1 N O R C O L D 3 l N C une ra FOR PROPANE Teste SIDNEY OHIO ene 10 WC bree 10 5 WC alimentati bruleur
55. n result in loose joints or deformed joint parts Either condition can result in LP gas leakage A WARNING When working on or near the LP gas system E Do not smoke or light fires Extinguish all open flames E Do not use an open flame to leak test any of the LP gas system components LP gas is highly flammable and explosive E Do not connect the refrigerator directly to the LP gas tank Always use an approved pressure regulator between the LP gas tank and the refrigerator LP gas system E Always use two wrenches to tighten or loosen connections to prevent damage to connections piping and components Damaged connections piping and components create the potential for gas leaks 26 N500 N510 Models www norcold com cda Refrigerator Service Manual A WARNING When working on or near the LP gas system E Always check for gas leaks after completing service or repairs to the gas system A propane gas leak can ignite and or explode which can result in extensive property damage serious personal injury or death Bi Check that all tubing is free of dents or kinks BI Do not alter tubing radius E When disconnecting LP gas lines make sure the main LP gas valve at the tank is closed LP Gas Pressure LP gas pressure must be supplied and maintained between 10 5 and 11 5 in water column Testing for Gas Leakage A WARNING Do not allow the leak detecting solution to wet or come in contact with electric
56. nd enclosure requirements appear on pages 21 and 22 Leveled Operation The circulation of the refrigerant through the cooling unit is accomplished by gravity flow therefore the refrigerator must be operated leveled Off level operation will effect the flow of the refrigerant through the cooling system The maximum off level operation limits are m 3 degrees from side to side m 6 degrees from front to back Exceeding the maximum off level limits can permanently damage the cooling unit The cooling unit or its performance are not affected when the vehicle is in motion Gradual Decrease in Cooling Efficiency A gradual decrease in cooling efficiency can be caused by the following factors M Ventilation obstruction Heat source failure Off level operation Lack of service or maintenance Inadequate repairs Unauthorized field modifications Cooling unit failure Note that a gradual decrease in cooling efficiency is not always an indication of cooling unit failure If any of these factors exist and are not corrected a replacement cooling unit will also perform inefficiently or fail Step by step troubleshooting is the best approach when dealing with a gradual decrease in cooling It is important to consider that the cooling unit is working though not efficiently A Cooling System Diagnostic Flowchart can be found on pages 34 and 35 The cooling unit must reach peak efficiency before troubleshooting can take place
57. nect LP gas supply Reconnect 12 Vdc power supply Plug in ac power cord Place refrigerator in service 42 N500 N510 Models www norcold com cda Refrigerator Service Manual ELECTRONIC COMPONENTS N510 MODELS Power Board N510 Models Description Inputs outputs monitoring and diagnostic functions are managed and controlled by the power board Inputs outputs monitoring information and diagnostic functions are communicated through the optical control assembly The wire harness interfacing the power board with the optical control assembly is foamed into the cabinet Wiring pictorials and schematics can be found on pages 54 and 55 NOTE Because the wire harness is foamed into the cabinet it is not a replaceable component The power board is located on the back of the refrigerator below the absorber coils It is seated on an insulated base to prevent the printed circuit from making contact with the refrigerator cabinet s metal plate The N510 power board seated in its base is shown in Figure 38 Two self tapping 1 4 inch hex head screws hold the power board and base in place The power board cover is held by three self tapping 1 4 inch hex head screws Removal Power Board 1 Turn OFF the refrigerator 2 Turn OFF the RV dc power to the refrigerator 3 Disconnect dc power supply wires from power board terminals 12 VDC and 12_VGND1 3 way refrigerators AC LP DC a Disconnect the DC heater w
58. nhibitor Refrigeration is accomplished by applying heat energy and venting the heat extracted from the freezer and fresh food cabinet while maintaining the unit leveled Heat Absorption The refrigerant transfers the heat from the freezer and the food cabinet to the absorber coils At the absorber coils the metal surface absorbs the heat and air flow over the external surfaces of the coils carries away the heat Athermal air current is created by the rising hot air and flows out of the enclosure through the roof exhaust vent or sidewall exhaust vent depending on installation The flowing air mass passes over the surface of the condenser fins where it absorbs heat transferred from the ammonia vapors flowing through the condenser The thermal airflow process creates a chimney effect The fresh air drafted by the chimney effect through the intake vent removes rejected heat supports combustion and expels the exhaust gases produced by the combustion process Any obstruction restriction or modification to vents or the enclosure will affect the cooling cycle Poor cooling unit performance may be due to E Loose insulation interfering with the ventilation process Construction material or debris left in the enclosure Insect screening covering vents Plastic sheeting covering vents Items stored in the enclosure Modifications to vents or enclosure No roof or sidewall exhaust vent opening Information pertaining to ventilation a
59. not operate the Check condition of door gaskets refrigerator if the cooling unit is leaking or a leak is suspected Repair replace door as Door gaskets required sealing properly Recheck cooling unit for leaks j Any signs of Replace cooling unit leakage present Test test cooling unit performance Replace cooling unit Cooling detected be Refrigerator Unit is operating normally temperatures normal Check thermistor and power board operation Ane Refrigerator Service Manual www norcold com cda Visual and audible signs of leak s E Yellow residue on the rear of the refrigerator E Ammonia smell E Gurgling noise not always present Cooling unit performance test 1 Disconnect thermistor from the wire harness 2 Set temperature setting to the coldest setting 3 Place thermometer in freezer 4 Allow unit to operate for 3 4 hours 5 Measure temperature The back of the freezer plate should be cool after 3 4 hours of continuous operation Temperatures given below are based on 90 F ambient temperature correct ventilation and operation at coldest setting for a period of 8 12 hours E Freezer 0 F to 10 F E Fin temperature 18 F to 25 F N500 N510 Models 35 Replacing the Cooling Unit Condenser Upper shroud N500 only Foam block Split loom tubing Cabinet Tape Absorber coils Combustion seal Rear mounting flange Li
60. nstallation Manual for more information ADo not work on live electrical circuits Turn off ac power and dc power sources before attempting to remove service or repair any of the refrigerator s electrical or electronic components ADo not modify bypass or eliminate any of the refrigerator s electrical components electronic circuits or propane gas system components ADo not wet or spray liquids on or near electrical connections or electronic components Most liquids including leak detection solutions are electrically conductive and pose the potential for an electric shock hazard short electrical components damage electronic circuits and or ignite a fire ADo not use leak test solutions that contain ammonia or chlorine Ammonia and chlorine degrade copper and brass components AThe cooling unit is a sealed system under pressure Do not try to repair or recharge the cooling unit Do not bend drop weld drill puncture saw or strike the cooling unit AdHandle a leaking cooling unit with extreme caution The cooling unit contains ammonia hydrogen and sodium chromate Ammonia can cause severe skin and eye burns Hydrogen is highly flammable can ignite and burns with an intense flame Certain chromium compounds such as sodium chromate are carcinogenic ADo not use extension cords Do not remove the grounding prong from the refrigerator ac power cord Do not use a two prong adapter to connect the refrigerator to the ac
61. onds trial for ignition is over 2 Shut off power to the solenoid gas valve 3 Set gas lock out See NOTE 2 4 Provide a visual warning by flashing alternating A no ac and F no flame fault codes shown below aclh heas 77 7lj A TC LP GAS aol AUTO H Alternating A and F Codes A 5 Record and store the no ac and no flame faults in diagnostics nonvolatile memory fault history In AUTO mode the controls maintain gas lock out until a full cooling cycle on AUTO AC is completed Turning the refrigerator OFF and back ON also clears gas lock out Troubleshooting a F and A Faults Use the following references to identify troubleshoot and correct an ignition failure and or no ac faults E Page 15 F fault code troubleshooting flowchart m Page 17 A fault code troubleshooting flowchart m Page 52 Diagnostic Mode N510 Models Screen 4 48 N500 N510 Models www norcold com cda Refrigerator Service Manual AUTO DC Operation 3 Way Units Only In AUTO DC mode the controls shift to dc power when ac power is not present and flame is not sensed When the conirols shift to AUTO DC 1 The AUTO mode operation indicator AC LP GAS displays AUTO DC AC LP GAS AUTO DC 3 When ac power is not detected the controls shift to AUTO LP mode The AC LPGAS AUTO and LP indicators display as the auro Dc controls start a 30 second trial for ignition
62. oot and correct a no ac fault E Page 17 A fault code troubleshooting flowchart m Page 52 Diagnostic Mode N510 Model Screen 4 AC Power Restored When ac power is restored the controls 1 Automatically restore AC Manual Mode operation 2 Clear the A fault code from the screen However the recorded fault history will not be erased from memory 3 Display the AC LED N500 N510 Models 49 LP Gas Manual Mode When LP Gas Manual Mode is selected LP gas is the only heat energy source selected by the controls When LP Gas Manual Mode is selected n E 1 Mode of operation is indicated by AC LPGAS n the LP GAS LED AUTO 2 The LP GAS LED stays on as the flame is sensed Flame Fails to Ignite or Flame Goes Out If a flame does not ignite or the flame goes out the controls 1 Set gas lock out and shut off power to the solenoid gas valve 2 Provide a visual warning by flashing ac TT lucas the F no flame fault code AUTO 3 Record and store the no flame fault in diagnostics nonvolatile memory fault history Clearing Gas Lock Out Gas lock out can be cleared by turning the refrigerator OFF and back ON Troubleshooting an F Fault Use the following references to identify troubleshoot and correct an ignition failure fault m Page 15 F fault code troubleshooting flowchart E Page 52 Diagnostic Mode N510 Mode Screen 4 DC Manual Mode 3 Way Units Only When DC Manual Mode is selected
63. or LP Manual Mode N510 operation Leak test LP gas connections while holding in gas safety valve N500 or during the 30 second trial for ignition N510 warna Do not attempt to repair LP gas leaks with the refrigerator in operation Before attempting to repair a gas leak E Turn OFF the refrigerator E Close the LP gas valve and the manual shutoff solenoid gas valve manual shutoff 28 N500 N510 Models www norcold com cda Refrigerator Service Manual ELECTRICAL REQUIREMENTS AND COMPONENTS AC Power AC Power Requirements All Models AC mode operation requires 108 to 132 Vac for ac heater operation AC power must be supplied through a 2 pole 3 wire 20 amp grounding type receptacle A WARNING Do not cut or remove the ground prong from the power cord Do not use a two prong adapter or an extension cord Connect the ac power cord only to a grounded three prong type receptacle Operation of the refrigerator without a ground connection or with a faulty ground connection can result extensive property damage injury or death A WARNING Electric shock hazard The refrigerator is fed power from more than one source Unplug the ac cord from the RV ac receptacle before servicing electrical or electronic components AC Heater Awarnina Do not wire the heater s direct Wiring heater s direct bypasses control safety devices and creates the potential for an electrical fire The ac heater see
64. ot stored in the built in diagnostic stored fault history accessible through the Diagnostic Mode Instead it is stored in a separate unaccessible stored fault history Second n Fault Code If the refrigerator does not complete a full cooling cycle after the user turns the refrigerator back on a power board reset is required To reset the power board see page 20 by Refrigerator Service Manual www norcold com cda A WARNING Do not operate the refrigerator if the cooling unit is leaking or leakage is suspected Refrigerant Leakage All Models Yellow powder or liquid deposits at the rear of the refrigerator or ammonia smell inside the refrigerator indicate refrigerant leakage Exercise extreme care when handling a leaking or a suspected leaking cooling unit The cooling system refrigerant solution consists of water ammonia sodium hydroxide and sodium chromate Disposal of Cooling Unit All Models A WARNING Do not under any circumstances release any waste or residue from the cooling unit directly into sewers or surface waters If any liquid leaks or spills from the cooling unit contact the nearest environmental services for guidance Dispose of cooling unit according to local state and federal guidelines and regulations Dispose of any liquid waste or residue according to pre emergency planning and all applicable local state and federal regulations Any cooling system replaced under the NORC
65. out and maintain uniform temperature throughout the test period 4 Close the shutoff valve at the refrigerator 5 Close the shutoff valve at the LP gas tank s 6 The LP gas system must maintain water column pressure over a period of 3 minutes i h Refrigerator Service Manual www norcold com cda N500 N510 Models 27 Burner Cleaning Procedure A WARNING Burn hazard Allow the burner box and burner components to cool before attempting to service the burner assembly or components 1 Turn OFF refrigerator 2 Close the LP gas tank valve s For steps 3 5 refer to Figure 32 page 37 N500 or Figure 33 page 38 N510 3 Close the gas valve manual shutoff 4 Remove the drip cup retaining screw then remove the drip cup A caution To prevent damage to connections piping and components always use two wrenches to loosen the burner tube Adamaged burner tube creates a potential for gas leaks 5 Remove the burner box cover retaining screw then slide the burner box cover out of the way For steps 6 8 refer to Figure 17 page 23 N500 or Figure 21 page 25 N510 6 Disconnect the burner tube from the orifice assembly 7 Remove the orifice assembly from the burner 8 Remove the burner retaining screw 9 Remove the burner from the burner box frame 10 Clean the burner The burner slots may be cleaned with a small flat file The inner bore of the burner body may be cleaned with
66. overlay ribbon connector to optical control circuit board See Figure 42 When connecting the display overlay ribbon connector to the circuit board be sure to keep the flat side of the connector against the board and the side with the arrow visible If this connector is installed incorrectly the refrigerator will not turn on 15 Install optical control circuit board then install the board retaining screws 16 Install the board bracket retaining screws 2 17 Reconnect wire harness 18 Install refrigerator in enclosure DB123456N0123456 To display overlay Display overlay ribbon connector Figure 43 Optical display circuit board jj Refrigerator Service Manual www norcold com cda N500 N510 Models 47 N510 Modes of Operation N510 models are designed for 2 way or 3 way operation AUTO Mode All N510 Units In AUTO mode ac power is the first heat energy source selected by the controls If ac power is not present the controls shift to LP gas the controls second priority heat energy source AUTO Mode N510 3 3 way units In 3 way units if ac is not available if a flame is not sensed the flame goes out or an ignition failure occurs the controls shift to dc power the third priority heat energy source For additional information on 3 way units in AUTO mode see page 49 AUTO AC Operation When AUTO mode is selected 1 Mode of operation is indi
67. quid heat exchanger Burner box Figure 31 Cooling unit and components This procedure supplements the instructions packaged A CAUTION 7 with N500 N510 model replacement cooling units Follow To prevent damage to connections piping and the procedure to install the cooling unit correctly components always use two wrenches to loosen and Incorrect installation adjustments or modifications will tighten LP gas connections Damaged connections affect cooling performance create a potential for gas leaks Removing the Refrigerator from the Enclosure Refer to Figures 31 32 and 33 to locate components 1 2 3 4 5 36 N500 N510 Models www norcold com cda Refrigerator Service Manual 6 Disconnect the RV LP gas supply line from the NOTE refrigerator gas valve A CAUTION Some of the refrigerator s metal components have Retain all parts and hardware for reinstallation Close the LP gas tank valve s sharp corners and edges Wear hand protection such Turn off gas valve manual shutoff at refrigerator as cut resistant gloves and exercise extreme care Unplug the ac power cord from the RV ac when handling the refrigerator receptacle Turn off RV dc power to the refrigerator Disconnect the dc power supply wires N500 units terminal block 3 and 4 N510 units power board Back View lt TT Condenser PUTT
68. r Switch Gas Valve Thermostat OFF M Regulates food cabinet temperature by controlling energy source 1 cold 5 coldest LP Gas M de LP Gas Mode Controls flow of gas to the AC Mode burner DC Mode 3 way AC Mode Controls ac power to the ac heater ON OFF DC Mode 3 way models Controls dc power to the dc heater models Figure 39 N500 Controls 44 N500 N510 Models www norcold com cda Refrigerator Service Manual Replacing Selector Switch N500 OT SK ONS gt go 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Turn OFF refrigerator Unplug ac power cord Disconnect 12 Vdc supply Disconnect LP gas supply Remove screws from back mounting flange if present Remove retaining screws located on the front of breaker will need to open door to remove Remove refrigerator from enclosure Remove wiring shroud four screws Mark selector switch wiring for ease of reinstallation See Figure 40 Remove selector switch knob Remove retaining nut from front of selector switch assembly Remove selector switch by pulling from back Remove wiring from selector switch and transfer to replacement selector switch See diagram on switch housing and Table 2 for wiring placement Replace switch assembly into controls Install retaining nut Replace selector switch knob Replace wiring shroud Install refrigerator in enclosure Install front breaker retainin
69. r board terminals FLP DC HEAT and DC_HT GND Connect the ac power cord to the power board Plug ac power cord into the RV ac receptacle Connect positive and the negative dc power wire leads to the power board MB Positive wire to terminal 12VDC M Negative wire to terminal 12_VGND1 Turn ON the RV dc power to the refrigerator Turn ON refrigerator then check all power board control functions before placing in service Place refrigerator in service 0341 621268 UT Figure 38 N510 Power Board N500 N510 Models 43 CONTROLS N500 Controls A WARNING Do not hold the gas safety valve plunger in open for more than 30 seconds If the burner does not ignite within 30 seconds wait at least five minutes before attempting to relight the burner Holding the gas safety valve plunger in open for more than 30 seconds will allow propane gas to pocket in and around the burner An LP gas pocket in the burner area can cause a fire or explosion which can result in extensive property damage burn injury and or death All N500 model controls operate on 12 Vdc The controls and their functions are shown in Figure 39 Gas Safety Valve Read warning above Flame Indicator E Plunger type spring loaded valve E Single LED red M Manually operated M Lights to indicate LP gas operation M Press and hold to ignite flame E On when flame present at burner E Release after flame indicator LED lights Selecto
70. ressure Manual tata RV Burner box base test port shown closed LP gas supply Figure 21 N510 LP gas system components Components Solenoid Gas Valve The solenoid gas valve shown in Figure 22 controls DC power connections Mounting bracket the flow of gas from the RV gas supply to the burner w pressure tap The valve s manual shutoff is a spring Solenoid loaded quarter turn manually operated valve a Integrated in the valve s body are a manual shutoff and To manually shut off gas to the burner pull the handle Gas inlet fitting slightly away from the body of the valve then turn it Gas outlet one quarter turn 90 degrees counterclockwise fitting from RV LP gas 7 y system LJ p Gas pressure The solenoid gas valve inlet fitting is 3 8 inch male threads the outlet fitting is 1 4 inch male threads Orifice Manual shut off test port shown closed warnine Do not separate the orifice from its threaded adaptor Figure 22 N510 solenoid gas valve The orifice and its adaptor are a sealed assembly Separating the orifice from the threaded adaptor can cause LP gas leakage An LP gas leak can ignite and cause an explosion and or fire which could result in substantial property damage burn injury or death The orifice meters the flow of gas to the burner The H D N510 model requires the LP10 orifice See Figure 23 A re
71. rload protection must not exceed 30 amps E Over 20 feet AWG 8 or larger wire gauge must be used The size fuse for circuit overload protection must not exceed 40 amps DC Heater 3 Way Refrigerators Only A WARNING Do not wire the heater s direct Wiring heater s direct bypasses control safety devices and creates the potential for an electrical fire When refrigerator is in dc operation and does not maintain refrigeration and ventilation is correct a Measure dc voltage input to the power board b Measure the heater s amp draw c If amp draw is not as specified measure the heater s resistance at ambient temperature The dc heater must be inserted into the heater tube until the stop bead makes full contact with the tube s rim The stop bead is shown in Figure 27 Heater data Stop bead Yellow wire leads Figure 27 DC heater DC Heater Circuit Fuse A WARNING Never replace a fuse with a higher amp rated fuse Always use the specified fuse The N500 dc heater fuse is a 25 amp inline fuse The N510 dc heater circuit fuse is a standard 30 amp green automotive blade type fuse It is located on the power board terminal F2 Replacing AC or DC Heater 1 Turn refrigerator OFF 2 Unplug ac power cord and disconnect 12 Vdc power source 3 Disconnect heater leads 4 Remove heater from heater well 5 Install replacement heater in heater well making sure that stop bead rests fully against h
72. should be used during any process that can cause material to become airborne such as removing a leaking cooling unit and cleaning components Attention Statements The safety alert symbol 4 followed by the word WARNING or CAUTION identifies potential safety hazards or conditions A WARNING The above heading identifies hazards or conditions which if ignored can cause serious injury death and or extensive property damage A CAUTION The above heading identifies hazards which if ignored can cause injury and or property damage Safety Statements ADo not modify alter or equip the refrigerator to the use of any other fuel natural gas butane etc N500 N510 refrigerators are designed and equipped for the use of LP gas propane gas only incorrect installation adjustment alteration or maintenance of the refrigerator can cause personal injury property damage or both ADo not smoke light fires or create sparks when working on the propane gas system ADo not use an open flame for leak testing any of the propane gas system components Propane gas is highly flammable and explosive AAlways use two wrenches to tighten or loosen LP gas connections Damaged connections piping and components create the potential for gas leaks AAI electrical connections and repairs to the refrigerator must comply with all applicable codes Refer to the certification and code requirements section of the N500 N510 I
73. stall the cooling unit into the refrigerator cabinet by inserting the foam plug into the cabinet step opening and pressing down firmly The foam plug must seat evenly against the cabinet step Install the longest freezer plate screw along with washer into the third hole from the left Install the three remaining freezer plate screws and washers Install the absorber retaining screws Install the four fin assembly screws Tape the edge of the foam plug to the cabinet Use HVAC metallic tape or heavy duty duct tape See Figure 31 N510 units a Install thermistor on 5th fin b Thread thermistor wires through back of refrigerator cabinet and through split loom tubing c Connect wires to P1 connector terminals 8 and 13 See Figure 34 for terminal location d Plug P1 connector into power board e Tape thermistor wiring to foam plug Units with fan a Install fan wiring Refer to wiring diagram on the outer surface of the fan bracket or refer to Figure 48 page 55 b Install thermostat on the first condenser fin c Install bracket d Install fan onto bracket Align the burner box with the cabinet then install burner box retaining screws Low temp ll4 evaporator 1 2 in bead of sealant Thermistor capillary tube wiring opening The sealant must be applied correctly to prevent air from sy Z az being drawn into the cooling unit s high and low of sealant High temp a evaporator evaporators
74. stricted clogged or damaged orifice will affect the burner s heat output which in turn affects the Figure 23 LP10 orifice performance of the cooling unit when the refrigerator is operating on LP gas The orifice should be checked and cleaned annually to maintain the LP gas combustion system at peak performance lt should also be checked before and after seasonal storage and before the recreational vehicle is placed in service See page 28 for more information on cleaning the burner and its components i h Refrigerator Service Manual www norcold com cda N500 N510 Models 25 LP GAS SYSTEM ALL MODELS Components Continued All Models Burner A five slot burner is the combustion chamber for the LP gas Poor or no cooling while operating on LP gas can usually be traced to a dirty clogged or damaged burner In most instances a weak or erratic flame indicates the burner and orifice need service The burner flame appearance should always conform to the pattern shown in Figure 24 To check burner performance 1 Set the thermostat knob to 5 2 Start and operate the refrigerator on LP gas Aca UTION The burner box cover and inspection port cover may be hot To prevent burns wear gloves and exercise extreme care when working on the burner cover or opening and closing the burner box inspection port cover 3 Open the burner box inspection port Refer to Figure 24 for flame appearance guidelines
75. supply ac power to the refrigerator Fault indicator displayed AC LP GAS AUTO Measure ac voltage input to power board ai NO 1 Check ac power input from RV to unit 2 Check for faulty ac power cord 132 Vac i yac p YES Check condition of F3 fuse NO Replace fuse Use a 5 amp 1 4 x 11 4 in power board AGC fast acting type fuse YES heck that fuse holder clips NO Adjust clips to ensure fuse contacts are are making full contact with be a firm in clips and making full contact fuse YES Replace power board See page 43 S Fault Code Flame sense circuit failure N510 Fault indicator displayed AC J LPGAS auto l Flame sense circuit failure Replace power board See page 43 ADC NOR NO Refrigerator Service Manual www norcold com cda N500 N510 Models 17 H Fault Code AC heater failed open N510 Before beginning this procedure make sure m RV ac voltage to the refrigerator is 108 to 132 volts No other appliance or lighting circuit is connected to the refrigerator ac circuit Fault indicator displayed di AC LP GAS AUTO Check ac heater wires for loose or damaged connector Heater connectors OK Repair or replace connectors If connectors cannot be repaired replace heater See page 30 Check ac heater resistance Resistance See Figure 9 58 to 64 Q Replace ac heater See page 30 Replace power board See page 43
76. terrupter terminals See Figure 6 No voltage 0 reading from straight interrupter terminal to ground See Figure 7 Replace thermocouple Replace gas safety valve See page 24 Check control switch connections Angled terminal Straight terminal Interrupter Interrupter Figure 5 Checking angled terminal Figure 6 Checking voltage across Figure 7 Checking straight to ground terminals terminal to ground 12 N500 N510 Models www norcold com cda Refrigerator Service Manual TROUBLESHOOTING FLOWCHART N510 UNITS Blank Display Refrigerator does not turn on N510 Before beginning this procedure make sure m 12 Vdc input to the power board is wired according to the N500 N510 Installation Manual m No other RV appliances or lighting circuits are connected to the refrigerator dc circuit Fault indicator displayed AC Blank LP GAS Display AUTO Screen Measure voltage at power board 12VDC and GND1 connections 10 5 to 15 4 Vdc 1 No dc power input from RV to unit 2 Faulty wiring or connectors Check condition of F1 fuse Replace fuse Use a standard 5 amp in power board See e p tan color automotive blade type fuse Figure 8 See procedure on page 14 Figure 8 Checking dc fuse continuity We by Refrigerator Service Manual www norcold com cda N500 N510 Models 13 Optical Display Does Not Turn On Power is available N510 Chec
77. tes in the following sequence 1 Because the fin temperature is above 40 F when the refrigerator is turned ON sampling begins when the refrigerator is turned ON and stops when the temperature falls below 40 F 2 Monitoring activates if the fin temperature rises above 40 F while the refrigerator controls are demanding cooling 3 Monitoring samples the fin temperature every ten minutes for a period of two hours 4 If there is no decrease in temperature in this two hour time period Monitoring turns off the active refrigeration heat source 5 After ten minutes Monitoring restarts the heat source and monitors the fin temperature every ten minutes for another 40 minutes 6 Within this 40 minute time period the temperature must decrease or Monitoring will turn off the refrigerator and lock out the heat sources 7 Once the heat sources are locked out the optical control assembly displays the n fault code First n Fault Code The first time the n fault code no cooling is displayed it can be cleared by the user by turning the refrigerator OFF and then back ON This gives the user the opportunity to check for problems that may have caused an n code such as obstructed ventilation This fault code occurrence is then stored by the controls If the refrigerator completes a full cooling cycle after it is turned back on this fault code occurrence will be erased from the controls An n fault code occurrence is n
78. ventilation air and combustion gases flow out of the enclosure through the roof exhaust vent The roof exhaust vent is equipped with a non removable metal mesh screen that prevents leaves debris birds or rodents from getting into the enclosure The roof cap is fastened to the exhaust vent with four screws The cap is always installed with the slope towards the front of the RV Baffles The minimum and maximum clearances for installing the refrigerator or correcting ventilation problems on roof vented units are listed in Table 1 Baffles are required whenever installations exceed maximum clearances listed in Table 1 Figure 13 and Figure 14 show baffle locations Minimum Maximum Bottom 0 inch 0 inch Sides each 0 inch 1 8 inch 0 inch 1 4 inch 0 inch 1 inch Roof exhaust vent Baffle full width of enclosure required to isolate top of refrigerator from rejected heat 1 4 inch or less Condenser 1 inch maximum if wider see Figure 14 Absorber coils Air intake vent Figure 13 Roof vented ventilation arrangement Vertical Angled Baffles Vertical angled baffles are required when the roof exhaust vent is installed inboard of the condenser Figure 14 shows the angled vertical baffles required on inboard roof vent installations The horizontal wall baffles are required whenever the distance between the cooling unit and the interior surface of the outside wall e
79. w Press the Q button to bring up screen 6 Refrigerator Service Manual Screen Erase Fault History Data Screen 6 provides a way to erase stored fault history from memory To erase stored fault history 1 Press and hold the Obutton when and TEMP SET r display 2 Release the O button when lr and r TEMP SET display 3 Wait five seconds 4 Press and hold the button until and TEMP SET display again Press the O button to bring up screen 7 MODE Screen Power Board Inputs Screen 7 displays live power board inputs using lighted LED segments The illustration below provides live inputs information and assigned LED segments If a power board input is active or live its assigned LED will light Thermistor sensing Sensing burner flame fin temperature Press the Q button to bring up screen 8 N Refrigerator Service Manual www norcold com cda Screen H Power Board Outputs Screen 8 display live power board outputs using lighted LED segments The illustration below provides live outputs information and assigned LED segments If the power board output is active or live the assigned LED will light AC power to ac heater DC power to gas valve DC power to ignition circuit Press the O button to bring up screen 9 MODE Screen Power Board DC Voltage Status Screen 9 display power board dc voltage status using l
80. water column Fault indicator displayed AC LP GAS AUTO Check burner and orifice Burner and orifice clean NO YES Gap NO 3 16 inch YES YES Check gas valve solenoid 79 to 85 Q resistance YES Check that electrode to burner air gap is correct Check spark sense electrode assembly for continuity Check gas valve solenoid wires for continuity Check voltage across power board terminals GV and GV_GND Voltage present Clean and service burner and orifice See page 28 Set electrode to burner gap 3 16 inch Replace spark sense electrode assembly See page 41 Replace gas valve Replace gas valve wires Replace power board See page 43 Faulty or obstructed gas valve Replace gas valve www norcold com cda N500 N510 Models 15 E Fault Code DC voltage high N510 Before beginning this procedure m Make sure RV dc voltage to refrigerator is 10 5 to 15 4 volts Determine if the E fault code displays when the converter is the source of dc power Fault indicator displayed AC LP GAS Check for dc voltage input to power board terminals 12VDC and GND1 Voltage higher than 15 4 Vdc See NOTE above to determine and correct an E fault Correct incoming dc power distribution to refrigerator Power distribution must be 10 5 15 4 Vdc Electronic controls operate on 12 Vdc When an ac dc converter is used to
81. wer board N510 See page 43 Ventilation obstructed Check enclosure for obstructed air flow The refrigerator does not Incorrect LP gas pressure Set gas pressure to 10 5 to 11 5 in w c cool efficiently on LP gas Dirty burner Clean burner See page 28 Missing flue baffle Replace flue baffle See page 26 Flue cap blocked Clear flue cap See page 26 i Poor ventilation Check enclosure for obstructed air flow Poor or no cooling Off level operation Level unit See page 32 Dirty burner Clean burner See page 28 Low ac voltage Check ac voltage input Cooling fan inoperative if present Test fan operation Improper installation Check installation See pages 21 and 22 and N500 N510 Installation Manual Incorrect orifice Install correct orifice LP10 6 N500 N510 Models www norcold com cda Refrigerator Service Manual N510 DISPLAYED FAULT CODES Code Probable Cause Reference Blank Refrigerator turned off Display No 12 Vdc to refrigerator See pages 13 and 14 Screen F1 fuse open LE Burner failed to ignite or reignite See page 15 5H Flame sense circuit failure See page 17 C H DC voltage low See page 16 E Hk DC voltage high See page 16 k AC relay stuck closed See page 18 No ac power available to refrigerator AC cord not plugged into power board See page 17 F3 fuse open Hk AC heater failed open See page 18 Flashing Temp Backup operating system in operation See page 19
82. xceeds one inch Roof exhaust vent Angled baffles required when the roof vent is inboard of the condenser Condenser Horizontal baffles required only when opening between outside wall and cooling unit is over 1 inch Absorber coils Air intake vent Figure 14 Roof vented ventilation with roof vent inboard of condenser www norcold com cda N500 N510 Models 21 Double Sidewall Venting Because of increased installation of refrigerators in RV slide outs NORCOLD has developed venting guidelines for double sidewall vent applications This ensures NORCOLD refrigerators meet the ANSI Z21 19 standards for cooling performance when used in slide out applications The challenge with slide out installations is that the chimney effect see page 32 that is present with roof vent installations is not as strong in slide outs To improve the airflow of the chimney effect side vent installations must have fans and baffles These fans and baffles direct the air flow through the surfaces of heat rejecting components NORCOLD has determined that the following four key design considerations optimize heat removal in N550 N510 slide out applications mm Refrigerators installed in slide outs must have a fan or fans to assist air flow Fan kits are available through NORCOLD E Fresh air must be directed to flow through the surface areas of the absorber coils condenser fins and the outer surface of the can
83. y Manual shut off Gas safety Flue tube Canister Electrode iso Burner Burner box base Figure 17 N500 LP gas system components Components Manual Shutoff Valve The manual shutoff valve controls the flow of LP gas from the RV LP supply to the gas valve thermostat assembly See Figure 18 Orifice A WARNING Do not separate the orifice from its threaded adaptor The orifice and its adaptor are a sealed assembly Separating the orifice from the threaded adaptor can cause LP gas leakage An LP gas leak can ignite and cause an explosion and or fire which could result in substantial property damage burn injury or death The orifice meters the flow of gas to the burner The N500 model requires the LP10 orifice See Figure 19 A restricted clogged or damaged orifice will affect the burner s heat output which in turn affects the performance of the cooling unit when the refrigerator is operating on LP gas The orifice should be checked and cleaned annually to maintain the LP gas combustion system at peak performance It should also be checked before and after seasonal storage and before the recreational vehicle is placed in service See page 28 for more information on cleaning the burner and its components Gas outlet fitting Gas inlet fitting from RV gas supply Mounting bracket Manual shut off Figur

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