517800 Active Smart Service Manual - USA
Contents
1. 22 6 1 5 1 Variable Capacity Compressor Control Overview 22 6 1 5 2 Built in Electronic Protections Within the Module Inverter 23 6 15 21 Compressor Statt up ee et ie bets 23 6 1 5 2 2 Overload Detection and Protection sssssssssseseem 23 6 1 5 2 3 Power Limitation Temperature 23 6 1 5 2 4 Short Circuit Protection ac reiten o ente re bu 23 6 1 5 3 VCC Module Inverter Identification 4 23 6154 FaWt FINOG M 23 6 1 5 4 1 High Voltage Power Supply Circuit 23 CTSA gale ir ranae 23 6 1 6 24 6 1 7 Thermal EE 25 6 1 8 Eow Ambient Heater 25 6 1 9 PG DTE 26 6 110 26 6 1 11 Thermistor Temperature 27 6 2 Fault Finding Procedure tec tee v tec ev tede e tite ce d ne de ev endow es nov es ride the 28 6 2 1 Fault Code Display Status 28 6 2 2 Diagnostic 31 6 2 3 Sensor Temperature Conversion2. 38 7 13 Replacement Of Low Ambient Heater Model In Return Air 38 7 14 Evaporator Replacetrent rn ei tenn e ELI ERI E ERR E E PO d CM Fee IRA Re 38 7 15 Removal Of The FC Evaporator nnne 39 7 16 Pressure Testing Of The Refrigeration 40 7 17 Transporting Of Refrigerators mi HE det gebe iHi dot 41 8 WIRING DIAGRAM M 42 9 SERVICE REFERENCE tnt ap 43 9 1 Models nii e ttg ele el 43 9 2 gt Models cheese bined codd 46 10 DIAGRAM Sir tea Ha en ee rodeo a eren atom e esa n pd 48 10 1 Refrigerator Operating ott tete ea deter ee eb ptus 48 10 2 No Power To Power Control Module And Or Display Module 49 10 3 PCF Warm anoeta eter e ut 50 10 4 Teo Gold PG TOO e RE iE n 51 10 5 PC Too Cold 2 n eee hits hate lads E A a 52 10 6 Ice Condensation Forming 53 10 7 ntc 54 10 8 Door Switch Not Operating ee ene erent 55 10 9 Defrost Heat
3. 31 6 2 4 Input Output Status tet eri ede tei de ette 32 6 2 5 Data Download ede a teh tee RO e ieu len 33 6 2 6 Manual Delrost 1 dete dr tentiae n RO fined RR deed puede t 33 6 2 7 Show Room ect e ete ehe den deett diee 33 6 2 8 Special Option Mode 34 6 3 Door Gasket Integral tede eu thee inde tidie d ne eee d uie 34 7 REMOVING AND REFITTING OF essen 35 7 1 Removal Of Power Control Module 2 1 00000000000000000000000442 1 35 7 2 Sensor 35 7 3 FC Sensor 35 7 4 PG Ran Motors 2 Model PS 36 7 5 PG Ean B Models iom ei err RI Fede ENG E HO d ERR 36 7 6 Cross Base Rail Door Reed 36 7 7 Defrost Heating Element enean epi montesmuetheei 36 7 8 Removal Of Display Module itt rente 37 7 9 Ua 37 7 10 Replacement Of Interior 37 7 11 Replacement Of Low Ambient Heater 37 7 12 Replacement Of Low Ambient Heater Model
4. Does PC light switch on amp off as PC door is opened and closed Yes Is door magnet in place Refit door magnet 1 Yes Are reed switch harness connections at power control module OK Replace reed switch Yes No Repair 55 10 9 Defrost Heater Faults Does the display module indicate a fault code No Is Smart Tool download available Repair replace faulty components Check correct operation of defrost heater Check location Yes of defrost sensor Check if door has been left ajar Refer to Section 6 2 1 Yes Repair or replace faulty components Does download confirm defrost failures Yes Are defrost heater resistance and connections OK Is there excessive solid ice build up on or around evaporator No Advise customer no fault found 56 10 10 Compressor Faults Compressor will Compressor will not run and is cold not run and is hot to touch to touch Compressor runs continuously Refer to Section Refer to Section Refer to Section 10 11 10 1 10 12 10 11 Compressor Runs Continuously Are the L E D s on the display module illuminated With FC door closed and PC door open press Mode button Yes Is Check for loss of refrigeration gas leak or taking place blockage Yes Check for correct fitting of AS ME Oe sensors Check sensor Refer to Section reaching
5. 3 celts Gu Y ERREZ 3A N e yeas AWS lt 1 l 04 5 2 ev n5 23 yas 09A LYVWS JALLOV 42 9 SERVICE REFERENCE 9 1 B Models PC TOO COLD Cold Crispers Ice In Crispers Bottom of Compartment Cold Top Warm Total Compartment Too Cold PC TOO WARM Top of Compartment Warm Bottom Cold Total Compartment Warm FC TOO COLD Total Compartment Too Cold Ambient heater open circuit alarm will sound and fault code will be displayed PC fan fitted upside down PC fan not going Air leakage base duct cover PC sensor location PC fan not going alarm will sound and fault code will be displayed FC fan not going alarm will sound and fault code will be displayed Short of gas PC sensor inaccurate PC fan not going alarm will sound and fault code will be displayed PC fan upside down Return duct iced up PC duct blocked Evaporator iced up No refrigeration Fans not working alarm will sound and fault code will be displayed Power control module failure FC sensor location Faulty sensor PC faulty fan alarm will sound and fault code will be displayed 43 Check continuity of element using multimeter Fan hub to be facing PC Check voltage to plug check wiring polarity
6. Yes Does the display module indicate a fault code Has product been initialised Yes Is there 12V DC at the display module No Yes Replace display module 48 FLOW DIAGRAMS Refrigerator Not Operating Check house outlet socket Is there power to the power control module No No Yes Repair or replace faulty components Are any L E D s on at the display module Yes Is the compressor warm Refer to Section 10 13 Refer to Section 10 12 10 2 No Power To Power Control Module And Or Display Module Is there power to the refrigerator PC light amp L E D s on Is there power to the house outlet Socket Repair fault in No pair fault i house wiring Yes Yes Is continuity of power cable and all harness connections OK Repair or replace faulty components Yes Compressor circuitry wiring OK Replace power control module Repair or replace faulty components 49 10 3 PC FC Warm Yes Adjust temperature temperature settings settings correct Advise customer product OK Does the compressor run No Refer to Section 10 10 Does the display module indicate a fault code Refer to Section Repair or replace faulty components No Are temperatures of contents of PC amp FC OK Is Smart Tool download a
7. 520 litres 18 36 cu ft ELECTRONICS 110 volt Display Module Part No 881218 Part No 881218 Power Control Module Part No 884252 Part No 884252 Module Inverter Part No 884260 Part No 884260 SUCTION LINE ASSEMBLY Part Number 875113 874810 DEFROST ELEMENT Part Number 881414 881414 COMPRESSOR SPECIFICATIONS Make Embraco Embraco Model VEG Y6H VEG Y6H Part Number 884259 884259 Volts 110 110 Hertz 53 150 53 150 Phase 3 3 Input Watts 55 7 205 55 7 205 Output Watts 97 468 97 468 Nominal BTU 330 1596 330 1596 Start Resistance Ohms 6 40 6 40 Run Resistance Ohms 6 40 6 40 Starting Device Type Inverter Inverter Oil Charge cm 430 430 Refrigerant Type R134a R134a Gas Charge 140 Grams of R134a 135 Grams of R134a 2 2 Model Number Identification The following is an example of the model number identification for Fisher amp Paykel Appliances E 522 B R E D FP SM Cabinet Door Colour 1 Brand Fisher amp Paykel Series 2 Style 3 Door Hinging Side 4 Freezer Location 5 Approximate Capacity in Litres 6 Type of System 7 1 Colour of Cabinet Door WW White Cabinet White Doors SM Silver Wrapper Matt Stainless Steel Doors SX Silver Wrapper Brushed Stainless Steel Doors 2 Series The series of the cabinet is located on the serial plate as Series A B etc 3 Style
8. Doors sealing adjust Is PC fan is running alarm will sound and fault code will B displayed if faulty If not refer PC too warm 46 ALARM ON Defrost heater Check display for fault code Check defrost element continuity Put cabinet into manual defrost wait for defrost relay to click on 2 minutes after pressing buttons If no click check power control module If click heard check the defrost heater 110v output at the power control module Sensors Check display for fault codes 0 5 Sensors above or below limit refer thermistor service table in service manual Door switch fault Check that no fault code is shown on the display Check that PC FC doors activate reed switches Check also reed switches with magnet Check wiring harness to power control module Check wiring harness to console board FAULT DISPLAYED NO ALARM Display flashing fault code A Alarm has been switched off by user but no alarm sounding Piezo alarm faulty on board replace board LIGHT NOT FUNCTIONING Blown bulb Check power supply to socket 7 Volts if nil check plug at display module Check continuity of bulb nil replace Cabinet type Power control module not initialised close FC door and press compartment select button Poor connection Spread halogen bulb legs Check lamp holder replace where possible Check connector on display module CONSOLE NO L E D LIGHT
9. Re terminate the 6 way RAST connector Replace the power module The resistance of the FC sensor is outside the normal range 45K Ohms Check the sensor connection at the power module Replace the sensor The resistance of the FC sensor is outside the normal range 660 Ohms Check the sensor connection at the power module Replace the sensor The resistance of the evaporator sensor is outside the normal range 45K Ohms Check the sensor connection at the power module Replace the sensor The resistance of the evaporator sensor is outside the normal range 660 Ohms Check the sensor connection at the power module Replace the sensor The resistance of the PC sensor is outside the normal range gt 45K Ohms Check the sensor connection at the power module Replace the sensor The resistance of the PC sensor is outside the normal range 660 Ohms Check the sensor connection at the power module Replace the sensor The current measured for the ambient heater PC fan and FC fan is lower than expected Check the 6 way fan LAH RAST connector at the power module Reterminate the 6 way fan LAH RAST connector Replace the power module The current measured for the ambient heater PC fan and FC fan is higher than expected Check the 6 way fan LAH RAST connector at the power module Reterminate the 6 way fan LAH RAST connector Replace the power module Low ambient heater is drawing less current t
10. The PC fan speed can be adjusted to meet the requirement of that compartment Therefore the PC fan speed will be set at the average speed used from the previous cycles under normal door openings and loading conditions During the off cycle of the compressor the PC fan will run at a very low speed to prevent air transfer in the ducts between the two compartments When the compressor is turned on the fans will also be switched on except immediately following a defrost cycle where there is a delay of 30 seconds after the compressor has started before the fans switch on FC FAN Viewed from front PC FAN Viewed from FC side Diagram 6 1 9 6 1 10 Light A 12 volt 10 watt halogen lamp is used in the PC To prevent overheating the lamp is turned off after 5 minutes of the door being left open The power control module controls this LIGHT FITTING LAMP AND COVER fh Diagram 6 1 10 NOTE It is important that the lamp pins are tight in the lamp socket 26 6 1 11 Thermistor Temperature Sensors These sensors are used to monitor temperatures within the refrigerator There are 3 of them 1 Defrost sensor mounted on the evaporator chassis above the evaporator used to measure the temperature when in defrost Colour Black 2 FC sensor mounted on the FC fan cover used to measure the temperature in the FC Colour White 3 PC sensor mounted in the PC on the duct cover and used to sense the PC temperature Colour White Thermistor
11. Either the wiring is shorted or the fan is faulty Check FC fan wiring and connections at both fan and power module Check fan If faulty replace V Example Fault Code 8 4 1 13 13 Low Ambient Heater Open Circuit 30 6 2 2 Diagnostic Mode To enter the diagnostic mode Press and hold the MODE button then press the TEMPERATURE UP button The L E D s indicate the PC sensor temperature The current PC sensor temperature is displayed in a code form refer Section 6 2 3 Sensor Temperature Conversion Return to normal operation by pressing the MODE button CAUTION In reading temperatures there is a need to enter the required mode when the door is first opened as all temperature readings are only sensor temperature air temperatures and these will change rapidly with the increase in air temperature as soon as the door is opened Press the up button 1 time FC sensor temperature The current FC sensor temperature is displayed in a code form refer Section 6 2 3 Sensor Temperature Conversion 2 times Defrost sensor temperature The current defrost sensor temperature is displayed in a code form refer Section 6 2 3 Sensor Temperature Conversion 3 times Inputs outputs status refer Section 6 2 4 Input Output Status To exit the diagnostic mode press the MODE button If not terminated manually diagnostic mode will time out and go back to default display after 5 minutes Note The door alarms do not operat
12. FAN COVER REMOVAL TOOL Material 1 x Screw Driver shaft diameter approx 4 5mm shaft length 200mm 2 20mm Radius FIT OR FORM A SUITABLE HANDLE AS PREFERED zm e 65mm BRAZE EASY FLOW a 40mm C gt FULCRUM LEVER PIN gt round at both ends Diagram 7 15 39 7 16 Pressure Testing Of The Refrigeration System The use of the in line pressure gauge can speed up and eliminate the incorrect diagnosis of a leak within a refrigeration system some cases it has been found to be the service manifold that was being used that was leaking and not the system There are very few parts on the in line pressure gauge that can leak Rule one In pressure testing any cabinet before disconnecting any joint please be 100 sure that it is not the joint that is at fault otherwise a lot of time can be lost looking for a joint leak that doesn t exist Rule two Only use dry nitrogen to pressure test a system NOT REFRIGERANT OR COMPRESSED AIR NEVER OXYGEN Rule three Don t over pressurise the system It could be dangerous How to use the In line Pressure Gauge Step 1 Cut and connect the pipe circuit to be tested to the in line pressure gauge and braze this joint Step 2 At the other end of the pipe circuit being tested crimp off the pipe with crimp off pliers and braze this end off to totally seal the circuit Step 3 Connect a nitrogen bottle to the in line pressure gauge by means o
13. To retrieve information from the control module one of the following is required ALight Pen part number 425930 a Cassiopeia Smart Tool Light Pen part number 425930 a laptop computer with the Fisher amp Paykel Smart Tool diagnostic program loaded The steps to download data are 1a Press and hold the MODE button a short beep will sound 1b Whilst still holding the MODE button briefly press the TEMPERATURE UP button a short will sound this enters diagnostic mode Steps 1 and 1b need to be completed within 8 seconds 2 Press the TEMPERATURE DOWN button once this enters data download mode A red L E D turns on and should be visible on the display 3 Place the Light Pen over the top of the red L E D until downloading is complete 4 Return to normal operation by pressing the MODE button If additional help or information is required please refer to the instructions provided with the Smart Tool or ask your Technical Representative 6 2 6 Manual Defrost To manually force a defrost the steps are 1a Press and hold the MODE button a short beep will sound 1b Whilst still holding the MODE button briefly press the TEMPERATURE DOWN button a long beep will sound Steps 1a and 1b need to be completed within 8 seconds 2 To check if the fridge is in defrost mode repeat step 1a amp 1b falong beep sounds then the defrost cycle has started 3 To exit manual defrost mo
14. air circulation in both the FC and PC compartments EVAPORATOR Aluminium corrugated type mounted vertically on the back wall of the FC SUCTION amp CAPILLARY LINE Foamed into the back of the cabinet with all joints of the evaporator in the FC POWER CONTROL MODULE Contains the microprocessor that controls all functions of the refrigerator and gathers data from the sensors This module also contains support circuitry to switch the various outputs DISPLAY MODULE Using signals from the Power Module this module generates the L E D display The lamp is also switched via this module REED SENSORS A reed switch encapsulated within a plastic housing mounted on the cross and base rails behind a plastic cover A magnet housed just under the lower end cap of each door activates this sensor when the door is closed LOW AMBIENT HEATER Two types are used type is used in the air duct of models blanket wire type is used in the divider of models 2 SPECIFICATIONS 2 1 Cabinet Specifications DIMENSIONS E521T E522B Height 1695mm 67 8 inches 1695mm 67 8 inches Depth 703mm 28 7 inches 703mm 28 7 inches Width 790mm 31 1 inches 790mm 31 1 inches CAPACITY GROSS VOLUME IN LITRES AS 1430 Provision Compartment 400 litres 14 1 cu ft 360 litres 12 7 cu ft Freezer Compartment 117 litres 4 13 cu ft 160 litres 5 65 cu ft TOTAL 517 litres 18 25 cu ft
15. be 110V mains voltage in the high voltage harness between the power control module and the VCC module inverter This can be checked by removing the rear cover of the VCC module inverter and testing with a multimeter There should be 110V across the spade terminals above the edge connector at the top of the module refer Photo 6 1 5 4 If this is not present check the continuity of the harness from the power control module If there is continuity through the harness replace the power control module 6 1 5 4 2 Signal Circuit With a multimeter that can measure frequency the signal circuit between the power control module and the VCC module inverter can be checked Remove the rear cover of the VCC module inverter and connect the multimeter across the two pins beside the signal harness edge connector When the compressor is meant to be running the frequency should be between 53Hz and 150Hz At start up the frequency will be 75Hz for 2 5 seconds then 53Hz for 27 seconds before changing to 150Hz Multiplying the frequency of the signal circuit by 30 will give the compressor speed so if the frequency is 53Hz the compressor speed will be 1590rpm and if it is 150Hz the compressor speed will be 4500rpm 23 High voltage test point Signal circuit test point 6 1 6 Defrost Heater A heating element is used to defrost the ice accumulated on the evaporator The defrosts are adaptive to the usage and environment and are controlled by the power contr
16. control reduces the current by reducing the speed of the compressor until the overload disappears when the speed will return to the required value If the overload increases the control will continue to decrease the current until the minimum speed of 1590 rpm may be reached at which point the compressor may stall and the control will return to the start up procedure 6 1 5 2 3 Power Limitation Temperature Protection The control limits the power supplied to the compressor to 200 watts to keep all electrical components below a safe operating limit The power is limited in the same way as the current in the overload protection 6 1 5 2 4 Short Circuit Protection In a case where a short circuit occurs eg motor winding damage connection faults etc the same current limiting control is actuated to reduce further damage In the case of a major failure a fuse within the inverter will break the current supplied to the control This fuse cannot be replaced in servicing 6 1 5 3 VCC Module Inverter Identification The module inverter has an identification label giving the following information Voltage 11 115 127V Inverter Version 24 220 240V Electronic board version VCC3 11 56 Stand alone version box Cable configeration 50 60 Hz Attached version box 6 1 5 4 Fault Finding 6 1 5 4 1 High Voltage Power Supply Circuit Whenever power is supplied to the refrigerator there should always
17. ease the back panel away from the cabinet slightly before pressure testing the internal pipework This will prevent a pressure build up within the cabinet should any leak be found internally in the foam insulation Such a leak could pressurise and damage the cabinet liner The back panel condenser comes as part of the back panel and should always be replaced as a complete assembly if the back panel is ever removed SINGLE EVAPORATOR TWIN FAN SYSTEM MULLIGN HEATER RIGHT HAND SIDE CONDENSER BASE PANEL BACK TUBE PANEL 1 CONDENSER Tum TE COMPRESSOR Diagram 5 4 2A 16 CONDENSER LAY OUT 680 790 T MODELS CONDENSER WITH TUBE CROSS RAIL UNIT UNIT COMPARTMENT COMPARTMENT BRAZED JOINT FLOW DIRECTION BRAZED JOINT FROM BACK PANEL CONDENSER BACK PANEL CIRCUIT REMOVED FOR CLARITY ALL BRAZED CONDENSER JOINTS ARE EXTERNAL IN UNIT COMPARTMENT Diagram 5 4 2B CONDENSER LAY OUT 680 790 B MODELS CONDENSER WITH TUBE CROSS RAIL UNIT UNIT COMPARTMENT COMPARTMENT DIRECTION BRAZED JOINT FROM BACK PANEL CONDENSER ALL BRAZED CONDENSER JOINTS ARE EXTERNAL IN UNIT COMPARTMENT Diagram 5 4 2C 5 4 3 Cross Rail The cross rail contains part of the condenser cop
18. module needs to know whether it is fitted into a B or model upon installation because it performs different functions when either the PC or FC doors are opened To do this we need to initialise the power control module To initialise the power control module the service technician must have the FC door closed and the PC door open then press any of the buttons on the user interface in the PC The power control module then knows that the reed switch that is open circuit is controlled by the PC door and the one that is closed circuit is controlled by the FC door If the power control module is not initialised as may be the situation for a new service module the lights will not turn on and the fans will run with the door open If the operator presses a button with both doors opened the illegal raspberry audible feedback will sound indicating that the module is unable to be initialised 7 2 PC Sensor Replacement 1 Unplug the refrigerator from the power supply 2 Remove all PC shelving 3 Remove bottom PC air duct cover 4 Remove polystyrene duct cover insulation 5 Disconnect low ambient heater T model only 6 Remove 1 screw from top duct cover and unclip T model only 7 Remove PC sensor from its location 8 Replacement of the new sensor is done by cutting the wiring back from the sensor end and soldering in a new sensor making sure both connecting wires are not shorting but are insulated with heat shrink
19. self test Primary Action Replace power control module Display Code 2 Reason The previous 2 defrosts were aborted after 30 minutes Primary Action Check defrost heater assembly in the FC If faulty replace Secondary Action Check power module is supplying 230V to heater during defrost If not replace power module Display Code 3 Reason The resistance of all the temperature sensors is outside the normal range 45K Ohms Primary Action Check the 6 way RAST connector at the power module Secondary Action Re terminate the 6 way RAST connector Tertiary Action Replace the power module 28 Display Code 4 Reason Primary Action Secondary Action Tertiary Action Display Code 5 Reason Primary Action Secondary Action Display Code 6 Reason Primary Action Secondary Action Display Code 7 Reason Primary Action Secondary Action Display Code 8 Reason Primary Action Secondary Action Display Code 9 Reason Primary Action Secondary Action Display Code 10 Reason Primary Action Secondary Action Display Code 11 Reason Primary Action Secondary Action Tertiary Action Display Code 12 Reason Primary Action Secondary Action Tertiary Action Display Code 13 Reason Primary Action Secondary Action The resistance of all the temperature sensors is outside the normal range 660 Ohms Check the 6 way RAST connector at the power module
20. sensors are used for temperature measurement therefore once the temperature of the refrigerator has reached its set temperature the power control module will turn the compressor off Their electrical resistance changes as the temperature changes table below lists some typical resistance values The temperature can be read using Diagnostic Mode as described in the next section Diagram 6 1 11 THERMISTOR SENSOR RESISTANCE TABLE TEMPERATURE RESISTANCE 5 27 6 2 Fault Finding Procedure 6 2 1 Fault Code Display Status If fault should develop in the temperature measurement system defrost system fans or low ambient heater a fault code will be shown automatically on the display and the fault audio alarm will sound At the same time the bottom L E D will flash red alternately with the fault L E D s When any control button is pressed the audio alarm is turned off although the display will continue to be flashed instead of the normal back lit display The refrigerator goes through a sequence of tests whenever it is turned on at the power supply or whenever the door is closed while it is on It takes 20 seconds to complete the test sequence and opening a door will interrupt it If for example there is a fault with the fans low ambient heater connector at the power module it may be unplugged and a door is opened as soon as the fault audio alarm sounds the fault code shown will be code 13
21. set Yes 10 3 temperatures resistances refer Section 6 1 11 Check for loss of gas leak or blockage 57 10 12 Compressor Will Not Run And Is Hot To Touch Has the System gone into defrost mode Yes No emove FC coveh Is there a full frost pattern on the evaporator Yes Check compressor and system for leaks blockages and repair as required Is current being drawn by defrost element Yes When defrost sensor reaches 8 degrees 46 degrees F the compressor will start 10 13 Compressor Electrical Tests Are compressor winding resistances OK Are electrical connections to compressor OK Yes Replace compressor module inverter Refit replacement electronic module inverter Refit original electronic module inverter Substiute electronic Substitute power control module Problem solved 10 14 Refrigeration System Faults Should the compressor be running Check defrost and cycle temperatures Wait until refrigerator completes defrost cycle Yes Adjust settings Advise customer Are the compartment temperatures set correctly product OK Yes Remove FC cover Is there a full frost pattern on the evaporator Check temperatures No Check compressor Is there power to and system for the compressor Refer Section 6 1 5 4 Yes leaks bloc
22. sleeving 9 Refit in reverse order 7 3 FC Sensor Replacement Unplug the refrigerator from the power supply Prise out the fan shroud using a flat blade screwdriver at the bottom of the grill cover Remove the FC fan motor plug connection Unclip the FC sensor and remove the evaporator coil cover Replacement of the new sensor is done by cutting the wiring back from the sensor end and soldering in a new sensor making sure both connecting wires are not shorting but are insulated with heat shrink sleeving 6 Refit in reverse order 35 7 PC Fan Motor Model Unplug the refrigerator from the power supply Remove all PC shelving Remove bottom PC air duct cover Remove polystyrene duct cover insulation Disconnect low ambient heater Remove 1 screw from top duct cover and unclip Unplug PC fan motor plug Withdraw downwards Refit in reverse order Note When refitting the fan motor the back of the fan motor faces downwards Ensure there is a loop in the wiring harness between the fan motor and its housing 7 5 PC Fan Motor Models 1 Unplug the refrigerator from the power supply 2 Remove all PC shelving 3 Remove the duct grill in the PC 4 Remove the PC duct cover and polystyrene insulation 5 Using 2 fingers withdraw the fan motor upwards It is mounted horizontally in the divider partition 6 With the motor out this wi
23. 00 rpm inclusive On the Fisher amp Paykel product we operate the compressor at a select number of different speeds between 1590 and 4500 rpm to reduce the variation in sound produced by the compressor An electronic module inverter connected between the power control module and the compressor controls the speed Refer Photo 6 1 5 1 This it does by supplying a modulated DC 3 phase supply to the compressor Warning Permanent damage will occur if the compressor is directly connected to the AC supply line The power control module monitors amongst other things the refrigerator compartment temperatures via thermistors and the defrost cycle and from this information sends signals to the electronic module inverter to determine compressor speeds Whenever the compressor starts it is run at 2200 rpm for 2 5 seconds to establish lubrication and is then run at 1590 rpm for a further 27 seconds before changing to any other higher speed as requested by the power control module This is to provide a softer start before the compressor potentially ramps up to some higher speed Whenever the fridge is plugged in turned on and or after a defrost in the first cooling cycle the control will run the compressor after its initial start procedure at its maximum speed which is 4500 rpm The compressor will stay at its maximum speed until both compartments have reached their cut out temperature at which point the compressor will switch off and the refrigerator
24. E Elegence Inox Iridium 4 Door Hinging L Left Hand R Right Hand 5 Freezer Location B Bottom T Top 6 Litreage of Cabinet Approximate total capacity 7 Type of System E Electronic N No Frost C Cyclic 2 3 Serial Number Identification The serial number consists of three letters and six digits and contains the following information Example Q 123456 Sequential Serial Number Manufacturing Plant Code FISHERPAYKUL Code indicates month of manufacture CUMBERLAND Code indicates year of manufacture Cumberland Code Letter C U M B E R L A N D Year 1 2 3 4 5 6 7 8 9 0 Fisherpaykul Code Letter F 5 K U L Month 1 2 3 4 5 6 7 8 9 10 11 12 Manufacturing Plant Code A Laundry Australia F Refrigeration New Zealand M Range amp Dishwasher N Laundry New Zealand Q Refrigeration Australia In the example above the appliance was manufactured in the second month of the fourth year 2004 at the New Zealand Refrigeration plant 3 SERVICING REQUIREMENTS 3 1 Interface Pen Mk 2 Used to retrieve and download data from the electronic control module when used in conjunction with the Fisher amp Paykel Smart Tool diagnostic program on a laptop computer The part number of the interface pen is 425930 3 2 Health amp Safety 3 2 1 Good Work Practices 1 Take care while removing all plastic components especially when cold 2 Leave the product clean a
25. Fisher amp Paykel appliances Service Manual 790 ACTIVE SMART REFRIGERATOR FREEZER 517800 MANUAL 517800 DATE OF ISSUE MAY 2004 The specifications and servicing procedures outlined in this manual are subject to change without notice The latest version is indicated by the reprint date and replaces any earlier editions Fisher amp Paykel Appliances Inc Fisher amp Paykel Appliances Ltd 27 Hubble Irvine Technical Publications California CA92618 PO Box 58 732 Greenmount Auckland USA 78 Springs Road East Tamaki Telephone 949 790 8900 New Zealand Facsimile 949 790 8911 Telephone 09 273 0600 Facsimile 09 273 0656 COPYRIGHT FISHER amp PAYKEL LTD 2004 2 1 2 2 2 3 3 1 3 2 4 1 4 2 4 3 5 1 5 2 5 3 5 4 CONTENTS TERMINOLOGY oeste oi het ette epis DERE Eod o e plam 6 SPECIEICATIORNS entem coe ecce Ret e etc tectae cene 7 Cabinet Specifications operi rH RR ERR 7 Model Number 8 Serial Number Identification 8 SERVICINGAREQUIREMENT S dica na 9 Int rface Pen inm e tue tie abit areae etait 9 Health amp Satety eot entes egt tb eed tede emt ecd 9 3 2 1 Good Work ese deeb tated Eee miae 9 3 2 2 En
26. S Power control module no Check harness and plugs 5 way display module power harness at both ends lnitialize cabinet RASPBERRY NOISE Power control module not Initialise power control module close FC door and push initialized any button on display module If raspberry noise still made check door switches NOISY FAN PC Wires touching Tuck wires away from fan blade Faulty fan Fit replacement NOISY FAN FC Ice on cover Clear ice off cover and check doors are sealing Ice on grill Clear ice off grill and check doors are sealing Fan off mountings Refit Wires touching Tuck wires away from fan blade Capillary touching Shift capillary from fan area make sure it is not touching any part of the cabinet Fan motor noisy Fit replacement Wires too tight route wiring ICE BUILD UP IN Doors sealing Check gaskets sealing adjust gaskets COMPARTMENT Check fans are operating REFRIGERATION NOISE Popping farting Evacuate recharge with ISCEON 49 check alignment of capillary Gurgling whistling Check alignment of capillary and apply sound dampening tape 47 10 10 1 Refer to Section 6 2 1 Repair or replace faulty components With FC door closed and PC door open press Mode button Is there 12V DC between the power control module and the display module Replace power control module Yes Is there power to the refrigerator
27. Seal with foam tape on duct divider spigot Ensure tip of sensor not against duct Check for mechanical obstruction Check power to plug Check polarity Check for broken wires Replace fan Check power to plug Check for broken wires Check polarity Replace fan Check run percentage if high check evaporator Check fully flooded evaporator check for leak Check calibration of sensor ice point using interface binary or refer to thermistor resistance table in service manual Check power to plug Check polarity Check for broken wires Check fan is not jammed with ice or anything else Replace fan Fan hub to be facing FC refit De ice duct area behind chassis Check PC duct insulation for good seal in return duct Check doors are sealing Defrost evaporator chassis Check for door seal Check defrost element check continuity Check door seal door left open Does cabinet run If not check power supplies If yes check refrigeration system If running check for live frost fully flooded evaporator If not check for leak Is there a 12Volt supply PC light working If yes check fan connection s at fan end also at power module end of the harness If no check for power control module failure Are lamp interface L E D s working If not check display module connection If OK is compressor running If not replace power module Check set temperature Sensor clipped and located in correct position Check calibration of sensor ice
28. age and environment NOTE The defrost cycle will not start if the defrost sensor is above 8 46 the defrost cycle follows a predefined sequence There is a delay of 2 minutes before the element starts to heat commonly known as evaporator warm up time The defrost element will remain on until the defrost sensor has reached 8 C 46 F The compressor will remain off for a further 4 minutes commonly known as drip time The compressor will restart and a further 30 seconds later both fans will restart The following table outlines the defrost cycle of an Active Smart refrigerator NOTE THAT THE DEFROST INTERVAL TIME BETWEEN DEFROSTS 1 CALCULATED FROM THE RUN OF THE COMPRESSOR NUMBER OF DOOR COUNTS AND THE LAST DEFROST TIME COMPRESSOR DEFROST ELEMENT DEFROST ELEMENT COMPRESSOR BOTH FC AND PC TURNS OFF TURNS ON TURNS OFF TURNS ON FANS TURN ON IF 30 MINUTES HAS ELAPSED DEFROST WILL BE ABORTED IF DEFROST SENSOR HAS NOT 2DEFROSTS FAULT CODE 2 So DISPLAYED Diagram 5 2 13 5 3 The Refrigeration Circuit The compressor discharges high pressure high temperature gas into the back panel condenser circuit first and then into the right hand side condenser in the cabinet by way of the base tube This tube runs from the compressor compartment forward to the front bottom edge of the cabinet returning down the left hand side to be connected to the left hand side condenser coil A loop from this condenser coil fo
29. at the power supply 33 6 2 8 Special Option Mode Israel The Active Smart refrigerator is fitted with a special option mode should the customer wish to disconnect the operation of the interior lights and the alarm To enter this mode the customer is required to push and hold the compartment select MODE button on the display board for 10 seconds When the cabinet is in this special option mode the following will not operate The interior light will not turn on when the PC door is opened There will be no set temperature lights L E D s displayed the display module The door alarm will be disconnected and will not sound even if the doors were to be left open The customer may exit this mode at anytime by pushing and holding the compartment select MODE button for 10 seconds Note When in the special option mode the Active Smart will operate as normal without the above being used In normal operation the set temperature L E D s and interior light will be seen when the PC door is opened 6 3 Door Gasket Integral The door gasket is able to be replaced as a separate part All replacement doors are supplied minus the door gasket The door gasket is a replaceable part of the door It is held in place against the door liner by means of a moulding which locks the gasket in place once pushed into it There are no screws or retainers to remove or fit To Remove the Gasket Pull on any section of the gasket to pull it away fr
30. atures correct Is Smart Tool download available Yes No Are contents of PC frozen No 52 Repair or replace faulty components Advise customer temperatures are OK Yes Are actual temperatures correct Check for blockages in air duct ice etc 10 6 Ice Condensation Forming Are the door gaskets Repair or replace sealing faulty components correctly Yes Does frost pattern on evaporator indicate heavy usage Is Smart Tool data available No Yes No Yes Explain to customer that Check that drain is some ice condensation is usage T not blocked normal in heavy usage situations Yes 53 10 7 No Light With FC door Has product closed and PC been initialised door open press Mode button Yes Replace faulty Check is light bulb OK component u Yes Are all connections OK No Repair Yes Refer to Section 9 8 OK Repair replace faulty component Yes Replace power control module 54 10 8 Door Switch Not Operating Switch product off and then on at power outlet to remove from any special modes Place diagnostics If available a Smart Tool data into input output download will verify door switch mode Refer failures by very high door open Section 6 2 4 counts V actual openings Does FC door L E D switch on amp off as FC door is opened and closed
31. cle to give 4 1 watts of heat This is achieved by the use of pulse width modulation PWM The heater is situated in the air duct of the T models and in the divider partition on B models The purpose of the element is to warm the area if the ambient becomes too low The element is on when the cabinet cycles off The low ambient heater operates during both the compressor on and off cycles when the percentage of compressor run time averaged over the previous four cycles drops below 65 switches off when the percentage run time increases to above 7096 The heater will always be switched off during the defrost cycle and whenever the PC door is open There may be less than 4 cycles in the calculation if a defrost has occurred or there were long cycle times MODEL a Sc LOW AMBIENT HEATER ow ambient heater location replacement part only MODEL Production DIVIDER Diagram 6 1 8 25 6 1 9 PC FC Fans There are two 12 Volt DC electrically commutated motor ECM fans They provide the required cooling power to both compartments The motors are provided with from 1896 to 10096 voltage by using a pulse width modulating PWM technique The power control module controls the switching on and off of the compressor and the fans The speed of the FC fan is set and the speed of the PC fan is regulated by altering the voltage supplied to it The FC fan will always runs at a constant speed
32. d door opening and other fault conditions 1 If the door is left open longer than 90 seconds the alarm will sound This will repeat every 30 seconds until the door is closed 2 If the doors are left open longer than 5 minutes the alarm will sound continuously and the PC light will turn off The alarm will stop with the closing of the door 3 All electronic faults when detected will sound the alarm and the L E D s on the display module will flash indicating the fault code The pressing of any button will cancel the alarm but the fault code will remain until the cabinet has been serviced 20 STAGE 4 2 POWER CONTROL MODULE Diagram 6 1 2 6 1 3 Display Module This module contains the user interface and also the circuitry to drive the lamp It is controlled via a 5 wire communications interface from the power control module The user interface of push button switches and Light Emitting Diode L E D display on the display module printed circuit board is used to input and display the required set temperatures for the refrigerator compartments The user interface is positioned at the rear of the provision compartment PC The interface automatically displays the current temperature setting for the PC compartment This is shown as a series of L E D lights on a thermometer symbol To adjust the temperature of the PC simply press the temperature up or down buttons to the appropriate setting Press the mode button on the left hand
33. de turn the refrigerator off at the power supply and then while pressing the MODE button switch the refrigerator on again at the power supply If this is not done the refrigerator will automatically exit from the manual defrost mode when the defrost is completed NOTE The defrost cycle will not start if the defrost sensor is above 8 C 46 F defrost cycle follows a predefined sequence There is a delay of 2 minutes before the element starts to heat commonly known as evaporator warm up time The defrost element will remain on until the defrost sensor has reached 8 46 F or until 30 minutes has elapsed if the defrost sensor does not reach 8 C 46 F The compressor will remain off for a further 4 minutes commonly known as drip time The compressor will restart and a further 30 seconds later both fans will restart 6 2 7 Show Room Mode Go into diagnostic mode press MODE and TEMPERATURE UP buttons together then hold the TEMPERATURE UP button only for 3 seconds The Show Room Mode will be entered which turns off the normal system control leaving only the PC light operating with no door alarms There will be a long beep and while the doors are opened the L E D display will go through an attention grabbing sequence unless buttons are pressed at which time the display will respond as normal 8 seconds after the last button press the display sequence will continue The mode may be exited by switching off the appliance
34. der around the joint area remove the iron and allow the joint to cool 15 The same applies for the capillary applying more heat to the transition joint as it is heavier in material than the capillary 16 Pressure test both joints 17 Fit heat shrink sleeving over the joint and heat having placed damp rags around the area of the ABS liner as heating the heat shrink can cause the liner to be overheated It is also important to keep the thermal fuse in the element circuit away from the heat gun as heat from the heat gun can cause the thermal fuse to go open circuit Note The solder used to solder these FC joints is a special solder containing 5 antimony and 95 tin and is supplied with the evaporator kit Also the solder contains a special flux as a resin core in itself No other type of solder should ever be used 38 7 15 Removal Of The FC Evaporator Cover Fan cover Removal Tool T models only The following illustration shows a tool that can be made in your workshop This tool can be used to release and remove the freezer compartment fan cover in the Active Smart T model refrigerators If preferred the tool can be made from a screwdriver with a shaft length of approximately 200mm 7 to 8 inches long and 4 5 mm 74 inch diameter B models are removed by grasping the bottom of the evaporator cover and pulling up and forward LOCATION CLIPS d LEVER DOWN amp EASE COVER FORWARD TO RELEASE LOCATION LOCK CLIPS
35. down in this manner you will see the power cord entering the cabinet at the bottom and the discharge and suction pipes on the compressor uppermost Refer diagram Note Tape Door Closed Discharge ie suction pipes Back of Cabine D Series Process pipe EE es MER This side down Power Cord Diagram 7 17A Note We mark all our refrigerator and freezer cartons with a number of stars on one side of the carton If the product is to be laid on its side for transporting at any time the side of the carton with stars on should face upwards see diagram If transporting a cabinet that has been used be sure to empty the water evaporator tray prior to laying the cabinet down as water from the water evaporator tray can enter the electronic power module which is attached to the side of the unit compartment Ideally the product should be transported standing upright 4 stars om the face upwards Side of Cabinet dr 1 2 8 CE Ez Top of Cabinet gat 5 Back of Cabinet un Diagram 7 17B 41 WIRING DIAGRAM 8 ON lMyd 884 MM 5 4 NO 5WNIFRIIL IG ON TWNIWNAL 21 3NIT NI XION NNUO SNIT NI X3IUI 5n7d B ISYY Dd SZ ISYY ISYY DOA MOLD r2 a NELLO C LANES 1 1
36. e Front and rear rollers are fitted ex factory e Cabinet levelling can be done by adjustment of the front roller levelling wheel fitted ex factory See diagram 4 1B e Weight should be lifted off the cabinet for ease of adjustment The product should be levelled with the majority of the weight on the hinge side front foot The opposite side front foot should then be adjusted to stabilise the product REAR ROLLERS Diagram 4 1A 20000 FRONT ROLLER LEVELLING WHEEL Diagram 4 1B 10 4 2 Air Space Requirements On all refrigerators and freezers it is important that an air gap is left around the product e 2inches clearance at top e 1 inch clearance each side 4 3 Temperature Adjustment Refer DISPLAY MODULE in Section 6 1 3 11 5 THEORY OF OPERATION 5 1 Internal Air Flow The freezer fan draws air through the evaporator and into a duct in the rear wall of the freezer compartment This air exits through the fan grill at the top of the freezer compartment The air behind the freezer coil cover is also diverted through the divider partition to another fan which supplies the cold air into the provision compartment The amount of air is controlled electronically by two sensors which in turn regulate the speed of both PC and FC fans to maintain selected temperatures in each compartment Air from the PC returns to the FC evaporator by way of the return air duct which is built into the divider partition This air is draw
37. e frost fully flooded evaporator If not check for leak Fans not working alarm will Is there a 12Volt supply PC light working sound and fault code will be f yes check fan connection s at fan end also at displayed power control module end of the harness f no check for power control module failure Power control module Are lamp interface L E D s working failure f not check display module connection f OK is compressor running 2 f not replace power control module PC delivery duct blocked De ice area behind chassis FC TOO COLD FC sensor location Check set temperature Sensor clipped and located in correct position Faulty sensor Check calibration of sensor ice point using interface binary or refer to thermistor resistance table in service manual PC faulty fanr Check PC cooling fan running FC TOO WARM No refrigeration Does cabinet run If no check power supplies If yes check refrigeration system If running check for live frost fully flooded evaporator If not check for leak TOTAL CABINET TOO WARM No refrigeration Does cabinet run If no check power supplies If yes check refrigeration system If running check for live frost fully flooded evaporator fnot check for leak Compressor is not running check power control module voltage outputs Check compressor and ancillaries FC COOLING PC WARMING ced up evaporator Check defrost circuit continuity
38. e in the centre of the liner A tube then allows the condensate to flow into a water evaporation tray above the compressor FILTER DRIER From condensor Mesh screen is TU first filter stage This material is highly absorbent to water Diagram 5 4 1 The filter drier or molecular sieve as the name suggests is both a filter and a drier Whenever a system is opened it is essential that the filter drier is replaced ALWAYS ensure that replacement filter driers are kept well sealed and airtight prior to being fitted to a system PLEASE NOTE When filter driers are replaced on systems being serviced it is important that the filter drier is either cut from the system or the desiccant is removed before heat is applied to the old filter drier Failure to do so will drive any moisture held in the desiccant back into the system ALWAYS mount vertically or as near to vertical as possible and use the correct desiccant to suit the refrigerant being used or XH9 suits R134a 5 4 2 Internal Condenser The internal condenser is made in three sections see circuit diagram below One third of the condenser is attached to the back panel and the other parts are attached to the inside of the right and left sides of the cabinet wrapper as viewed from the back all being foamed into place lt is very important if pressure testing the high side circuit to split the condenser into its 3 sections to locate which section is at fault Always
39. e when the appliance is in diagnostic mode 6 2 3 Sensor Temperature Conversion To obtain the temperature of either compartment sensor or defrost sensor 1 Enter the diagnostic mode refer Section 6 2 2 Diagnostic Mode and scroll to the appropriate sensor temperature 2 Add up the binary number indicated by the L E D light pattern refer figure below 3 Subtract 40 from the result to get the temperature 32 dip SS 31 Example Add up the number corresponding to each L E D that is on 5 0 5 4 8 32 44 5 Subtract 40 from the result 44 5 40 4 5 Hence the temperature is 4 5 6 2 4 Input Output Status The Input Output Status menu displays what devices e g light PC door FC door compressor etc are currently running or turned on To enter the menu the steps are 1a Press and hold the MODE button a short beep will sound 1b Whilst still holding the MODE button briefly press the TEMPERATURE UP button a short beep will sound this enters diagnostic mode Steps 1a and 1b need to be completed within 8 seconds 2 Press the TEMPERATURE UP button 3 times The respective L E D turns on when a device is running as shown below PC fan on Upper door open AM Low ambient heater on Lower door open Light on Sul FC fan on Defrost heater on V Compressor on 3 Return to normal operation by pressing the MODE button 32 6 2 5 Data Download
40. ea Check PC duct insulation for good seal in return duct Check doors are sealing Check display for any fault code Check defrost element continuity Put cabinet into manual defrost wait for defrost relay to click on 2 minutes after pressing buttons If no click check power control module If click heard check the defrost heater 110v output at the power control module Check console for fault codes 0 5 Sensors above or below limit refer thermistor service table in service manual Check that no fault code is shown on the display Check that PC FC doors activate reed switches Check also reed switches with magnet Check wiring harness to power control module FAULT DISPLAYED NO ALARM LIGHT NOT FUNCTIONING CONSOLE NO L E D LIGHTS Display flashing fault code but no alarm sounding Blown bulb Cabinet type Poor connection Power control module no power Power control module not initialized 44 Alarm has been switched off by user Piezo alarm faulty replace power control module Check power supply to socket 7Volts if nil check plug at display module Check continuity of bulb if nil replace Power console module not initialised close FC door and press compartment select button Spread halogen bulb legs Check lamp holder replace where possible Check connector on display module Check harness and plugs on 5 way display module harness at both ends Initiate cabinet Initialize power contro
41. er 56 10 10 Compressor Eaults 2 5 eto Enceinte tipo nebula totiens 57 10 11 Compressor Runs ERARAS PAKDE EEEN 57 10 12 Compressor Will Not Run And Is Hot To 58 10 13 Compressor Electrical 1100000 nennen nnne nennen 58 10 14 Reirigeration Systermr Eaults t ie ee 59 1 TERMINOLOGY The following are terms used in this manual MODELS Dual temperature refrigerator freezers in which the freezer compartment is below the refrigerator compartment T MODELS Dual temperature refrigerator freezers in which the freezer compartment is above the refrigerator compartment FC COMPARTMENT Freezer compartment The compartment in a dual temperature refrigerator used for keeping frozen food where the temperature is maintained at approximately 16 3 F PC COMPARTMENT Provision compartment The compartment in a dual temperature refrigerator used for keeping fresh food where the temperature is maintained at approximately 4 C 39 F CABINET WRAPPER Pre painted steel LINER A one piece vacuum formed ABS liner with a plug in divider DIVIDER PARTITION Injected moulding of HIPS with two outer injected moulded housings and an insulated ducted moulded polystyrene inner core FAN MOTORS DC 12 volt brushless variable speed fan motors for
42. f a hose with a Schrader valve depressing key in the hose coupling Step 4 Open the nitrogen bottle fully with the regulator backed off Step 5 Increase the regulator pressure in the circuit being tested to 150 psi Step 6 Close nitrogen bottle valve back off pressure regulator Step 7 Disconnect the hose coupling to the Schrader valve fitting Step 8 Seal the Schrader valve with its sealing cap Step 9 Use a bit of masking tape to mark the face of the pressure gauge at the set pressure Record date and time also Step 10 Check all exposed brazed joints with soap bubbles including the joints on the in line pressure gauge Step 11 Allow pipe circuit under test to sit on drop off test This could take a number of days for a result NOTE In some cases a leak may not be found by pressurising the circuit whereas a vacuum pulled on the same circuit will find it Keep this in mind as oil within the circuit can block a hole In some cases if the brazed joint is warmed while under pressure this can thin the oil and help to expose the leak A heat gun or hair drier is useful 40 7 17 Transporting Of Refrigerators It is preferable to transport the refrigerator in an upright position It is recommended that If a cabinet is to be transported lying down then the cabinet should be placed on the right hand side when standing facing the front of the refrigerator If looking at the back of the refrigerator when it is laid
43. goes into the warm up cycle In the subsequent cooling cycles the algorithm will vary the compressor speed according to the amount of cooling required to achieve an average temperature in each compartment as measured by the thermistors equal to the compartment set temperatures with a 1 hour run time In low ambients where the heat load and or cabinet usage is low the compressor will be likely to run at its minimum speed 1590rpm and switch off more frequently than once every hour similar to most non VCC product When the compressor is running at slow speeds the evaporator may not be fully flooded but this is normal Photo 6 1 5 1 Power control module Variable Capacity Compressor st ue ka ag wis i NOI 32N02 Module inverter 6 1 5 2 Built in Electronic Protections Within the Module Inverter 6 1 5 2 1 Compressor Start up In case any anomaly occurs during compressor starting the control will wait 6 seconds before repeating the start up If the compressor doesn t start after 12 trials the control will wait 8 minutes before repeating the start up procedure this condition may be when pressures are not equalised between suction and discharge sides in the refrigeration system eg after an interruption in the mains supply 6 1 5 2 2 Overload Detection and Protection The control can detect an overload condition by monitoring the current consumed by the compressor overload is detected the
44. han expected Either the heater or wiring is open circuit or the heater is faulty Check wiring and connections at both heater and power module Check ambient heater resistance If not within limits replace 29 Display Code 14 Reason Primary Action Secondary Action Display Code 15 Reason Primary Action Secondary Action Display Code 16 Reason Primary Action Secondary Action Display Code 17 Reason Primary Action Secondary Action Display Code 18 Reason Primary Action Secondary Action Low ambient heater is drawing more current than expected Either there is a short in the heater or wiring or the heater is faulty Check wiring and connections at both heater and power module Check ambient heater resistance If not within limits replace The PC fan is drawing less current than expected Either the wiring is open circuit or the fan is faulty Check PC fan wiring and connections at both fan and power module Check fan If faulty replace The PC fan is drawing more current than expected Either the wiring is shorted or the fan is faulty Check PC fan wiring and connections at both fan and power module Check fan If faulty replace The FC fan is drawing less current than expected Either the wiring is open circuit or the fan is faulty Check FC fan wiring and connections at both fan and power module Check fan If faulty replace The FC fan is drawing more current than expected
45. kage and repair as required No Repair as required 59
46. l module close FC door and push any button on display module If raspberry noise still made check door switches NOISY FAN FC ICE BUILD UP IN COMPARTMENT REFRIGERATION NOISE Ice on cover Ice on grill Fan off mountings Wires touching Capillary touching Fan motor noisy Wires pulled tight Doors sealing Popping farting Gurgling whistling Clear ice off cover and check doors are sealing Clear ice off grill and check doors are sealing Refit Tuck wires away from fan blade Shift capillary from fan area make sure it is not touching any part of the cabinet Fit replacement Re route wiring Check gaskets are sealing adjust gaskets Check fans are operating Evacuate and recharge with ISCEON 49 Check alignment of capillary and apply sound dampening tape 45 9 2 Models PC TOO COLD FC fan not going alarm will Check power to plug sound and fault code will be Check polarity displayed Replace fan Short of gas Check run percentage if high check evaporator Check fully flooded evaporator check for leak PC sensor inaccurate Check calibration of sensor ice point using interface binary or refer to thermistor resistance table in service manual PC TOO WARM Evaporator iced up Check defrost element check continuity Check door seal door left open Norefrigeration Does cabinet run If no check power supplies If yes check refrigeration system If running check for liv
47. ll expose a small multi plug and socket connection to the fan motor and wiring harness Unplug 7 To refit back together fit the wiring harness multi plug first into the pocket of the divider partition 8 Using your 2 fingers slip the motor back into the divider partition to fit horizontally Note The back of the fan motor faces upwards 9 Refit duct covers and test The PC fan is supported by a rubber band type suspension It is important that the fan sits central to the housing and that there is a loop in the fan motor wiring harness between the motor and the housing This loop should be on a horizontal plane to the fan motor This also applies to the FC suspended fan T 6 Cross Base Rail Door Reed Switches 1 Unplug the refrigerator from the power supply 2 Remove the door switch cover located in the center of the cross and base rails 3 Unclip the encapsulated reed switch from the housing 4 Replacement of the new switch is done by cutting the wiring back from the switch end and soldering in a new switch making sure both connecting wires are not shorting but are insulated with heat shrink sleeving Take care not to leave too much excess wire as the reed switch must be able to be fitted back in to the housing 5 Refit in reverse order 7 7 Defrost Heating Element Unplug the refrigerator from the power supply Remove the fan grill cover This unclips with the aid of a small screwdriver Unplug the fan motor and unclip
48. low ambient heater drawing less current than expected This is because the low ambient heater is the first item tested and so the refrigerator will fault for this but carry on with more tests If the doors are left closed until the tests are completed the fault code shown will be code 11 the current measured for the ambient heater PC fan and FC fan is lower than expected It is therefore recommended that if the fault audio alarm sounds as soon as the refrigerator is turned on or as soon as the doors are closed the service technician should wait for 20 seconds before opening the door to check the fault code This will allow the refrigerator to complete the sequence of tests and will ensure that the fault code displayed is the correct one To reset the audio alarm disconnect the refrigerator from the power supply for few seconds If this is not done the audio alarm will automatically reset after 72 hours Fault codes will be in a binary code and the L E D s that flash will have the following binary values LC 64 o 128 A N Temperature Up Mode Button V lt lt Temperature Down To determine the value of the displayed fault code add up the values of the L E D s that are flashing ignore the flashing red L E D The faults and their respective fault code that can be checked and serviced in the field are as follows Display Code 1 Reason On the last power up the power control module failed its
49. n across the evaporator by the evaporator FC fan motor to be recirculated again throughout the PC FC compartments B Model Model Active Smart Active Smart J Lc PC Sensor Tiefrast smir 7 fi Tefros Heater Display Modale t Lamp PC Fan R ed Seine PCSensor k 1 vamp Disptzy Moda ke V ontrol Madule Reed Road leeh Power Control aee Diagram 5 1A Diagram 5 1B 12 5 2 Defrost Cycle A heating element is used to defrost the ice accumulated on the evaporator The defrosts are adaptive to the usage and environment and are controlled by the power control module During a defrost the temperature above the evaporator is sensed by the defrost sensor located on the evaporator chassis This sensor must register 8 C 46 F before terminating the defrost heater element If the sensor does not register a temperature of 8 46 F within 30 minutes of the commencement of the defrost cycle the defrost will be terminated If two successive defrost attempts fail to reach this temperature fault code is displayed refer Section 6 2 1 Previous defrost history the number of door openings and the compressor run time are used to determine the interval between defrosting The typical time interval for defrosts is between 12 and 24 hours However it can be as short as 5 hours or as long as 96 hours depending on the us
50. nd tidy when service work is completed 3 Extreme heat in cabinets will cause plastic deterioration or distortion and thermal fuses in the defrost heater to go open circuit be careful with heat guns 3 2 2 Environmental Health And Safety When servicing products consider safety and health issues and requirements which must be adhered to at all times Specific safety issues are Electrical safety Electrostatic discharge Mixing of foam insulation Vapours while brazing Reclaiming of refrigerant 3 2 3 Good Practice And Safety 1 Take care when removing or servicing any electrical components to avoid electrical shock or short circuit conditions 2 Take care when removing plastic components at low temperatures as breakages can occur with these components Extreme heating of plastic components can cause distortion of those parts being heated Avoid overheating temperature sensitive devices such as the element thermal fuses and cabinet sensors Avoid using solvents citrus based cleaners on all plastic parts We advise only warm soapy water be used 4 INSTALLATION INSTRUCTIONS 4 1 Levelling The word is somewhat of a misnomer as spirit level need not be used to set the appliance level It is preferable to have the appliance level in appearance where both doors will close with the aid of the door closing components It is also important that the appliance sits solidly on the floor
51. ng a fan motor which is housed in the front cover Having determined that the evaporator needs replacing 1 Unplug the refrigerator from the power supply 2 Recover the refrigerant 3 Remove the FC door 4 Remove the evaporator coil cover 5 Clean both suction and capillary pipes with emery cloth 6 With the tube cutter cut the suction pipe as close as possible to the induction brazed joint cutting the suction capillary side of the joint 7 With a file or knife cut the capillary where it enters the transition joint on the evaporator 8 With the element wiring disconnected the evaporator can be removed 9 Take the replacement evaporator and fit it to the carrier fitting the defrost element assembly and the 2 heat shrink sleeving onto the pipes 10 Align the evaporator and joints ready to be soldered into position 11 Lay the product on its back 12 Place a protective covering over the back of the liner to protect it should solder drop onto it while the joint connections are being made 13 Having fitted the suction and capillary lines together with a protective heat shrink sleeving placed on the pipe first away from the heated area heat the J type soldering iron to temperature with the oxy acetylene or LPG This should be cleaned and tinned prior to the soldering operation 14 Hook the iron over the joint area and allow the pipework to heat while applying the solder Once the joint appears to have a full puddle of sol
52. ol module During a defrost the temperature above the evaporator is sensed by the defrost sensor located on the evaporator chassis This sensor must register 8 C 46 F before terminating the defrost heater element Previous defrost history the number of door openings and the compressor percentage run time are used to determine the interval between defrosting The typical time interval for defrosts is between 12 and 24 hours However it can be as short as 5 hours or as long as 96 hours depending on the usage and environment DEFROST ELEMENT Diagram 6 1 6 24 6 1 7 Thermal Fuses There are two thermal fuses mounted in the wiring harness of the defrost element having a tripping temperature of 72 161 F Once open circuit they can not be reset Replacement is part of the element heater assembly These fuses in both leads of the element protect the refrigerator from any over heating through failure of the element itself or a triac failure in the power control module Both sides are protected in case phase and neutral are reversed NOTE Care should be taken if manually defrosting the evaporator i e using heat guns to ensure that the thermal fuses are not over heated 6 1 8 Low Ambient Heater In low ambient temperatures a 12 Volt 7 Watt low power heater is used to keep the temperature in the provision compartment above freezing The ambient heater is controlled by the power control module which runs the heater at 58 duty cy
53. om the moulding To Replace the Gasket Having removed the old gasket lay the new gasket around the door gasket moulding First fit all corners then push the remaining gasket into place around the door PRESS DOWN V Uers Vow RETAINER ASSEMBLED Diagram 6 3 34 7 REMOVING AND REFITTING OF COMPONENTS T 1 Removal Of Power Control Module Located in the unit compartment on the right hand side and held in place by 2 self tapping screws 1 Unplug the refrigerator from the power supply 2 Remove both mounting screws and earth screw on the green yellow earth wire on the compressor mounting tray 3 Pull the power control module outwards to disengage the mounting lugs at the back of the module 4 Remove all connectors along the top edge of the power control module 5 Remove the defrost connector brown wires and the VCC high voltage supply connector which is connected to the terminals marked H Rail on the side of the power control module 6 Refit in reverse order Note It is important that the power control module is clipped securely to the side of the unit compartment and the copper earth spring clip is not damaged as this maintains good earthing and provides a low inductance path to the chassis for RF voltage Check that the flat pins at the back of the module are properly engaged with the lugs on the unit compartment when refitting Initialisation Of The Power Control Module After Installation The power control
54. per tubing mullion heater providing heat to the gasket area between the PC and FC compartments preventing sweating of the gasket Also mounted on the cross rail is the Reed Sensor under the plastic cover in the centre 5 4 4 Divider Partition This is moulded in two outer pieces and has an inner polystyrene moulded duct assembly that is wax coated This provides a barrier between the FC and PC compartments also allowing return air from the PC to move back to the FC evaporator in T models In both models it houses the PC fan motor The divider is fitted into the cabinet as an assembly and cannot be replaced DIVIDER PARTITION Diagram 5 4 4 19 6 ELECTRONICS SECTION 6 1 Overview Function Description The electronic system consists of several parts Power control module display module compressor defrost heater ambient heater provision compartment fan freezer compartment fan light temperature sensors and door sensors The purpose of the power control module is to turn on the compressor which cools the evaporator then to use the fans to efficiently cool the compartments Both fans turn on with the compressor The freezer compartment FC fan is kept at a constant speed while the provision compartment PC fan is regulated to provide the balanced cooling for both compartments The function of the microprocessor in the power control module is to provide independence of both compartments to their set temperatures al
55. point using interface binary or refer to thermistor resistance table in service manual Check PC cooling fan running FC TOO WARM Total Compartment Warm Iced up evaporator Norefrigeration Check defrost element is working alarm will sound and fault code will be displayed if faulty replace if faulty Check doors are sealing or have they been left open adjust and advise customer FC fan jammed clear restriction replace fan if necessary Check defrost sensor position reposition onto chassis if not already there Does cabinet run If no check power supplies If yes check refrigeration system If running check for live frost fully flooded evaporator if not check for leak TOTAL CABINET TOO WARM FC COOLING PC WARMING ALARM ON Norefrigeration Iced up evaporator Iced up return duct Defrost heater Sensors alarm will sound and fault code will be displayed Door switch fault Does cabinet run If no check power supplies If yes check refrigeration system If running check for live frost fully flooded evaporator If not check for leak Compressor is not running check power control module voltage outputs Check compressor and ancillaries Check reed switches are working OK by entering the Input Output mode refer to Section 6 2 4 and placing a magnet over the reed switch Check defrost circuit continuity Doors sealing adjust PC fan is running if not refer PC too warm De ice duct ar
56. rms the cross rail mullion on dual temperature cabinets The condenser then continues across the top front edge of the cabinet to form the right hand side condenser before entering the filter drier which is mounted vertically in the unit compartment Now the high pressure gas has been condensed the liquid refrigerant flows through the capillary tube entering the evaporator mounted in the freezer compartment The liquid refrigerant then boils off due to the low suction pressure applied to within the evaporator from the compressor The heat laden vapour is drawn back to the compressor by way of the suction line to start the cycle all over again The above information relates to the cabinet not the drawing below SINGLE EVAPORATOR TWIN FAN SYSTEM CROSS RAIL MULLION HEATER H RM D gt LEFT HAND SIDE INDEPENDENTLY AA ROLLED CONDENSER aw FRU PPOR ENS H Mam 1 BASE PANEL PACK TUBE PANEL CONDENSER L Eu udi ee COMPRESSOR Diagram 5 3 14 5 4 Servicing Features 5 4 1 Condensate Disposal During the defrost cycle which is electronically timed and controlled live frost is melted off the evaporator by means of heat from the defrost element Condensate from the evaporator defrosting drops into a collection trough which has an outlet hol
57. side of the interface to select the FC compartment The indicator light will flash for 8 seconds to show a new compartment has been selected Press the up or down buttons to adjust the temperature as necessary Further presses of the mode button will toggle between the PC and FC compartments DISPLAY MODULE Stage 4 2 Diagram 6 1 3 6 1 4 Door Switches Reed switches are used to detect the opening and closing of the doors Two small magnets that are built into the PC and FC doors activate them The reed switches are encapsulated within a plastic housing which is clipped under the plastic covers on the base and cross rails 21 6 1 5 Compressor The compressor is turned on when cooling is required It is switched by the power control module sending a low voltage frequency signal to the inverter The refrigerator is fitted with a variable capacity compressor VCC This improves energy efficiency and maintains a more stable temperature in both the provision compartment and the freezer compartment The compressor windings are wired in a 3 phase star formation with the resistance between any two pins being the same 6 4 ohms 6 1 5 1 Variable Capacity Compressor Control Overview The V4 2 power control module on VCC product is identical to that on non VCC product The stage 4 2 power control module senses if it is connected to a VCC compressor and uses the appropriate algorithm The compressor can operate at speeds between 1590 and 45
58. the evaporator sensor Remove the evaporator cover Lift the evaporator upwards to clear the bottom of the divider partition and pull the bottom edge of the evaporator forward Remove the cable ties from the thermal fuses Bend the first half of the evaporator clips and side deflectors away from the front bank of the evaporator on both sides 8 Drop the element down and out of the evaporator bank 9 Refit in reverse order Oo RON 36 7 9 Removal Of Display Module Unplug the refrigerator from the power supply Remove all PC shelving Remove bottom PC air duct cover Remove polystyrene duct cover insulation Disconnect low ambient heater T model only Remove 1 screw from top duct cover and unclip T model only Compress clips on display module and release it from the top duct cover Unplug the 5 and 3 way edge connectors from the display module Refit in reverse order Thermal Fuse This is part of the element assembly and is to be replaced as part of the defrost heater element assembly Having a tripping temperature of 72 162 F they are not resettable 7 10 Replacement Of Interior Lamp Unplug the refrigerator from the power supply Remove the lens cover with the aid of a small flat bladed screwdriver Remove the faulty lamp With the protective wrapper still covering the new lamp fit it into the holder Cu
59. though the environment of one compartment effects the other as they are linked by the ducts as can seen by the diagrams showing internal air flow of the cabinet diagrams 5 1A and 5 1B 6 1 1 Control amp Peripheral Functions The control system consists of the power control module located in the unit compartment of the refrigerator the slave display module located in the back of the refrigerator compartment and various sensors and actuators controlled by the power module The function and brief description of each of these units is defined below 6 1 2 Power Control Module This module is the electronic brain and control centre of the refrigerator It contains a microprocessor support circuitry and switching devices The power control module controls the Provision Compartment PC and Freezer Compartment FC temperatures by sensing the temperature and door state and operating the compressor and fans accordingly This module also houses the alarm beeper The power control module collects information on the refrigerator operation Faults and diagnostic information is stored in its memory They include the temperature setting the history of FC and PC temperatures approx 18 hours defrost history the last 12 defrosts and fault history This will help the service technician find and remedy the cause of failure All this memory will be retained even when the fridge is disconnected from mains power supply The beeper is used to signal prolonge
60. tthe wrapper from the lamp Avoid handling of the new lamp as this will shorten the life of the new lamp Refit the lens cover and test NB Only a 12 volt 10 watt halogen lamp should be fitted It is important that the lamp terminal is tight in the lamp socket Diagram 7 10 7 11 Replacement Of Low Ambient Heater T Model Unplug the refrigerator from the power supply Remove all PC shelving Remove bottom PC air duct cover Remove polystyrene duct cover insulation Disconnect low ambient heater Refit in reverse order 37 7 12 Replacement Of Low Ambient Heater Model This element is mounted in the floor of the divider and is not replaceable If it should be found to be open circuit a replacement low ambient heater can be fitted to the return air grill 7 13 Replacement Of Low Ambient Heater Model In Return Air Grill This element is mounted in the return grill of the divider It is of the blanket wire type on an aluminium tape stuck to the grill itself Unplug the refrigerator from the power supply Remove all the PC shelving and crisper bins Remove the PC duct cover Remove the PC air return grill and unplug the element from the harness Peel off the old element and replace with the new Refit in reverse order DARON 7 14 Evaporator Replacement The evaporator is located in the FC compartment mounted on the back wall on its own carrier with a grill coveri
61. vailable No Yes Yes Advise customer temperatures OK Is there excessive ice on FC cover or evaporator Are there any signs that FC amp PC temperatures fan speeds or defrosts are not OK Refer to Section Yes Yes 10 6 No No Using an external sensor Advise customer Is the defrost are the temperatures refrigerator working sensor Repair relocate of contents of PC OK located amp FC OK correctly No Is defrost heater installed correctly or drain iced blocked Repair clear blockage etc Yes 50 10 4 FC Too Cold PC Too Warm Does the 7 Yes Refer to Section Repair or replace indicate a 6 2 1 faulty components fault code No Are temperature settings correct Adjust temperature settings Clear ice amp check Advise customer for causes product OK Yes Yes Do download Is Smart Tool Air ducts temperatures and download actual contents blocked with available ice temperatures match Are sensors and covers installed correctly Install components correctly sealing Check door gasket sealing is OK Yes any air leaks 51 10 5 PC Too Cold Does the display module indicate a fault code Refer to Section No Are temperature settings correct Adjust temperature settings No Advise customer product OK Yes Are recorded temper
62. vironmental Health And 9 3 2 3 Good PracticeArid Satety ide ordeo teste b tete edi ter teet reae einn 9 INSTALEATION INSTRUGTIGONS 221 rp 10 Levelling tae WO 10 Air Space Requirements nei ie eget 11 Temperature a ican eet iet tete ete leto 11 X 12 Air ete du 12 Bros 13 The Retrigeratlon Gircuit iicet ree eta reser dod deed pretia eges 14 oervicirig Features coco UD ER nt ected ad bo oct nit ted 15 5 4 1 Gondernsate DISposSal estesa eene dee abd aequi boues 15 5 4 2 Internal Condenser 16 5 4 3 Cross 19 5 4 4 Divider Partition nen a Paci 19 ELECTRONICS SECTION 222 002 3 20 Overview Function Desctlptlon 20 6 1 1 Control amp Peripheral 20 6 1 2 Power Control 20 6 1 3 Display ero 21 6 1 4 21 6 1 5
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