Service Manual REFRIGERATED BACK COUNTER
Contents
1. Do set unit on a curb or seal to the wall Do block the slots in the front kickplate e Operate equipment only on the type of electricity indicated on the specification plate e Retain this manual for future reference in Service Manual for Refrigerated Back Counter RBC 48 60 CONTENTS INTROUC TION e 4 lxmeleec 4 INSTALLATION EE 4 MOC AUIOM 54 ET 4 Iside S o 4 Outside Unit occ ecccccccccceceseeeseeceeeceecseeeeeeceeeeeeseeseseeegeceeeesesaeaeseseceeeeeesseeeeseeceeeeeeesesaesaeseeeseeees 4 Kg se tec cca ac E 4 Eee 4 Electrical Connection 4 5 MAIN TIENANG Etanol mean 6 STAINLESS STEEL CARE AND CLEANING 6 PREVENTIVE MAINTENANCEE enhn gait nin nass sana serrer ens 6 Cleaning the Condenser CON rr 6 Gasket Maintenarce crscs ssccceswasarsenancedeassaswsanssaerenedsasentareschatnetGvasswdadestcemegeetaesearseasanewtaseuaetances 7 Drain Maintenance Base 4 7 PARTS REPEAGEMENT 8 e a ak aking detta 8 EVAPORATOR FANS 4 8 REFRIGERATION SYSTEM UNIT REPLACEMENT 9 DOOR REPLACEMENT AND ADJUSTMENT pp 9 DOOR GASKET REPLACEMENT rrrnnnnnnnnnnnvrnnnnnnnnnnnrnnenrnrnnnnsnsnsnnennnrnnnnana2. 10 Greendale Business Park Woodbury Salterton Exeter Devon UK EX5 1EW Tel 01395 234140 FAX 01395 234154 Asia Office Duke Food Service Equipment shanghai Company Limited 1F Building 17 2 658 Nong Jin Zhong Road Shanghai China 200335 Tel 86 21 6876 9272 Fax 86 21 33600628 16 PN 219211
3. amount of debris dust or grease that has accumulated prior to the 60 day time frame In these cases the condenser coil should be cleaned every 30 days Condenser Coil is located behind the filler pane Figure 3 Location of Filter and Condensing Coil iii Service Manual for Refrigerated Back Counter RBC 48 60 If the build up on the coil consists of only light dust and debris the condenser coil can be cleaned with a simple brush heavier dust build up may require a vacuum or even compressed air to blow through the condenser coil If heavy grease is present there are de greasing agents available for refrigeration use and specifically for the condenser coils The condenser coil may require a spray with the de greasing agent and then blown through with compressed air Failure to maintain a clean condenser coil can initially cause high temperatures and excessive run times continuous operation with dirty or clogged condenser coils can result in compressor failures Neglecting the condenser coil cleaning procedures will void any warranties associated with the compressor or costto replace the compressor CAUTION Never use a high pressure water wash for this cleaning procedure AN as water can damage the electrical components located near or at the condenser coil Gasket Maintenance Gaskets require regular cleaning to prevent mold and mildew build up and also to keep the elasticity of the gasket Gasket cleaning can be done
4. the temporary valve and again 2 below the crimp just made Leaving the crimp tool in place remove the temporary valve braze shut the end of the process tube allow to cool approximately 5 minutes time remove the crimp tool and leak check the brazed end Mi Service Manual for Refrigerated Back Counter RBC 48 60 TROUBLESHOOTING SYMPTOM CAUSE REMEDY Cabinet too warm Unit not plugged in Plug unit in Thermostat set too warm Set thermostat colder the higher the number the colder the unit will be Faulty thermostat in the coldest position the switch is not closed Replace thermostat Doors not sealing Adjust doors Torn or damaged door gaskets Replace gaskets Evaporator fan not running Check motor repair or replace Condenser fan motor not running Check motor repair or replace Condenser coil dirty filter dirty Clean coil or filter Refrigerant leak Leak check unit repair and recharge Cabinet too cold Thermostat set too cold Faulty thermostat in the off position the switch does not open stuck closed Turn thermostat to a warmer setting the higher the number the colder the unit will be Replace thermostat Water in the bottom of the unit Drain tube plugged Clear drain tube Drain tube loose or disconnected from drain pan Tighten or re connect drain tube 11 Service Manual for Refrigera
5. Service Manual REFRIGERATED BACK COUNTER MODEL RBC 48 RBC 60 Please read this manual completely before attempting to install operate or service this equipment This manual is Copyright 2011 Duke Manufacturing Co All rights reserved Reproduction without written permission is prohibited Duke is a registered trademark of the Duke Manufacturing Co Duke Manufacturing Co 2305 N Broadway St Louis MO 63102 Phone 314 231 1130 Toll Free 1 800 735 3853 Fax 314 231 5074 www dukemfg com P N 219211B Service Manual for Refrigerated Back Counter RBC 48 60 iii 7 IMPORTANT WARNING AND SAFETY INFORMATION WARNING READ THIS MANUAL THOROUGHLY BEFORE OPERATING INSTALLING OR PERFORM ING MAINTENANCE ON THE EQUIPMENT WARNING FAILURE TO FOLLOW INSTRUCTIONS IN THIS MANUAL CAN CAUSE PROPERTY DAMAGE INJURY OR DEATH WARNING DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE WARNING UNLESS ALL COVER AND ACCESS PANELS ARE IN PLACE AND PROPERLY SE CURED DO NOT OPERATE THIS EQUIPMENT CAUTION Observe the following Minimum clearances must be maintained from all walls and combustible materials Keep the equipment area free and clear of combustible material Adequate clearance for air openings Unit exhausts air to the bottom and the rear
6. ation inside and out These units should be located so that they can be moved for service Major service to the refrigeration system is done from the end of the cabinet The outline dimensional drawings for the units are shown below in Figures 1 and 2 Figure 1 48 Refrigerated Back Counter RBC 48 Figure 2 60 Refrigerated Back Counter RBC 60 Inside Unit Take care notto block airflow to the fans and allow space along the front back and sides Outside Unit Be surethatthe unithas access to ample air avoid hot corners and locations near stoves and ovens CAUTION This unit exhausts air to the bottom and the back Do not seal the unit to the wall or set unit on a curb The ventilation AN slots in the kickplate must remain open Leveling Be sure that the units are placed on a firm flat surface floor Check for cracks in flooring or tile and avoid these areas if possible If necessary place support pads properly rated for the weight of the unit to bridge uneven or cracked flooring Level unit accordingly Stabilizing Use the leg adjustments to insure that the unit is solid to the floor surface at all four contact points Insure that the unit does not rock when pressure is applied to the top corners iii Service Manual for Refrigerated Back Counter RBC 48 60 Electrical Connection WARNING TheRBC48and RBC 60are available asa 120VAC REFER TO THE AMPERAGE DATA 60 Hz or as 220VAC 50 Hz depe
7. for Refrigerated Back Counter RBC 48 60 ii 7 7 PARTS REPLACEMENT THERMOSTAT REPLACEMENT The thermostat is located inside the main electrical control box and is accessible through the right side door 1 Disconnect and isolate the refrigerator from the power source 2 Removeupper sheet metal shroud behind right side door to gain full access to control box Remove the control box from the unit Remove the thermostat from the control box Remove interior ductwork from the right inside of the unit to gain access to the evaporator fan assemble Remove the evaporator fan assembly Remove the thermostat control cap tube from the evaporator coil 8 Remove thermostat from the unit 9 Install replacement thermostat 10 Replace the thermostat control cap tube 11 Replace the evaporator fan assembly 12 Replace all ductwork reinstall the thermostat into the control box and reinstall the control box 13 Replace the sheet metal shroud 14 Reconnect main power source and test refrigeration unit NOTE Care should be taken not to kink the new thermostat cap tube NOTE 8 of the end of the thermostat cap tube must be in the evaporator coil to ensure proper operation EVAPORATOR FANS The evaporator fans are a part of the main refrigeration unit The refrigeration unit is accessed through the right side of the unit and is slid out as an assembly from the right side 1 Disconnect and isolate the refrigerator
8. from the power source 2 Remove right rear corner angle strip Completely remove the right side laminate panel from its guide way 4 Remove the inner right side access panel Remove the refrigeration unit main mounting hardware 6 Slide the entire refrigeration unit out through the right side as an assembly Disconnect and label the evaporator fan wiring Remove the evaporator fan mounting hardware 9 Remove the evaporator fan 10 Install the replacement evaporator fan 11 Replace evaporator fan mounting hardware 12 Reconnect the evaporator fan wiring 13 Slide the refrigeration unit back to original mounting position 14 Replace and secure the refrigeration unit main mounting hardware 15 Replace side access panel laminate panel and right rear corner angel strip 16 Reconnect main power source and test the refrigeration unit ii Service Manual for Refrigerated Back Counter RBC 48 60 REFRIGERATION SYSTEM UNIT REPLACEMENT 1 Disconnect and isolate the refrigerator from the power source Remove right rear corner angle strip Completely remove the right side laminate panel from its guide way Remove the inner right side access panel Remove the refrigeration unit main mounting hardware 6 Slide the entire refrigeration unit out through the right side as an assembly 7 Install the replacement refrigeration unit onto the slide bars 8 Slide the replacement refrigeration unit bac
9. k to its mounting position 9 Replaceand secure the refrigeration unit main mounting hardware 10 Replace side access panel laminate panel and right rear corner angel strip 11 Reconnect main power source and test refrigeration unit DOOR REPLACEMENT AND ADJUSTMENT Doors may become misaligned during shipment but can be easily adjusted 1 Onthe door that is hanging low tighten hinge screws on top and bottom hinge with a 3 8 open wrench until snug Do not over tighten 2 Placeaflat screwdriver against the side of the bottom hinge and lightly tap with a hammer until door is properly aligned 3 Depending upon the degree of misalignment it may be necessary to adjust the top hinge as well by gently tapping on the inside of the hinge 4 Once doors have been aligned assure that all screws are tight on all of the hinges DOOR GASKET REPLACEMENT The door gasket is pulled from its retainer 1 Starting in a corner firmly pull the gasket from the retaining channel 2 Toreinstall start in the corner and firmly press the gasket into the retaining channel MULLION AND CABINET HEATER REWIRING General In the event of mullion or cabinet heater failure rewiring to the alternate heater HTR2 is required Mullion Heater The mullion heater is accessed behind the angle bracketthat attaches the mullion to the main cabinet The cabinet heater is accessed through the right side cabinet by removing the laminate f
10. lable use the same type of refrigerant as used in the system e Evacuate system to 500 microns The system is now ready to receive the refrigerant charge per the data plate information 10 CAUTION Never use oxygen or acetylene in place of refrigerant and dry nitrogen for leak testing A violent explosion may result causing personal injury or death Always use a pressure regulator when using nitrogen to pressure test Failure to do so will result in extremely high pressure which could exceed the burst pressure of the compressor or other system components and result in personal injury or death NOTE Before beginning the repair ensure there is enough of the process tube present to complete the repair using the above procedure If not install a new process tube approximately 12 before beginning the repair sequence 1 Install a temporary access valve on the high and low side process tubes as close to the factory crimps as possible 2 Through the use of temporary valves Duke Manufacturing will not reimburse the cost of permanently installed valves perform the required service needed to repair the unit 3 Once the repair has been made evacuate the system using the triple evacuation method described in Duke Manufacturing Service Bulletin Number 26 After the evacuation is complete recharge the system as stated on the nameplate using the proper refrigerant Continue by crimping the process tube just below
11. n the unit We also suggest you record all the information listed and retain for future reference MODEL NUMBER SERIAL NUMBER DATE OF PURCHASE DEALER TELEPHONE SERVICER TELEPHONE NORTH AMERICA amp LATIN AMERICA UK amp IRELAND Duke Manufacturing Company Duke Mfg UK 2305 N Broadway St Louis MO 63102 Phone 314 231 1130 Toll Free 1 800 735 3853 Fax 314 231 5074 CONTINENTAL EUROPE EU Headquarter Office Duke Manufacturing CR s r o Vitavska 219 Stechovice 25207 Phone 420 257 741 033 TO ACCESS INTERNET www dukemfg com Duke House Unit 10 Greendale Business Park Woodbury Salterton Exeter Devon UK EX5 1EW Tel 01395 234140 FAX 01395 234154 ASIA Asia Office Duke Food Service Equipment shanghai Company Limited 1F Building 17 2 658 Nong Jin Zhong Road Shanghai China 200335 Tel 86 21 6876 9272 Fax 86 21 33600628 Please provide the following information when you write or call model number serial number date of purchase your complete mailing address including zip code and description of the problem 15 Service Manual for Refrigerated Back Counter RBC 48 60 ii 7 Your Solutions Partner Duke Manufacturing Company 2305 N Broadway St Louis MO 63102 Phone 314 231 1130 Toll Free 1 800 735 3853 Fax 314 231 5074 www dukemfg com EU Headquarter Office Duke Manufacturing CR s r o Vitavska 219 Stechovice 25207 Phone 420 257 741 033 Duke Mfg UK Duke House Unit
12. ndent on model LIST IN THE SPECIFICATIONS OR All electrical connections should be performed by THE SERIAL TAG DATA AND YOUR a certified electrician and should comply with local LOCAL CODE OR THE NATIONAL electrical codes for your municipality ELECTRICAL CODE TO BE SURE UNIT IS CONNECTED TO THE PROPER POWER SOURCE A PROTECTED CIRCUIT OF THE CORRECT VOLTAGE AND AMPERAGE MUST BE RUN FOR CONNECTION OF THE SUPPLY CORD OR PERMANENT CONNECTION TO THE UNIT THE POWER MUST BE TURNED OFF AND DISCONNECTED WHENEVER PERFORMING MAINTENANCE OR RE PAIR FUNCTIONS Service Manual for Refrigerated Back Counter RBC 48 60 MAINTENANCE STAINLESS STEEL CARE AND CLEANING To prevent discoloration or rust on stainless steel several important steps need to be taken Stainless steel contains 70 8096 iron which will rust It also contains 12 3096 chromium which forms an invisible passive film over the steels surface which acts as a shield against corrosion As long as the protective layer is intact the metal will not corrode If the film is broken or contaminated outside elements can begin to breakdown the steel and begin to form rust or discoloration Proper cleaning of stainless steel requires soft cloths or plastic scouring pads CAUTION Never use steel pads wire brushes or scrapers Cleaning solutions need to be alkaline based or non chloride cleaners Any cleaner containing chlorides will damage the protective film of the stainles
13. nnnnennnnnnnnnnnnnsnnnennnnnnnnsnnen 9 MULLION AND CABINET HEATER REWIRING pt 9 ETC UC Eiaa a aiii 9 Mullion a C C MRRRRRRRRRRRRRRRRRRRRRRRRREEEMMMMMMMMMMMMMMEMMMMMMMMMMMMMMEMMMMMMMMMMMMMMMMMMMMMMMM 9 RECHARGING REFRIGERANT SYSTEM cccccccsscessssseeeecececeecasseecseeeeeceeeaesesnseeeeesesseesesseess 10 General EE EE 10 Tools Reguired ee 10 faa gt RE 10 gu euBzceenicom 11 WIRING DIAGRAMS 4 12 CUSTOMER ASSISTANGE helene en Me aS 15 Service Manual for Refrigerated Back Counter RBC 48 60 SPECIFICATIONS INTROUCTION MODEL DESCRIPTION VOLTAGE AMPS PH RBC 48 48 Refrigerated 120 VAC 60 Hz 10 Back Counter 220 VAC 50 Hz 5 x ER zx RBC 60 60 Refrigerated 120 60 Hz 12 Back Counter 220 VAC 50 Hz 6 MODEL DESCRIPTION HEIGHT WIDTH LENGTH RBC 48 48 Refrigerated 40 00 In 29 50 In 48 00 In Back Counter RBC 60 60 Refrigerated 40 00 In 29 50 In 60 00 In Back Counter INSTALLATION Location Units represented in this manual are intended for indooruse only Be sure the location chosen has a floor or counter strong enough to support the total weight of the units Reinforce the floor or counter if necessary to provide for maximum loading For the most efficient operation be sure to provide good air circul
14. rom the right side of the unit Remove appropriate wire nuts mullion heater or spade connectors cabinet heater and transfer the supply power to the alternate heater Service Manual for Refrigerated Back Counter RBC 48 60 RECHARGING REFRIGERANT SYSTEM General To analyze the performance of a refrigeration system temperature readings can be taken and converted to pressures using a standard pressure temperature chart When access into a factory sealed refrigeration system is necessary to perform service the following procedure must be followed to ensure the system is returned to a properly sealed state Tools Required Standard hand and refrigeration service tools no special tools needed e Refrigerant Type R 134A 8 ounces Charging Procedure NOTE When service of the refrigeration system is necessary care must be given during the evacuation process to ensure removal of air moisture and other non condensables from the system To evacuate the refrigeration system properly Duke Manufacturing recommends a triple evacuation procedure outlined below Failure to follow this process could cause poor performance of the refrigeration system e Evacuate system to 1500 microns Break the vacuum to 2 psig with dry nitrogen if dry nitrogen is unavailable use the same type of refrigerant as used in the system Evacuate system to 1500 microns Break the vacuum to 2 psig with dry nitrogen if dry nitrogen is unavai
15. s steel Chlorides are also commonly found in hard water salts and household and industrial cleaners If cleaners containing chlorides are used be sure to rinse repeatedly and dry thoroughly upon completion Routine cleaning of stainless steel can be done with soap and water Extreme stains or grease should be cleaned with a non abrasive cleaner and plastic scrub pad It is always good to rub with the grain of the steel There are also stainless steel cleaners available which can restore and preserve the finish of the steels protective layer Early signs of stainless steel breakdown can consist of small pits and cracks If this has begun cleanthoroughly and startto apply stainless steel cleaners in attempt to restore the passivity of the steel CAUTION Never use an acid based cleaning solution Many food AN products have an acidic content which can deteriorate the finish Be sure to clean all food products from any stainless steel surface Common items include tomatoes peppers and other vegetables WARNING THE POWER MUST BE TURNED OFF AND DISCONNECTED AT ALL TIMES WHEN PERFORMING MAINTENANCE OR REPAIR FUNCTIONS PREVENTIVE MAINTENANCE Cleaning the Condenser Coil The condenser coil is located behind the filter panel and is accessed through the front of the unit See Figure 3 The condenser coil requires regular cleaning and is recommended every 60 days However in some instances you may find that there is a large
16. ted Back Counter RBC 48 60 WIRING DIAGRAMS EVAPORATOR COMPARTMENT POWER SAVE ON LIGHT OFF HEATER REFRIGERATED BODY SWITCH BOX POWER SAVE THERMOSTAT 220V 120V SWITCH SWITCH 1207 vs VS Tot Black Sos mu ite 5 White uh 09 Grooves x VS o o a 220V d Red Black VS VS White CONTROL VS z 120V 220V 4 2 BOX Black Red 18 le Is VS VS S 3 E z E a g Em COMPRESSOR oy TRAY a o 3 120 220 o CONDENSING Black Red V e UNIT Ws WS 12 G VS Vendor Supplied Subject to change 12 220V 50 60 Hz L1 12 CONDENSING UNIT THRERMOSTAT EVAPORATOR FAN EVAPORATOR FAN S2 DOOR HEATER POWER SAVE SWITCH MULLION HEATER Service Manual for Refrigerated Back Counter RBC 48 60 120V 50 60 Hz L1 e L2 CONDENSING UNIT THRERMOSTAT EVAPORATOR FAN EVAPORATOR FAN S2 DOOR HEATER POWER SAVE SWITCH MULLION HEATER NOTE HTR2 IS A FAULT BACKUP FOR HTR1 IN THE HEATER ASSEMBLIES 13 Service Manual for Refrigerated Back Counter RBC 48 60 iii 7 7 7 7 NOTES 14 ii Service Manual for Refrigerated Back Counter RBC 48 60 CUSTOMER ASSISTANCE To aid in reporting this unit in case of loss or theft please record below the model number and serial number located o
17. with the use of warm soapy water Avoid full strength cleaning products on gaskets as this can cause them to become brittle and prevent proper seals Also never use sharp tools or knives to scrape or clean the gasket which could possibly tear the gasket and rip the bellows Gaskets can easily be replaced and do not require the use of tools or authorized service persons The gaskets are Dart style and can be pulled out of the groove in the door and new gaskets can be pressed back into place Drain Maintenance Base Each unit has a copper drain tube located inside the unit which removes the condensation from the evaporator coil and deposits it onto a drain pan where it can evaporate See Figure 4 If you notice excessive water accumulation on the inside of the unit be sure that the drain tube is connected from the evaporator housing to the condensate evaporator drain pan If water is collecting underneath the unit you may want to check the condensate evaporator drain tube to be sure it is still located above the drain pan The leveling of the unit is also important as the units are designed to drain properly when on a level surface if your floor is not level this can also cause drain problems Be sure the drain pan is keptfree of dirt dust and other debris as excessive amounts will cause water to back up and overflow from the drain pan Draln Tuba Grain Pan Figure 4 Location of Drain Tube and Drain Pan Service Manual
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