Service Manual
Contents
1. Turn the thermostat to the 1 position 6 Service Manual N300 Models Battery drain In AC operation there is no battery drain In DC operation the refrigerator draws 11 amps at 14 volts If the battery charging stops during DC operation change the refrigerator to gas or AC operation until the battery charging starts again Check the voltage when in DC operation The voltage should never drop below 13 5 volts Refrigerator Maintenance Gas flame appearance While in LP gas operation examine the appearance of the gas flame Turn the thermostat to the 5 position Open the lower intake vent CAUTION The burner box cover can be hot Wear gloves to avoid burns Open the burner box door 3 and look at the gas flame 1 See Art00955 and Art00982 The flame should be a darker blue inside and a lighter blue outside and should be a constant and steady shape The flame should not be yellow and should not have an erratic and unstable shape Make sure the flame does not touch the inside of the flue tube 2 Close the burner box door Remove and clean the burner orifice To remove and clean the burner orifice Close the valve at the propane gas tank s Open the lower intake vent Close the manual shut off valve of the refrigerator Turn the gas control to the OFF position Q Remove the burner box cover by removing one screw WARNING To avoid possible propane gas leaks always u2. oic ceto qe tee 7 Wiring Diadora e 7 Troubleshooting Charts i 8 Refrigerator will not operate on AC 8 Refrigerator will not operate on DC 3 way models 9 Burner ignites but does not maintain flame 10 Part Replacement niisiis 11 Selector 11 Thermostat iaia 11 AC healer 5 o AL 11 DC heater 3 way models 11 Thermocouple 12 Thermocouple interrupter 12 Gas safety valve ii 12 Introduction This Service Manual supplies information for the experienced repair technician The repair technician should have working knowledge of the operation of an absorption refrigerator system and should have basic knowledge of LP gas and electrical systems Read and understand the Installation and Owner s Manual all service procedures cautions and warnings before doing any service work on the refrigerator If you are unable to resolve the problem by using this Service Manual technical service support is available at 1 800 444 7210 Only use genuine Norcold replacement parts on the refrigera tor Generic parts do not meet Norcold s specifications for reliability performance and safety and will void the Norcold Limited Warranty 2 Service Manual N300
3. Com 3 way models Selector svvitch Service Manual N300 Models 7 Is selector switch in the AC position Turn selector switch to AC and start up Is AC voltage at output of selector switch Replace selector switch and start up Is AC voltage at input of thermostat Correct power source to thermostat YES selector switch Refrigerator will not operate on AC 15 thermostat at mid range or higher Put thermostat at mid range or higher amp start up Is AC voltage at input of Correct power source to selector switch Is AC voltage at output of thermostat Replace thermostat and start up 8 Service Manual N300 Models Is circuit breaker or fuse blown AC source Reset breaker replace fuse and start up Is AC voltage at output of 3 Amp fuse Replace 3 Amp fuse and start up Is AC voltage at input of heater black wires Correct power source to heater and start up Is the power cord in the receptacle Put the cord in the receptacle and start up Is AC voltage at input of 3 Amp fuse Correct power source to 3 Amp fuse Replace AC heater Are any wire connections loose Repair connections and start up Is AC voltage at terminal block Correct power source to terminal block Art00997 Is selector switch in the DC position Turn selector switch to DC and start up Replace DC heater Refrigerator will not opera
4. around the refrigerator Ignition propane gas operation 1 Open the valve at the propane gas storage tank 2 Open the manual shut off valve of the refrigerator 3 Turn the thermostat 1 to the 5 position See Art00976 4 Turn the selector switch 2 to the gas position 8 5 Push and hold in the safety valve 3 and in rapid succes sion push in the igniter several times for about five seconds WARNING Do not hold the safety valve in more than 30 seconds If there is no flame in this time wait at least five minutes before you try ignition again If you continue to hold in the safety valve gas will collect in the burner area This could cause a fire or explosion and result in dangerous personal injury or death When a flame is present and the flame meter 5 moves into the green area release the safety valve If the flame meter does not move into the green area or does not remain in the green area wait about five minutes and do this step again 6 Turn the thermostat to the temperature setting that you wish Start up AC electric operation Make sure that 120 volts AC is available Turn the selector switch to the AC position CE Turn the thermostat to the temperature setting that you wish Start up DC electric operation 3 way models Make sure that 12 volts DC is available Turn the selector switch to the DC position 2 Shut down Turn the selector switch to the OFF position
5. to the touch If the fins do not feel cold to the touch after two hours the cooling unit is not operating correctly If the cooling problem does not occur when operating on all energy sources the problem is not the cooling unit Use the Troubleshooting Charts to determine the cause of the problem Wiring Pictorial The parts of the wiring pictorial are See Art01020 Te dha ada 120 Did Terminal block lla 3 Amp fuse PRETERITO Selector switch Thermocouple A EA Thermostat gas safety valve pc Thermocouple interrupter Lyc NN Flame meter EHE AC heater deci 12 VDC Power supply 3 way models dur meee ree cee 12 VDC Power supply 3 way models 12 ua 20 fuse 3 models 164 5 cis DC heater 3 vvay models VViring Diagram The parts of the vviring diagram are See Art01021 tin alal 120 VAC Dei tetas EAEE a tica al 3 Amp fuse Thermostat heater o 120 VAC 6 cte m ee tatem eris Gas safety valve poe Thermocouple interrupter a Flame meter CIA RO e READER POR OMA el Piezo lighter jm RS Spark gap Thermocouple ddr 12 VDC 3 way models AA IN 20 Amp fuse 3 way models WA GE DC heater 3 way models Itaca era tera 12 VDC
6. Models Safety Awareness Read this manual carefully and understand the contents before you install and operate the refrigerator Be aware of possible safety hazards when you see the safety alert symbol on the refrigerator and in this manual A signal word follows the safety alert symbol and identifies the danger of the hazard Carefully read the descriptions of these signal words to fully know their meanings They are for your safety WARNING This signal word identifies a hazard which if ignored can cause dangerous personal injury death or much property damage CAUTION This signal word identifies a hazard which if ignored can cause small personal injury or much property damage Safety Instructions A warna This refrigerator is equipped for the use of propane gas only and can not be changed to use any other fuels natural gas butane etc Incorrect installation adjustment changes to or maintenance of this refrigerator can cause personal injury property damage or both Obey the instructions in this manual to install the intake and exhaust vents Do not install the refrigerator directly on carpet Put the refrigerator on a metal or wood panel that extends the full width and depth of the refrigerator Propane gas can cause a fire or an explosion that can result in property damage personal injury or death Do not smoke or create sparks while doing any work on the propane gas supply system Do not
7. NORCOLD Service Manual For model N300 a 2 7 cu ft 2 way refrigerator For model N300 3 a 2 7 cu ft 3 way refrigerator NORCOLD Inc P O Box 4248 Sidney OH 45365 4248 Part No 619127A 6 98 Table of Contents Introduction citi a t enr e 2 Safety Awareness i 2 Safety Instructions ii 2 A ped pe OR AE 3 Operating limits 2 tereti ettet e 3 Ratings a 3 Current Erat oe 3 Replacement fuses refrigerator control panel 3 Ventilation Requirements i 4 Propane Gas Components 4 Examine the gas supply system for leaks 4 Electrical Components seen 5 Examine the 120 volts AC supply 5 Examine the 12 volts DC supply 3 way models 5 Controls eere ne alii 5 Ignition and Start UD io 6 Ignition propane gas operation 6 Start up AC electric operation 6 Start up DC electric operation 3 way models 6 SHUt down alan Battery Refrigerator Maintenance Gas flame appearance Remove and clean the burner orifice 6 Diagnosing Cooling Problems 6 Wiring Pictorial e tee s
8. a If you use compressed air for the test The pressure of the compressed air at the manual shutoff valve of the refrigerator must not be more than 1 2 psig 14 inches Water Column If the pressure of the compressed air is more than 1 2 psig 14 inches Water Column remove the gas supply line from the manual shutoff valve of the refrigerator before the test If the pressure of the compressed air is equal to or less than 1 2 psig 14 inches Water Column close the manual shutoff valve of the refrigerator before the test Electrical Components This refrigerator operates on these electrical sources AC Operation 120 volts AC voltage 108 volts min 132 volts max DC Operation 3 way models 14 volts DC voltage 13 5 volts min 15 4 volts max Operation out of these limits may damage the refrigerator s electrical circuit parts and will void the warranty Examine the 120 volts AC supply WARNING Connect the AC power cord only to a grounded three prong receptacle Do not remove the round ground prong from the power cord Do not use a two prong adapter or an extension cord Operation of the refrigerator without a correct ground could cause dangerous electrical shock or death if you are touching the metal parts of the refrigerator or the vehicle Make sure the AC power cord is in a grounded three prong receptacle Make sure the receptacle is within easy reach of the lower intake vent Make sur
9. ake sure the connection does not leak 8 Assemble the replacement safety valve to the gas outlet fitting 9 Turn the thermocouple interrupter only about half way into the replacement safety valve 10 Turn the thermocouple only about half way into the thermocouple interrupter 11 Using two wrenches fully tighten the thermocouple interrupter onto the safety valve 12 Fully tighten the thermocouple onto the thermocouple interrupter 13 Attach the wires to the thermocouple interrupter 14 Examine all the gas connections for leaks Refrigerator 1 Close the valve at the main propane gas tank s 2 Remove the gas supply line from the bulkhead fitting of the refrigerator 3 Remove the AC power cord from the receptacle 4 Remove the DC input leads from the refrigerator Put tape on the positive lead to prevent an accidental electrical short and a blown fuse 5 Remove the screws that attach the refrigerator to the floor 6 Remove the screws that attach the refrigerator to the wall 7 Remove the refrigerator from the opening 8 To install the refrigerator do steps 1 7 in reverse 9 Examine all the gas connections for leaks 00956 Art00955 Art00976 l Art00982 Service Manual N300 Models 13 sno a Pe Della GRN YEL Art01020 Art01021 14 Service Manual N300 Models
10. be through the back of the refrigerator cabinet 9 To install the replacement thermostat do steps 1 8 in reverse Make sure the capillary tube is flat against the cooling fin 10 Examine all the gas connections for leaks AC heater 1 Remove the AC power cord from the receptacle 2 To make sure the other energy sources do not activate turn the selector switch to the OFF position 3 Remove the two blue wires that connect the AC heater to the terminal block 4 Using a utility knife vertically cut through the insulation that surrounds the flue tube 5 Remove the insulation 6 Pull the AC heater up and out of the heater well 7 Push the replacement AC heater down into the heater well Make sure the bead of weld on the AC heater touches the top of the heater well 8 Put the insulation around the flue tube Make sure the insulation is completely around the flue tube 9 Tape the insulation closed 10 Attach the two blue wires of the AC heater to the terminal block 11 Put the AC power cord in the receptacle DC heater 3 way models 1 Remove the DC input leads from the refrigerator Put tape on the positive lead to prevent an accidental electrical short and a blown fuse 2 To make sure the other energy sources do not activate turn the selector switch to the OFF position 3 Remove the two yellow wires that connect the DC heater to the terminal block 4 Using a utility knif
11. change the flame from high fire to low fire as do other RV refrigerators If the cooling load changes you must manually change the gas control to maintain the same temperature inside the refrigerator When the outside air temperature is less than 50 F the refrigerator may have a tendency to freeze food at the colder temperature settings To reduce the tendency to freeze food Turn the thermostat to a warmer temperature setting Keep the refrigerator full Put foods that are more likely to freeze on the upper shelf The selector switch 2 changes the energy source of the refrigerator between propane gas A AC electric and DC electric 25 and shuts down the refrigerator at the OFF O position The gas safety valve 3 is built into the control panel As long as a flame is present the valve is open and allows gas to flow into the burner Any loss of flame empty propane gas tank blow out etc closes the valve and stops the flow of propane gas The igniter 4 makes a spark which ignites the flame in the burner The flame meter 5 shows if a flame 15 present in the burner Service Manual N300 Models 5 Ignition and Start Up Before ignition or start up of the refrigerator Make sure the air flow in the lower intake vent through the refrigerator coils and condenser and out the upper exhaust vent is not blocked or decreased Make sure there are no combustible materials in or
12. e vertically cut through the insulation that surrounds the flue tube 5 Remove the insulation 6 Pull the DC heater up and out of the heater well 7 Push the replacement DC heater down into the heater well Make sure the bead of weld on the DC heater touches the top of the heater well 8 Put the insulation around the flue tube Make sure the insulation is completely around the flue tube 9 Tape the insulation closed 10 Attach the two yellow wires of the DC heater to the terminal block 11 Make sure that a 20 Amp fuse is in the fuse holder 12 Attach the DC input leads from the refrigerator Service Manual N300 Models 11 Thermocouple 1 Close the valve at the main propane gas tank s 2 Remove the thermocouple from the thermocouple inter rupter 3 Remove the burner box cover 4 Remove the two screws that attach the thermocouple bracket to the burner box 5 Remove the thermocouple from the thermocouple bracket 6 Remove the wires from the thermocouple interrupter 7 Using two wrenches loosen the thermocouple interrupter from the safety valve 8 Turn the thermocouple interrupter about half way out of the safety valve 9 Turn the thermocouple only about half way into the thermocouple interrupter 10 Using two wrenches fully tighten the thermocouple interrupter onto the safety valve 11 Fully tighten the thermocouple onto the thermocouple interrupter 12 Attach the wires t
13. e in flame amp clean Adjust or clean thermocouple 16 30 milli volts on both terminals Replace safety valve 15 propane gas pressure 10 5 11 W C Correct propane gaspressure Is propane gas at tap tee 10 5 11 W C Replace thermostat Art01093 Part Replacement If the Troubleshooting Charts tell you to replace a part use the follovving instructions Selector svvitch 1 Close the valve of the propane gas tank s 2 Pull the knob off the selector switch 3 Remove the two screws that attach the selector switch 4 Gently pull the selector switch away from the back of the control panel 5 Remove each wire one at a time from the selector switch and install in exactly the same location on the replacement selector switch See Art01020 and Art01021 6 To install the replacement selector switch do steps 1 4 in reverse Thermostat 1 Close the valve of the propane gas tank s 2 Pull the knob off the thermostat 3 Remove the gas supply line from the inlet flare fitting of the thermostat 4 Remove the safety valve from the thermostat See page 12 5 Remove the two screws that attach the thermostat to the bracket 6 Remove the two red wires from the thermostat 7 Remove the clips that attach the capillary tube to the cooling fin inside the refrigerator NOTE The capillary tube is located on the fifth cooling fin from the right 8 Gently pull the capillary tu
14. e sure there is sufficient intake of fresh air for combustion Make sure the living space is completely isolated from the combustion system of the refrigerator Make sure there is complete and unrestricted ventilation of the flue exhaust which in gas mode can produce carbon monoxide The breathing of carbon monoxide fumes can cause dizziness nausea or in extreme cases death Certified installation needs one lower intake vent and one upper exhaust vent Install the vents through the side wall of the vehicle exactly as instructed in this manual Any other installation method voids both the certification and the factory warranty of the refrigerator The bottom of the opening for the lower intake vent which is also the service access door must be even with or immedi ately below the floor level This allows any leaking LP gas to escape to the outside and not to collect at floor level American Gas Association Canadian Gas Association AGA CGA certification allovvs the refrigerator to have zero 0 inch minimum clearance at the sides rear top and bottom While there are no maximum clearances specified for certification the following maximum clearances are necessary for correct refrigeration Bottom 0 inch min 0 inch max Each Side 0 inch min 1 8 inch max Top 0 inch min 1 4 inch max Rear 0 inch min 1 inch max These clearances plus the lower and upper vents cause the natural air draft that is necessary for good refrig
15. e the power cord does not touch the burner cover the flue pipe or any hot component that could damage the insulation of the power cord Examine the 12 volt DC supply 3 way models The refrigerator gets power from the 12 volt system of the vehicle either from the battery or from an auxiliary house battery The battery system not only supplies DC power to the refrigerator but also to other components of the vehicle The DC heating element which supplies power for cooling during DC operation has a high current draw and can cause rapid battery drain Make sure the 12 volt DC supply is connected correctly Make sure the DC negative wire from the battery is connected to the black DC wire on the terminal block of the refrigerator Make sure the DC positive wire from the battery is connected to the red DC wire on the terminal block of the refrigerator Make sure an in line fuse is installed on the DC positive wire as near the battery as possible between the battery and the terminal block of the refrigerator NOTE This in line fuse is necessary for added safety even though the refrigerator has a DC fuse in the control assembly Controls The thermostat 1 changes the amount of propane gas that goes to the burner See Art00976 This acts as the tem perature control of the refrigerator Number 5 is the coldest temperature setting NOTE The thermostat is not an automatic gas control It does not automatically
16. eration Cooler air goes in through the lower intake vent goes around the refrigerator coils where it removes the excess heat from the refrigerator components and goes out through the upper exhaust vent If this air flow is blocked decreased the refrigerator may not cool correctly Each NORCOLD model is certified by AGA and CGA for correct ventilation 4 Service Manual N300 Models Propane Gas Components This refrigerator operates on propane gas at a pressure of 10 5 inches Water Column min to 11 5 inches Water Column max WARNING Be very careful when working on or near the propane gas system Do not smoke or use an open flame near the propane gas system Do not use an open flame to examine for leaks Do not connect the refrigerator to the propane gas tank without a pressure regulator between them To avoid possible propane gas leaks always use two wrenches to tighten or loosen the gas supply line connections Leaking propane gas can ignite or explode and result in dangerous personal injury or death Examine the gas supply system for leaks WARNING Do not allow the leak detecting solution to touch the electrical components Many liquids are electrically conductive and can cause a shock hazard electrical shorts and in some cases fire Using a solution of liquid detergent and water make sure the gas supply line and all gas connections have no leaks Do not use any liquid that contains ammoni
17. ion baffle is correctly installed Examine the cooling unit for leaks WARNING If you think that the cooling system has a leak do not operate the refrigerator Replace the cooling unit before operating the refrigerator If you smell ammonia the cooling unit has a leak and must be replaced If you see a yellow powder or residue anywhere at the rear of the refrigerator or in the enclosure the cooling unit has a leak and must be replaced Determine if the cooling problem occurs while operating the refrigerator on propane gas AC electric and DC electric Determine if the selected energy source is operating and heating correctly CAUTION Touch only the outside of the insulation sleeve During normal operation some tubes of the cooling unit are hot Do not touch any tubes of the cooling unit Within 20 minutes of starting the refrigerator touch the outside of the insulation sleeve The outside of the insulation sleeve should be warm to the touch If the outside of the insulation sleeve is not warm the selected energy source may not be operating correctly Start up the refrigerator on a different energy source and repeat the procedure for all energy sources If the outside of the insulation sleeve is warm to the touch make sure the unit is cooling correctly Within one hour after starting up the refrigerator touch the fins on the inside of the fresh food com partment The fins should feel cold
18. o the thermocouple interrupter 13 Do steps 1 5 in reverse 14 Examine all the gas connections for leaks Thermocouple interrupter 1 Close the valve at the main propane gas tank s 2 Remove the thermocouple from the thermocouple inter rupter 3 Remove the wires from the thermocouple interrupter 4 Using two wrenches remove the thermocouple interrupter from the safety valve 5 Turn the replacement thermocouple interrupter only about half way into the safety valve 6 Turn the thermocouple only about half way into the replacement thermocouple interrupter 7 Using two wrenches fully tighten the thermocouple interrupter onto the safety valve 8 Fully tighten the thermocouple onto the thermocouple interrupter 9 Attach the wires to the thermocouple interrupter 10 Open the valve at the main propane gas tank s 11 Examine all the gas connections for leaks 12 Service Manual N300 Models Safety valve 1 Close the valve at the main propane gas tank s 2 Remove the thermocouple from the thermocouple inter rupter 3 Remove the wires from the thermocouple interrupter 4 Using two wrenches remove the thermocouple interrupter from the safety valve 5 Remove the gas outlet fitting from the safety valve 6 Remove the safety valve from the thermostat 7 Assemble the replacement safety valve to the thermostat NOTE Put Loctite or similar product on the threads of the gas outlet fitting to m
19. or around Ratings the refrigerator creates a fire hazard Do not use the area behind the refrigerator to store flammable AC Operation 110 Volts AC 180 Watts materials gasoline cleaning supplies etc DC Operation 14 Volts DC 150 Watts Do not remove the round ground prong from the 3 way models refrigerator AC power cord Do not use a two prong adapter or extension cord on the AC power cord Propane Gas 640 BTU per Hr Input Operation 11 Inch W C Gas Supply A circuit overload can result in an electrical fire if the No 10 Orifice LP10 wires and or fuse sizes are not correct Use only the wire and fuse sizes written in the Owner s Manual Current draws and Installation Manual AC Heater 1 6 Amps 110 VAC To prevent child entrapment make sure all shelf 15 Amb 5 120 VAC retainers are correctly fastened and remove the Resistance 67 2 Ohms doors before disposing of the refrigerator DC Heater 10 7 Amps 14 VDC caution Resistance 1 3 Ohms The rear of the refrigerator has sharp edges and Replacement fuses corners To prevent cuts or abrasions when working on the refrigerator be careful and wear cut resistant AC Circuit Amp Type 1 1 4 x 1 4 gloves Norcold P N 61654622 Make sure all fasteners and connections are tight DC Circuit 20 Amp Type 1 1 4 x 1 4 Norcold P N 61440522 Service Manual N300 Models 3 Ventilation Requirements The completed installation must Mak
20. se two wrenches to loosen and tighten the gas supply line at the refrigerators manual shut off valve Remove the flare nut from the orifice assembly 1 See Art00956 Remove the orifice assembly from the burner 2 WARNING When cleaning do not try to remove the orifice 3 from the orifice adapter 4 Removal will damage the orifice and can cause a propane gas leak Leaking propane gas can ignite or explode and result in dangerous personal injury or death Do not clean the orifice with a pin or other objects Clean the orifice assembly with air pressure and alcohol only Using a wrench assemble the orifice assembly to the burner Assemble the flare nut to the orifice assembly Examine all of the gas connections for leaks Diagnosing Cooling Problems WARNING The refrigerator cooling system is under pressure Do not try to repair or to recharge a defec tive cooling system The cooling system contains sodium chromate The breathing of certain chromium compounds can cause cancer The cooling system contents can cause severe skin and eye burns and can ignite and burn with an intense flame Do not bend drop weld move drill puncture or hit the cooling system Make sure the cooling unit has the correct ventilation Make sure that the intake and exhaust vents are not blocked Make sure that the air flow through the back of the refrigerator is not decreased or blocked Make sure the ventilat
21. te on DC Is circuit breaker or fuse blown DC source Reset breaker replace fuse and start up Is DC voltage at input of heater yellow wires Correct power source toheater and start up Are any wire connections loose Repair connections and start up Is DC voltage at output of YES selector switch Replace selector switch and start up Is DC voltage at terminal block Correct power source to terminal block Is DC voltage at input of YES selector switch Correct power source to selector switch YES 20 Amp fuse Is DC voltage at input of 20 Amp fuse Correct power source to 20 Amp fuse Is DC voltage at output of Replace 20 Amp fuse and start up Art00998 Service Manual N300 Models 9 0 milli volts on both terminals Replace thermocouple Burner ignites but does not maintain flame Is the main gas supply valve open Open main gas supply valve 18 refrigerator gas valve open Open refrigerator gas valve Is thermocouple and interrupter connection tight Tighten connection Check for voltage milli volts at terminals of interrupter 10 15 milli volts on both terminals Replace safety valve 10 Service Manual N300 Models 15 30 milli volts on one terminal 0 milli volts on the other Replace interrupter Is exhaust vent unobstructed Remove obstruction from exhaust vent Is tip of thermocoupl
22. use an open flame to examine the gas supply piping or fittings for leaks To avoid possible propane gas leaks always use two wrenches to tighten or loosen the gas supply line connections Make sure the electrical installation obeys all appli cable codes See the Certification and Code Requirements section of the Owner s Manual and Installation Manual Disconnect both the AC and DC power sources before doing any maintenance work on the refrigera tor Do not bypass or change the refrigerator s electrical components or features Do not spray liquids electrical outlets connec tions or the refrigerator components Many liquids are electrically conductive and can cause a shock hazard electrical shorts and in some cases fire Specifications Operating limits The refrigerator cooling system is under pressure Do not try to repair or to recharge a defective cooling AC Operation 108 VAC Min 132 VAC Max system The cooling system contains sodium chromate The breathing of certain chromium DC Operation 13 5 VDC Min 15 4 VDC Max compounds can cause cancer The cooling system 3 way models contents can cause severe skin and eye burns and can ignite and burn with an intense flame Do not Propane Gas 10 5 Inch Water Column Min bend drop weld move drill puncture or hit the Operation 11 5 Inch Water Column Max cooling system The storage of flammable materials behind
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