7998600 Rev. 4
Contents
1. 5 O m LOWSTAGE LD6 Compressors Rr 55 07 Re HCHSTACE LD5 BOCST LD2 amp LD3 ON BUCK LD1 ON NORMAL LD2 amp LD4 ps a OUTPUT LD4 ee 012 D13 LD Section 4 Hidden Functions 4 1 Hidden Test The Hidden Test Mode is used for testing freezer components The test functions are listed and described below To enter Hidden Test mode press the left and right arrow keys simultaneously Press the right or left arrow until the appropriate function appears in the message center a High Stage Compressor To test the high stage compressor 1 Press the right arrow until HS COMPRESR ON is displayed in the message center 2 Press up down arrow to toggle to OFF 3 Press enter to initiate the test High Stage compressor will manually be turned ON as used in normal operation To deactivate an on going test press up down to toggle to OFF and then press Enter To exit test mode press the mode key and the freezer will resume normal operation If no keys are pressed within a one hour interval the freezer will return to Run mode b Low Stage Compressor The low stage compressor is manually turned ON OFF as used in normal operation c Fan 1 Fan is manually turned ON OFF as used in normal operation d Fan2. 20 DESCRIPTION REVISION DATE 05 14 02 CAD KOG MAH SCALE NONE USTOMER JOB TITLE 86 C 23 CU UPRIGHT FREEZERS 230 V COMMON 706 906 695 6505 6595 5706 amp 5505 23 FREEZERS 230 V DWG TITLE REFRIGERATION SCHEMATIC COCATION NUMBER DRAWING NUNGER 8606 90 0 B ORAWING NUNSER 8655 90 0 8 224220 EVISION 0 1776 03 09 04 AOT LON RELEASED ES PROOUCTION HIGH TEMP STAGE 241017 CASCADE REFRIGERATION 1211039 HIGH TEMPERATURE STAGE REFRIGERANT 4 23 CUFT UNITS R 404A 24 02 6609 21 2 OZ 149 241027 HIGH TEMPERATURE STAGE DIL MOBILE EAL ARCTIC 22CC POLYOL ESTER DIL COMPRESSOR 24 02 7101 TEMPERATURE STAGE REFRIGERANT 23 CUFT UNITS R 290 0 9 02 149 MAX VAC TO 4 PSIG R S083 15 02 3689 1 4 02 6792 OR 4 PSIG 133 PSIG 3 PSIG SS TEMPERATLRE STAGE 011 ZEROL SCT WITH 2 AQDITIVE 211032 COMPRESSOR 24 02 710nl OIL SEPARATOR 15 07 44441 220553 ALL PSIG MEASUREMENTS WHEN SYSTEM IS AT 23 C LOW TEMP STAGE THIS OOCUMENT CONTAINS PROPRIETARY 1 1 23 CU FT UP RIGHT FREEZERS 120 VOLT 05 0 TO OTHERS FOR HEES NOR SCHEMATIC WRITTEN PERHISSION FROM ELECTRON 04 Cal appo DI
3. 6 Connon 3 RxD 98 PIN 7 Nornally PIN 5 GNO CONTACT RATING 30V gg CONTACTS IN ALARM STATE 00 SW1 Settings for Analag Dutot SW2 Settings far Communication Output ete 1 2 3 01 4 207 Output RS 485 ee 102 4142 03 0 1 Output RS 242 eos 05 0 5 Output 1 Schematic represents single amp double door upright madels and chest models All heaters are on uprights only Expansion solenoid 17 23 amp 28 uprights only 2 Door switches shown open position 3 Battery switch shawn in the OFF position 4 Circuit breaker switch shown in OFF position 5 Options and acessories shown in dashed lines 8 58 1654 06 13 05 GLS AKS REV BATTERY CIRCUIT WIRING 5 Made 5 7 1764 16 13 05 LON 400 VACUUM RELIEF HEATER amp CHG DISPLAY 80 5602 5605 5606 5612 98 1768 11 09 04 aot LON CHANGED DISPLAY 80 191751 FROM 191715 J 5 _ FR 1789 08 14 04 ADT KOG LON CHANGED MICRO BOARD 191656 TO 191804 56 19 5620 8602 8605 REV wl can DESCRIPTION OF REVISION 8606 9607 8612 8619 THIS DOCUMENT CONTAINS PROPRIETARY Tag euer 8600 SERIES 230 ULT FREEZERS INFORMATION AND SUCH INFORMATION IS NOT a 2 J 2 DISCLOSED TO OTHERS FOR ANY PURPOSE OWG TITLE UNIT SCHEMATIC 8620 d 8627 8624 H 8691 USED FOR MANUFACTURING PURP
4. 2 4 2 6 dOOr 2 5 2 7 Low battery 2 6 Te 2 6 2 9 Hot condenser 1 2 7 2 10 High stage system failure alarm 2 8 2 11 Power failure 2 9 2 12 Wrong power 2 10 2 13 Low Temperature 2 10 2 14 High temperature alarm or system not maintaining temperature 2 11 2 15 Troubleshoot 2 13 2 16 Voltage Compensation Failure 2 14 Section 3 Charts and Schematics 3 1 Analog Output Reference Table 3 1 3 2 RTD Temperature vs Resistance 3 2 3 3 Pressures vs Cabinet Temperature 3 3 3 4 Refrigeration 3 4 3 5 Electrical Schematics 3 6 3 6 Micro Board iaia 3 8 3 7 High Voltage 3 8 ill Section 4 Hidden Functions 4 1 Hidden 2 22 4 1 4 2 Hidden Calibration 4 2 Appendix A Glossary Glossary Of terms 1 Appendix Compressor 2 B 1 General Operation 1 1 Initial Start Up 7 8 Power Switch on Cabinet temperature 0 5 C or warmer than set point Fans 1 and 2 turn ON High stag
5. 2 14 Symptom High Temperature Alarm or System is not maintainin g temperature Order Possible Cause Verification Action 1 Door Inspect gasket for ice or excessive frost Clear ice or frost from door and gasket Check door adjustment fit and gasket compression Adjust door to restore uniform gasket compression Frequency and duration of door openings and product loading size of load and temperature of introduced product If customer usage is high or suspected as high then verify actual performance with a datalogger Work with customer to communicate effects of loading Load evaluate customer usage Install thermocouple at control sensor and verify control RTD temperature is accurate Troubleshoot control probe with Probe 1 2 3 amp 4 failure procedure LA Defective control probe See procedure for troubleshooting probes Probe 1 2 3 or 4 Failure Single Probe Normal relay s on high voltage board LD 2 and LD 4 on high voltage board are not lit 120v units Line voltage 105 140 230V 60Hz units Line voltage 210 260 230V 50Hz units Line voltage 190 230 Line voltage is within specified limits For LD2 check voltage between U13 12 and 11 1 on micro board for LD4 measure between U13 14 and J11 1 if voltage is less than 1OVDC replace micro board If voltage is greater than 10 then check DC voltage from right side of D3 to right side of D4
6. 041 183 330VAC
7. LD2 from right D7 amp right side of D8 LD4 on high voltage board If is less than 1OVDC check ribbon cable If ribbon cable OK replace high voltage board 2 14 Symptom High Temperature Alarm or System is not maintainin g temperature continued 5 AC power to low stage compressor No voltage at compressor LD6 LS on high voltage board is on Check connections enclosure high pressure cutout switch Ohm out pressure switch Switch to be closed Switch OK measure voltage between pins 1 and 2 of J30 If no voltage replace high voltage board Switch defective jumper around switch and continue to test No voltage at compressor LD6 LS is off and should be on If voltage between U13 16 and J11 1 on micro board is less than 10VDC replace micro board If voltage greater than 10 check DC voltage across D13 on high voltage board is less than 10VDC check ribbon cable If ribbon cable OK go replace high voltage board If 13 voltage greater than 10VDC Go to previous verification LD6 maybe defective Voltage at compressor Check continuity of compressor thermal switch Check winding resistance of compressor See Appendix B Check compressor starting hardware Replace parts as needed LS compressor cycles on high pressure cutout Install pressure gauges on low stage and verify that high pressure cutout is functioning normally Replace defective high pressure cutout Hig
8. 2 Fan 2 is manually turned ON OFF as used in normal operation e Heaters The freezer heaters are manually turned ON OFF as used in normal operation f High Stage Heat Exchange Temperature Displays the temperature 9 High Stage Condenser Temperature Displays the temperature h Toggle Remote Alarm Contacts The remote alarm contacts are toggled ON OFF ON places the contacts in alarm condition OFF represents no alarm condition Press enter i Serial Port Data Burst The freezer transmits a 2 second data stream from the RS 232 RS 485 port 1 EEPROM Initialize This function is used for field software updates All settings will be reset to factory default settings upon initialization 1 Press the right arrow until EEPROM INIT is displayed in the message center 2 Press enter 3 OK EE INIT will be displayed in the message center 4 Press enter to begin initialization k Refrigeration Tank Solenoid The refrigeration tank solenoid is manually opened closed OPN CLS as used in normal operation 4 2 Hidden Calibration The Hidden Calibration Mode is used for calibrating freezer control and voltage components These calibration functions listed below should be performed by qualified service technicians To enter Hidden Calibration mode press the up and down arrow keys simultaneously The message center will display CAL MODE Press the right or left arrow until the appropriate function appears in the message c
9. 7 35 7 6 5 200 aj 3 2 39 38 3 3 3 3 33 32 3 29 28 2 2 2 2 3 af oroj za af ej 35 ejmen ss efaj 50 afaa sa afea 590 Suction Pressure psig for Positive Pressures inches Hg for Negative Pressures Pressures vs Cabinet Temperature Thermo Forma Model 8695 Gan Upright ULT 230V 50Hz 20 0 10 20 30 40 50 60 70 80 Cabinet Temperature C HS Disch Pressure LS Disch Pressure LS Suct Pressure HS Suct Pressure Discharge Pressure psig HIGH TEMP STAGE CASCADE REFRIGERATION 241017 HIGH TEMP STAGE REFRIGERANT R d04A 24 OZ 680g 12 OZ 140 1211033 HIGH TEMPERATURE STAGE OIL MOBILE EAL ARCTIC 22CC POLYOL ESTER OIL COMPRESSOR 24 O2 710n1 203031 LOW TEMP STAGE REFRIGERANT R 290 1 0 07 289 VAC 5 PSIG 5088 17 3 07 490g 1 4 02 79 OR 5 PSIG 152 PSIG 3 PSIG H LOW TEMPERATURE STAGE DL 7 0 1507 WITH 2 ADDITIVE 900111 LH COMPRESSOR 24 0Z 710n1 DIL SEPARATOR 15 02 44441 900111 CH KE ALL PSIG MEASUREMENTS WHEN SYSTEM IS AT 23 C ome 220309 211033 202032 MAH 220554 ROTOLOCK VALVE 220553 MAH CORRECTED COMPRESSOR STOCK NUNBERS LOW TEMP STAGE FOR MANUFACTURING PURPOSES WITHOUT R EAEN eee WRITTEN PERMISSION FROM ELECTRON REV
10. connectors are seated together Re seat connection Installed in wrong connector Verify the plug is in the correct receptacle Re seat plug in correct receptacle Improper door alignment Verify door gap Single door 600 Double door 700 both measured from the hinge side Make adjustment as required Bad door switch Verify continuity on door switch by opening and closing door If no continuity of switch during opening and closing of door replace door switch Defective micro board Short out door switch connector If alarm does not clear replace micro board Or else repeat starting at Step 1 2 6 Symptom No Door Access Order Possible Cause Verification Action 1 Door locked Check to ensure door is not locked Unlock door Vacuum relief assembly is frozen over 2 Visually inspect vacuum relief port for any restrictions Clean as necessary Follow routine maintenance instructions in user s manual to periodically clean the port Release 3 unit Vacuum relief not functioning Release 3 units built after 6 2005 vacuum relief port in door Check voltage at J7 on the display board for 14V 0 5 YES 14 unplug heater harness from measure resistance across heater leads Heater resistance should be between 9 and 30 Ohms assembly NO Check and reseat connections on heater harness Measure DC voltage
11. micro board at connector labeled DC power from HV board pins 1 and 6 Check connector seating on ribbon cables Replace if required Is unit operating fans compressors If no replace micro board If yes continue to step 4 Micro board Micro LED LD1 functioning no display LED LD2 Turn unit off then turn unit back on Miscellaneous characters displayed Replace display board Check connection of 25 pin D sub cable at both ends Waiting Comm is displayed Replace micro and or display as needed Display Missing segment Visual Replace display board Keys not responding Check continuity for buttons on overlay Replace overlay LEDs not functioning Ohm out LEDs Replace overlay No Alarm Press any key on overlay If no audible replace display board 2 5 Symptom Door Ajar Alarm Order Possible Cause Verification Action 1 No magnet Visually inspect for magnet in door handle Replace magnet as required Worn door handle Inspect inside of door latch for signs of metal Replace latch if necessary and verify vacuum relief 2 aluminum wear wobbly handle port operation as well as the door alignment Improper connection Wires loose from door switch connector Verify wires are properly seated in connector If required re seat the wire connection Door switch connector not seated to board connector Verify
12. 15 Contact manufacturer Ribbon cable connection between high voltage and micro board Cables properly seated Ribbon cables damaged Reseat connections Replace cable s High voltage board failure AIUI N Measure AC voltage between left side F1 and left side of R9 Voltage should be between 25 and 95 VAC If incorrect voltage replace high voltage board Measure frequency between pins 4 and 5 of U1 Frequency is not twice the frequency of wall outlet Replace high voltage board 6 Micro board failure Measure AC voltage across R40 on micro board Voltage should be between 25 and 95 VAC No voltage replace ribbon cable Good voltage replace micro board Measure frequency between pin 10 of U14 and pin 8 of U28 No measurement check ribbon cable If ribbon cable is ok replace micro board 2 13 Symptom Low Temperature Alarm Order Possible Cause Verification Action 1 Relays on high voltage board not being Verify that LEDs 1 05 LD6 on the high IF LDS and LD6 on and voltage is greater than turned off voltage board are illuminated and voltage across 10DC replace micro board If LD5 and LD6 are D12 and D13 is greater than 1OVDC off and voltage is less than 10 replace high voltage board 2 Wrong probe value Verify probe resistance with Temperature vs Resistance Chart page 3 2 Replace as required
13. 33 61 8 160 2 040 0 260 1 300 62 8 053 2 013 0 253 1 267 63 7 947 1 987 0 247 1 233 64 7 840 1 960 0 240 1 200 65 7 733 1 933 0 233 1 167 66 7 627 1 907 0 227 1 133 67 7 520 1 880 0 220 1 100 68 7 413 1 853 0 213 1 067 69 7 307 1 827 0 207 1 033 70 7 200 1 800 0 200 1 000 71 7 093 1 773 0 193 0 967 72 6 987 1 747 0 187 0 933 73 6 880 1 720 0 180 0 900 74 6 773 1 693 0 173 0 867 75 6 667 1 667 0 167 0 833 76 6 560 1 640 0 160 0 800 77 6 453 1 613 0 153 0 767 78 6 347 1 587 0 147 0 733 79 6 240 1 560 0 140 0 700 80 6 133 1 533 0 133 0 667 81 6 027 1 507 0 127 0 633 82 5 920 1 480 0 120 0 600 83 5 813 1 453 0 113 0 567 84 5 707 1 427 0 107 0 533 85 5 600 1 400 0 100 0 500 86 5 493 1 373 0 093 0 467 87 5 387 1 347 0 087 0 433 88 5 280 1 320 0 080 0 400 89 5 173 1 293 0 073 0 367 90 5 067 1 267 0 067 0 333 91 4 960 1 240 0 060 0 300 92 4 853 1 218 0 053 0 267 93 4 747 1 187 0 047 0 233 94 4 640 1 160 0 040 0 200 95 4 533 1 133 0 033 0 167 96 4 427 1 107 0 027 0 133 97 4 320 1 080 0 020 0 100 98 4 213 1 053 0 013 0 067 99 4 107 1 027 0 007 0 033 100 4 000 1 000 0 000 0 000 RTD Temperature vs Resistance Table For European Curve Alpha 00385 ITS 90 1 Celsius Increments Source http Wwww omega com temperature Z pdf z252 254 pdf 687 410 400 ersa 490 eoj 650 8 83 82 2 1 0 7 eof 40 aert 350 7 6 5 1
14. 57 58 59 60 61 62 63 64 65 66 67 69 70 72 73 74 75 76 Hi 1 19 91 h Voltage Board 558 Switching Power Supply 400165 85 485 J16 ps 232 Remote Alarn oR Analog Dutput Jl J19 J18 J17 7 Board 191885 J13 ana 27 SI 21 gt Disploy Board 191902 ight L 191751 Chest 3 E abe 2 1 gt BUS Over lay a ae Single Door Heater 132115 Double Doar Heater 132114 3 Pos Ribbon 430329 20 Pos 430219 Ribbon Pos Ribbon 430309 Pos Ribbon 430309 12 0 Fan 900134 Backup Battery 400159 20 Pos Ribbon 430219 Backup Solenoid LN2 290129 Coe 290131 Backup Probe 290038 Heat Exchanger Probe 290177 Condenser Prabe 290178 Control Probe 290176 Sanple Probe 290177 Cobex Probe 290180 Double Door Heater 132114 Lid Switch 350256 Door Switch 350230 Switch Double Door 360230 25 Pos Serial Cable 430336 upright 195442 chest Micro Board Battery 400159 Recorder 201210 STANDARD 9627 amp 98628 Vacuum Relief Heater Assy 1950069 800 8600 Series Madels 5602 5605 5606 5612 5619 5620 8602
15. 60 0 840 4 200 25 17 333 4 333 0 833 4 167 24 17 227 4 307 0 827 4 133 23 17 120 4 280 0 820 4 100 22 17 013 4 253 0 813 4 067 21 16 907 4 227 0 807 4 033 20 16 800 4 200 0 800 4 000 19 16 693 4 173 0 793 3 967 18 16 587 4 147 0 787 3 933 17 16 480 4 120 0 780 3 900 16 16 373 4 093 0 773 3 867 15 16 267 4 067 0 767 3 833 14 16 160 4 040 0 760 3 800 13 16 053 4 013 0 753 3 767 12 15 947 3 987 0 747 3 733 11 15 840 3 960 0 740 3 700 10 15 733 3 933 0 733 3 667 9 15 627 3 907 0 727 3 633 8 15 520 3 880 0 720 3 600 7 15 413 3 853 0 713 3 567 6 15 307 3 827 0 707 3 533 5 15 200 3 800 0 700 3 500 4 15 093 3 773 0 693 3 467 3 14 987 3 747 0 687 3 433 2 14 880 3 720 0 680 3 400 1 14 773 3 693 0 673 3 367 0 14 667 3 667 0 667 3 333 Temp C 4 20 4 20mA 0 1V 0 5V mA with 250 Ohm resistor 6 14027 3 507 0 627 3 133 8 13813 3455 0 613 3 067 9 13 707 3427 0 607 3 033 Temp C 4 20 4 0 1V 0 5V mA with 250 Ohm resistor 51 9 227 2 307 0 327 1 633 52 9 120 2 280 0 320 1 600 53 9 013 2 253 0 313 1 567 54 8 907 2 22 0 307 1 533 55 8 800 2 200 0 300 1 500 56 8 693 2 173 0 293 1 467 57 8 587 2 147 0 287 1 433 58 8 480 2 120 0 280 1 400 59 8 373 2 093 0 273 1 367 60 8 267 2 067 0 267 1 3
16. 8605 8606 9607 8612 8619 8620 8627 8629 8691 9694 8695 8602 70 1 0 Rev 8 Page 2 of 3 WIRE COLOR GAUGE WIRE COLOR GAUGE 79 1 BLK 14 25 WHT 18 2 REO 14 26 BLK 18 3 GRN YEL 14 27 BLK BO 4 REO 14 28 REO 18 5 BLK 14 29 Bl BLK 18 30 7 BLK 18 31 GRN YEL 14 5 H BLK 18 ER BLK 14 B2 H BLK 18 ER BLU 14 10 BLK 18 34 BLK 14 B3 11 BLK 18 35 BLU 14 12 BLK 18 36 BLK 14 13 BLK 18 37 BLU 14 B4 14 GRN YEL 18 BLK 14 15 GRN YEL 18 38 BLU 14 5 16 GRN YEL 18 40 BLK 14 17 GRN YEL 14 41 BLU 14 18 GRN YEL 14 42 BLK 14 19 BLK 14 43 BLU 14 20 BLK 14 44 BLK 14 B7 21 BLK 18 45 BLU 14 22 18 46 BLK 14 23 BLK 18 47 BLU 14 24 REO 18 4B BLK 14 49 BLU 14 89 50 BLK 14 EI BLU 14 Uprights Chests 9 1 SIZE THERMO THERMO SIZE THERMO WOH 13 9602 9691 5602 12 7 9612 5612 17 8605 8694 5605 17 8619 5619 92 23 8506 8595 5506 20 8520 5520 28 8607 20 8628 93 13 8627 94 RS 232 SPECIFICATION 95 BAUD 1200 REMOTE CONTACTS ANALOG OUTPUT PARITY N DIN 1 Analog Output BITS 8 PIN 2 Analog STOP BITS 2 PIN 3 Not Connected PIN 4 Not Connected RS 232 PORT 97 5 Nornally Clased PIN 2
17. 8692 8693 8803 70 1 0 Rev of 3 8 ET DI UJ 65 66 G7 68 69 70 72 Le 74 Ta 76 H 1 i 9 gh Voltage Board 1 680 Switching Power Supply 400165 25 232 Renate or Analog Output 25 485 J5 cro Boord Mi 191804 EEN ES E et C b Ss i 22 Backup 1 gt a a 191685 we J19 J18 Display Board 191802 Upright 191751 Chest BUS Overlay 1 4 900 4 2 BET E Recorder Lg Fa 3 201210 gt Probe Optional 2 0 24 Single Heater 132115 Double Door Heater 132114 Vacuum Relief Heater Assy gt 1950069 900 8600 Series Pas Ribbon 430329 20 Pos 430219 Ribbon Pos Ribbon 430309 Pos Ribbon 430309 12VDC Fan 900134 Backup Battery 400159 20 Pos Ribbon 430219 Backup Solenoid LN2 250129 2 250131 Backup Probe 290038 Hent Exchanger Probe 290177 Condenser Probe 2901789 Control Probe 290176 Sample Probe 290177 Cobex Probe 290180 Double Daor Heater 192114 Lid Switch 360256 Door Switch 360230 Doar Switch Double Door 360230 25 Pos Serial Cable 430336 Uprig
18. E 03 09 04 SCALE WE MATERIAL PAINT COLOR N A 1 COMMON TO 756 556 90 8656 9660 5758 5656 23 CU FT FREEZERS 120 V Thermo TENCE ES ERIE SED CRAVING ERC acm es 8656 90 0 D O O s mon e POWER CONNECTI 230V 19 24 OPERATING RAN S0 B0HZ 12 0 FLA GE 208 240 A 853 Power Inlet 460169 Circuit Breaker Switch 230184 Transfarner 420090 Transformer 420090 High Pressure Cutout 1 High Voltage 91658 207010 HS Compressor 203031 Contains Start Relay 300319 Run Capacitor 170145 20uF 440V Start Capacitor 170191 108 130uF 250V High Pressure Cutout 207008 LS 203032 Cantains Start Relay 300319 Run Capacitor 170149 10uF 440V Start Capacitor 170192 43 52uF 250V HS Fan 900113 LS Fan 900113 Double Door Heater 132116 13 17 cuft 132117 23 cuft Expansion Solenoid 220626 Fuse 2 285626 Madels 5602 5605 5606 5612 5619 5620 8602 8605 8606 8607 8612 8619 8620 8627 8628 8691 9694 8695 8602 70 1 0 Heu H Page af 3 gt oon ww 50 51 52 53 54 55 56
19. IONS MATERIAL JOK ELECTROSTATIC Thermo PAN CL 9603 70 1 0 Rev CAT TOLERANCE UNLESS OTHERWISE SPECIFIED DRAWING NUMBER SIZE SENSITIVE DEVICES Contral led Er n Equlpnent ANGLES DECIMAL 5 9603 70 1 0 at 3 MICRO BOARD Ce cag U13 Ul6 HIGH VOLTAGE BOARD 011 014 015 J29 SIMTCHER BLACK BLACK INPUT J BLACK IS BLACK J20 1 c Cu BUE mt ne 9 d 09 Di 014 015 co D BLACK v L Fans Heaters Ce el Cy Solenoid BLUE BLLE BLUE 3 E
20. OSES WITHOUT 85694 85695 WRITTEN PERMISSION FROM THERMO ELECTRON OWN AOT APPO MAH 3 22 02 SCALE NONE OBSERVE PRECAUTIONS MATERIAL OQ FLECTROSTATIC PAINT COLOR 9602 70 1 0 Rev 8 TOLERANCE UNLESS OTHERWISE SPECIFIED DRAWING NUMBER SIZE 52 ELECTRON CORPORATION SENSITIVE DEVICES Zi 9602 70 1 0 Page 3 of 3 3 8 H 20V 10 24 2 16 0 ERATING RANGE 108 1307 FLA High Voltage Boord 191680 Power Inlet 460169 Circuit Breaker Switch 230183 Transforner 420065 High Pressure Cutout 207010 HS Compressor 203029 Contains Start Relay 300323 Run Capacitar 170108 35uF 370V Start Capacitor 170155 189 227uF 250 High Pressure Cutout 207008 LS Compressor 203030 Cantains Start Relay 300319 Run Capacitor 170160 40uF 370V Start Capacitor 170010 B 108uF 250V HS Fan 900113 LS Fan 900113 Double Door Heater 132116 13 17 cuft 132117 23 cuft Expansion Salenoid 220626 Fuse 2A 285626 Madels 5603 5604 5615 5618 3521 5656 8603 8604 8615 8618 8621 8656 8690
21. Thermo ELECTRON CORPORATION Controlled Environment Equipment Ultra Low Temperature Freezer Troubleshooting Service Guide 8600 Series 7998600 Rev 4 CAUTION Contains Parts and Assemblies 4 aA Susceptible to Damage by Electrostatic Discharge ESD The material in this manual is for information purposes only The contents and the product it describes are subject to change without notice Thermo Electron Corporation makes no representations or warranties with respect to this manual In no event shall Thermo be held liable for any damages direct or incidental arising out of or related to the use of this manual MANUAL NO 7998600 FR 1789 22216 22179 gt 2 _ ificati 21605 aks EV ECR ECN bal Table of Contents Section 1 General Operation 1 1 Initial Start Up 1 1 1 2 Equipment 1 1 1 3 Operating Pressure High and low stage systems 1 1 Section 2 Troubleshooting Charts 2 1 Probe 1 2 3 and 4 failure alarm tee eset ett thes 2 1 2 2 Probe 1 2 3 and 4 failure alarm All probes 2 1 2 3 Unit will not communicate with alarm EK EG 2 2 2 4 Display Keyboard not functioning 2 3 2 5 Door ajar alarm
22. at the switching power supply On the 6 pin connector measure between pins and 6 14 0 5 Check and reseat connectors between switching power supply and high voltage board Also check and reseat connections between high voltage If not between 9 and 30 Ohms replace VRP board and micro board Release 1 unit Vacuum relief not functioning Release 2 units built between May 2003 and June 2005 do not use a heated vacuum relief assembly Blown fuse Micro board Verify unit is colder than 50 90 130VAC at heater YES Ohm out heater Heater to be 1037 1210 Ohms Cabinet temperature must be colder than 50 C to activate vacuum relief heater Replace heater if required NO Check connections Check fuse Check voltage between U16 13 and J11 1 on micro board Re seat connection s If problem still exists continue troubleshooting Ohm out fuse replace fuse as required If voltage is greater than 1OVDC replace micro board High voltage board Check DC voltage across D15 on high voltage If voltage is less than 1OVDC replace high voltage board 2 7 Symptom Low Battery Alarm Order Possible Cause Verification Action 1 New battery new unit or freezer just placed into service Ask customer end user Complete steps 2 3 amp 4 If yes batteries required 36 hours for charging If no continue to step 5 Mis
23. board L Display Brightness 1 Press the right arrow until D BRIGHT is displayed in the message center 2 Press the mode key to adjust the brightness level The adjustment result is immediately visible by viewing the display m Control Probe Zero Offset 1 Press the right arrow until CONT T X X is displayed in the message center 2 Press Enter or right arrow key This function displays the amount of offset the control probe currently carries The amount is displayed in degrees Celsius with a 1 degree of accuracy Sample Probe Zero Offset optional 1 Press the right arrow until SAM OF is displayed in the message center 2 Press Enter or right arrow key This function displays the amount of offset the sample probe currently carries The amount is displayed in degrees Celsius with a 1 degree of accuracy This option is only available if there is a sample probe installed Note the freezer must be powered up with J10 of the micro board jumpered in the S position to activate the menu o Analog Type 1 Press the right arrow until ALG OUT is displayed in the message center 2 Press up down arrow to toggle between VOLT for 0 to 1 volt or 0 to 5 volt or CRNT for 4 to 20mA 3 Press Enter to save to memory This option must match the analog output dip switch settings on the micro board p Analog Calibration Connect a decade box set at 250 Ohms to pin 1 positive and pin 2 negative on the r
24. bration Offset 1 Press the right arrow until RST DAC OFST is displayed in the message center 2 Press Enter to save to memory The analog calibration offset is reset to factory default h Serial RS232 RS485 1 Press the right arrow until SERIAL RS232 is displayed in the message center 2 Press up down arrow to toggle to 5485 3 Press Enter to save to memory This option must match the serial output dip switch settings on the micro board See unit schematic page 3 7 i Line Voltage Calibration 1 Press the right arrow until LINE XXXVAC is displayed in the message center 2 Press up down arrow to increase decrease the line voltage to match a digital volt meter 3 Press Enter to save to memory j Battery Voltage Calibration 1 Press the right arrow until BAT XX XVDC is displayed in the message center 2 Press up down arrow to increase decrease the line voltage to match a digital volt meter 3 Press Enter to save to memory Digital volt meter is connected across freezer battery k BUS Battery Voltage Calibration optional 1 Press the right arrow until BBAT XX XVDC is displayed in the message center 2 Press up down arrow to increase decrease the line voltage to match a digital volt meter 3 Press Enter to save to memory Digital volt meter is connected across BUS battery Note to differentiate between the BUS battery and freezer unit battery trace the battery harness from the BUS battery to BUS
25. cessary Bad control probe Display reads 99 Bad control probe will also cause a high temperature alarm and lock both compressors on Replace probe Short Open Wrong value Verify probe resistance with Temperature vs Resistance Chart page 3 2 3 Micro board Temporarily switch control probe with heat If the same error exists replace micro board exchanger probe Micro board EEPROM Problem still exists after re initializing unit Re initialize eeprom in test mode If problem remains replace the micro board Note all calibration set points and configuration are set to default 2 3 Symptom Unit will not communicate with alarm system Remote Alarm Contacts Analog System Serial communication Order Possible Cause Verification Action 1 Remote Alarm Contacts Check that all connections are tight and properly wired Missing wires Tighten and or correct wiring Measure continuity of alarm contacts between pins 6 amp 7 and 6 amp 8 while toggling in test mode pin 6 is common Replace micro board if contacts do not change State 2 Analog Output Verify the setting is correct in hidden calibration and corresponds to the dip switch settings on the micro board per the electrical schematic Make changes so the dip switch settings and hidden calibration settings match Measure output Compare with Analog Output Reference Table page 3 1 Call the
26. e compressor turns ON after ten seconds delay Low stage compressor turns ON when A Thirty seconds after high stage starts and heat exchanger probe reads 41 C or colder or B Five minutes after high stage starts and heat exchanger probe reads between 33 C to 40 If heat exchanger probe warms up to 20 C or warmer the low stage compressor shuts down until either condition 5 or 5B is met After thirty minutes if condition 5A or 5B is not met the high stage system failure will be activated Once the cabinet temperature reaches 50 C the expansion tank solenoid is opened de energized The vacuum relief heater and mullion heater on double door units are energized and operate continuously until the cabinet is warmer than 50 Set point achieved fans and compressors cycle off Steps 2 though 7 repeat cycle Items or functions unique to this system 1 2 Expansion Tank Assembly and Solenoid Valve Location Suction side of low stage system Purpose Tank assembly increases low stage system refrigeration capacity Prevents excessive low stage pressures at temperatures warmer than 50 Operation The tank assembly solenoid valve is normally open The solenoid valve is energized closed when the control probe senses temperature warmer than 50 C The solenoid valve is de energized open when the control probe senses temperature colder than 50 1 3 Operating Pressure High and low stage syste
27. eat or replace as required Circuit Breaker Power switch breaker power switch to high voltage board inputs High voltage board and ribbon cable connection from high voltage Switching power supply board to DC switching power supply A Defective switching power supply Verify input line voltage and output voltage Replace if required 14 VDC is present at switching power supply 5 Damaged components or wiring Inspect relay enclosure for damaged components Replace as required and wiring 6 Defective starting hardware or Check both stages for L R A If compressor attempts to run and draws L R A compressor s check start relay for proper operation and values on start and run capacitors Ohm compressor windings and compare to nominal values Appendix B 7 Facility Wiring Dedicated circuit and correct rating Advise customer breaker Connections gauge size and length Try a different circuit Fix as required 2 12 Symptom Wrong Power Order Possible Cause Verification Action 1 Sequence that battery and power switch was Was battery switch turned on before power switch Turn both switches off Turn power switch on then was turned on turned on start up only turn battery switch on Facility wiring incorrect 230V receptacle 115 supply Proper line voltage Need correct operation voltage Wrong line cord set Verify correct line cord plug 5 15 120V 15A 5 20 120V 20A 6 15 230
28. ed 2 PIN 6 Connon 3 RXO gg PIN 7 Nornally Open PIN 5 GNO CONTACT RATING 14 30V CONTACTS IN ALARM STATE 00 Settings for Analog Output SW2 Settings for Conmunicotion Output 14243 sl wie 0 4 20 Output RS 485 oe 02 192 3 03 0 1 Output RS 232 z 04 192 93 a 5 0 5 Output 07 1 Schematic represents single amp dauble door upright models and a chest models All heater are for uprights only Expansion solenoid on 17 amp 23 cuft uprights only 2 Door switches shown in open position 3 Battery switch shown in the OFF pasitian 4 Circuit breaker switch shown in OFF position 5 Options and acessories shown in dashed lines Models 06 13 05 GLS AKS BATTERY CIRCUIT WIRING 7 06 13 05 KOG LON RELIEF HEATER amp CHG DISPLAY 17 11 09 04 ADT LON CHANGED 191751 FROM 191715 5603 2604 26 5 a6 8 1769 08 14 9 oR 2021 5 8503 8604 THIS DOCUMENT CONTAINS PROPRIETARY 8600 SERIES 120 FREEZERS 8615 8618 8621 i 8656 INFORMATION SUCH INFORMATION 15 NOT EE DISCLOSED TO OTHERS FOR ANY PURPOSE NOR i ATTENTION USED FOR MANUFACTURING PURPOSES WITHOUT 8690 869 9693 WRITTEN PERMISSION FROM THERMO ELECTRON OWN ADT ADT DATE 3 22 02 SCALE NONE OBSERVE PRECAUT
29. emote alarm analog connector on the freezer Connect a digital volt meter across the decade box 1 Press the right arrow until ANALOG CAL is displayed in the message center 2 Press enter 3 Observe the temperature display Using the analog output reference table find the display temperature Locate the appropriate output for the temperature Using the up down arrows and enter key on the freezer control panel adjust the reading until the meter reading is equal to the output shown on the chart Press enter Note You must press enter for the output to change Appendix A Glossary Display board customer interface for entering and displaying information All settings are sent to micro board for storage High stage system removes heat from the interstage heat exchanger and transfers heat to condenser High voltage board distributes AC power to boost buck transformers compressors fans solenoids and heaters Generates signal for micro board to identify line voltage Supplies DC power to micro board Interstage heat exchanger device that transfers heat from low stage system to the high stage system Low stage system removes heat from cabinet and transfers heat to interstage heat exchanger Micro board receives input from temperature sensors and signals high voltage board to turn on compressors solenoid fans and heaters Initializes communication with display board The micro board stores all s
30. enter To exit hidden calibration mode press the mode key and the freezer will resume normal operation If no keys are pressed within a one hour interval the freezer will return to Run mode a Manual Calibration 1 Press the left arrow key until the MANUAL CAL is displayed in the message center 2 Attach 1000 Ohms resistance Press enter 3 Attach 806 Ohms resistance Press enter b Reset Control Probe Offset 1 Press the right arrow until RST CONT OST is displayed in the message center 2 Press Enter to save to memory The control probe offset is reset to factory default c Reset Sample Probe Offset optional 1 Press the right arrow until RST SAMP OST is displayed in the message center 2 Press Enter to save to memory The sample probe offset is reset to factory default d Reset Line Voltage Offset 1 Press the right arrow until RST LV OFSET is displayed in the message center 2 Press Enter to save to memory The line voltage offset is reset to factory default e Reset Battery Voltage Offset 1 Press the right arrow until RST BAT OFST is displayed in the message center 2 Press Enter to save to memory The battery voltage offset is reset to factory default f Reset BUS Battery Voltage Offset optional 1 Press the right arrow until RST BBAT OFS is displayed in the message center 2 Press Enter to save to memory The battery voltage offset is reset to factory default 9 Reset Analog Cali
31. et points receives signal from high voltage board to indicate line voltage and then signals high voltage board to engage or disengage boost buck Probe 1 Control probe A defective control probe will cause a probe failure and a high temperature alarm Both compressors will lock on Probe 2 Heat Exchanger Probe A defective heat exchanger probe will cause a probe failure Unit will continue to operate normally Low stage will start 5 minutes after high stage starts Probe 3 Condenser Probe Probe 4 Optional Sample Probe Unit battery supplies DC power to micro and display boards so that cabinet temperature can be displayed alarms can be activated and optional recorder can operate Vacuum relief assembly allows pressure inside freezer cabinet to equalize after a door opening Compressor Information Resistance 25 C 7 Compressor Hardware Compressor Start Run Start capacitor Run capacitor Start relay Winding Winding RF40C1E CAA 2 800Q 0 510Q 88 106uf 40uf 370VAC 3ARR3CT10V5 250VAC RF41C1E CAA 3 2200 0 4150 189 2270 35946 370VAC 3ARR3CT10S5 250 RF40C1E CAV 18 300Q 2 100Q 43 52uf 10uf 440VAC 3ARR3CT10V5 250VAC RF41C1E CAV 6 300Q 1 650Q 108 130uf 20uf 440VAC 3ARR3CT10V5 250VAC KALB 010L CAV 4 5250 1 3700 145 174uf 40uf 370VAC 3ARR3CT24ES 370VAC AFE13C3E IAA 7 32 5 1 09 5 189 227uf 041 147 165VAC 2 AFE13C3E IAZ 34 40 5 5 00 5 50 60uf
32. factory service department 888 213 1790 See section 4 2 p Analog Calibration page 4 3 Check that all connections are tight and properly wired Missing wires Tighten and or correct wiring 3 Serial Communication Verify address is correct in configuration menu and matches the 1535 address Change so that the unit address of the freezer matches the 1535 address Verify the setting is correct in hidden calibration and corresponds to the dip switch settings on the micro board per the electrical schematic Make changes so that the dip switch settings and hidden calibration settings match Check that all connections are tight and properly wired Missing wires Tighten and or correct wiring Tighten and or correct wiring Verify that the cable is a DB9 straight through extension cable Replace cable if necessary 2 4 Symptom Display Keyboard Not Functioning Order Possible Cause Verification Action 1 Turned battery on before AC power is applied initial start up issue only Ask customer end user Turn unit power off Turn battery off Reapply AC power before the battery is turned on 2 No AC power and no battery power Verify supply AC voltage is present Supply correct line voltage Micro board Micro LED LD1 on micro board not functioning 14VDC on switching power supply If not replace switching supply 14VDC on
33. ge suspect partial restriction in cap tube Compare high stage static and low stage static pressures Are the static pressures on high and low stages identical Yes replace interstage and recondition both the high and low stages No go to next verification Static pressure unacceptable Suspect under or overcharge Recondition refrigeration system for system in question Compressor Starting Problem Measurements of wall voltage Unit off Unit at start up If unacceptable work with customer to correct If acceptable go to next step Verify compressor attempts to start draws L R A or turns over briefly If no attempt to start Check voltage to compressor No voltage at compressor LD5 HS LD6 LS is on No voltage at compressor LD5 HS LD6 LS is off If compressor attempts to run and draws L R A check start relay for proper operation and values on start and run capacitors If voltage at compressor isolate compressor Ohm compressor windings at compressors and compare to nominal values Appendix B Check connections enclosure high pressure cutout switch Ohm out pressure switch Switch to be closed Voltage between U13 15 HS 013 16 LS and 1 1 on micro board is less than 1OVDC replace micro board Else if DC voltage across D12 HS or D13 LS on high voltage board is less than 10VDC replace high voltage board 2 15 Symptom Troubleshoot comp
34. ge and verify that high pressure cutout is functioning normally Replace defective high pressure cutout HX probe reading incorrectly Compare T C reading on interstage heat exchanger to resistance of HX probe and display value See Resistance to Temperature Chart page 3 2 If T C differs from resistance and displayed value defective probe If displayed value differs from T C and resistance value replace micro board 2 10 Symptom High Stage Sy stem Failure Alarm continued Order Possible Cause Verification Action 5 Restriction in high stage capillary Measure the temperature at the heat exchanger Recondition high stage tube If a restriction exists the heat exchanger will be warmer than normal 2 11 Symptom Power Failure Alarm Order Possible Cause Verification Action 1 Unplugged line cord Check that line cord is properly seated in wall Re attach line cord and install strain relief per connection and relay enclosure user s manual if required 2 Unit circuit breaker power switch Verify switch circuit breaker power switch Replace if required continuity or test for line voltage on high voltage board where wires from switch are connected to board Verify switch circuit breaker does not trip below Replace if required amperage rating If trips above rating go to step 5 3 Loose wires Verify line voltage connection from circuit S
35. h stage refrigeration system failure Verify interstage heat exchanger temperature is above 33 Troubleshoot with Troubleshooting Compressor Low Stage refrigeration system failure Verify interstage heat exchanger temperature is below 33 Troubleshoot with Troubleshooting Compressor 2 15 Symptom Troubleshoot compressor Order Possible Cause Verification Action 1 Low suction pressure problem Verify compressor starts and run continuously If yes install gauges and go to next step If no go to order 3 of Compressor starting problem Verify suction pressure is above High Stage 0 psig Low Stage 10 vac If suction pressure is proceed to next step If suction pressure is below limits conduct equalization test if equalization test fails blocked cap tube recondition refrigeration system If equalization test passes warm unit go order 2 unit at room temp heat exchanger at room temp Verify discharge pressure is below 175 psig conduct efficiency test Suspect bad compressor values replace compressor recondition refrigeration system If discharge pressure is above LS 175 psig HS 250 psig Suspect non condensables recondition the refrigeration system in question Unit at room temperature heat exchanger at room temperature Verify static pressures are acceptable Recondition low sta
36. hts 195442 Chests Micro Board Battery 400159 Models 5603 5604 5615 5618 3621 5656 8603 8604 9615 8618 8621 8656 9690 8692 8693 8603 70 1 D 8 Page 2 of 3 WIRE COLOR GAUGE WIRE COLOR GAUGE 79 1 BLK 14 25 WHT 2 14 26 BLK 3 GRN YEL 14 27 BLK 80 4 RED 14 RED 18 5 BLK 14 29 8 BLK 3 7 BLK 31 GRN YEL 14 5 BLK 18 32 BLK 14 92 9 BLK 18 33 BLU 14 10 BLK BLK 14 93 11 BLK 18 35 BLU 14 12 BLK 18 36 BLK 14 13 BLK 18 a7 BLU 14 94 14 E 18 BLK 14 15 GRN YEL 18 38 BLU 14 85 16 GRN YEL 18 40 BLK 14 17 GRN YEL 14 41 BLU 14 GRN YEL 14 42 BLK 14 g6 19 BLK 14 43 BLU 14 20 BLK 14 87 21 BLK 18 22 RED 18 23 BLK 18 88 24 RED 18 91 Uprights Chests SIZE THERMO YWR SIZE THERMO VWR g2 13 8603 B692 5603 12 7 8615 5615 17 9604 8693 5604 1 8618 5618 9 23 8656 B690 5656 20 8621 5621 94 RS 232 SPECIFICATION 95 BALD 1200 REMOTE CONTACTS ANALOG OUTPUT PARITY N 1 Analog Output BITS 8 PIN 2 Analog Qutput STOP BITS 2 HIR 3 Not Connected PIN 4 Not Connected RS 232 PORT 97 PIN 5 Norral ly Clas
37. is within specified limits For LD2 measure voltage between U13 12 and J11 1 for LD4 measure voltage between U13 14 and J11 1 on micro board If voltage is less than 1OVDC replace micro board If voltage is greater than 1OVDC for LD2 measure voltage from right side of D3 to right side of D4 for LD4 measure from right D7 amp right side of D8 on high voltage board If voltage is less than 10VDC check ribbon cable Ribbon cable OK replace high voltage board No voltage at compressor LD5 HS on high voltage board is on Check connections enclosure high pressure cutout switch Ohm out pressure switch Switch to be closed Switch OK measure voltage between pins 4 and 5 of J30 If no voltage replace high voltage board Switch defective jumper around switch and continue to test No voltage at compressor LDS HS is off and should be on If voltage between U13 15 and J11 1 on micro board is less than 10VDC replace micro board Else if DC voltage across D12 on high voltage board is greater than 1OVDC check ribbon cable If ribbon cable OK go to previous verification Else if D12 voltage less than 10 replace high voltage board Voltage at compressor Check continuity of compressor thermal switch Check winding resistance of compressor See Appendix B Check compressor starting hardware Replace parts as needed HS compressor cycles on high pressure cutout Install pressure gauges on high sta
38. ms The suction side pressure for both systems typically runs in a vacuum Prior to opening a system for a pressure reading always purge your lines according to the manufacturer s recommended procedure For further information call Thermo Forma Service Department 230 Volt Freezers Only the compressors require 230 volts The remaining high voltage components operate using 115 volts 2 1 Symptom Probe 1 2 3 or 4 Failure Alarm SINGLE PROBE FAILURES Order 1 Possible Cause Verification Action Probe Unplugged Re seat connector Re seat all connections Not fully seated Verify wires are fully seated in connectors and connectors are seated together Replace probe if necessary Bad probe Short Display reads 99 Verify probe resistance See Replace probe Open Temperature vs Resistance Chart Page 3 2 Wrong value Verify probe resistance See Temperature vs Replace probe Resistance Chart Page 3 2 Micro board Temporarily switch suspect probe with control or heat exchanger probe If the same error exists replace micro board 2 2 Sym ptom Probe 1 2 3 and 4 Failure Alarm ALL PROBES EA L Possible Cause Verification Action Control probe not installed Startup only Re seat connector Verify wires are fully seated in connectors and connectors are seated together Reinitialize re start unit Reseat all connections Replace probe if ne
39. o voltage check voltage between U13 10 and 11 1 016 10 and 711 1 on micro board If less than 10VDC replace micro board Else if DC voltage across D11 and D14 on high voltage board is less than 1OVDC check ribbon cable If ribbon cable OK replace high voltage board If voltage exists measure Ohms for fans at connector that plus into J29 on high voltage board First column of black wires for fan in front of high stage second column of black wires for fan in front of low stage Ohms should be 130 to 145 in 23 C Replace fan s with improper Ohms Defective probe See Probe 1 2 3 or 4 failure alarm troubleshooting chart Condenser probe plus into J4 of micro board 2 10 Symptom High Stage Sy stem Failure Alarm Order Possible Cause Verification Action 1 Clear HS System Failure Alarm in Configuration Mode Fan s not running 2 See procedure for troubleshooting fans under Hot Condenser alarm High stage compressor not starting or not running Inadequate power at the customer s site Check voltage at the wall and monitor for large voltage drop during start up If voltage drops below 90V for 120V units or 180V for 230V units contact customer AC power to high stage compressor If required go into test mode turn both fans and high stage compressor on No voltage at compressor LD2 and LD4 on high voltage board are not on Line voltage
40. ressor continued Order Possible Cause Verification Action 3 Verify if compressor tripping on high pressure switch and confirm that discharge is reaching 375 psig 25 psi If tripping on pressure switch and discharge pressure is high then troubleshoot why discharge pressure is high If tripping on high pressure switch and pressure is not running at 375 psig 25 then replace pressure switch Verify if compressor is tripping on thermal switch off If yes recondition low stage If no troubleshoot high voltage board board turning compressor 2 16 Symptom Voltage Compensation Failure 1 Voltage Compensation Failure Unit will operate normally Turn unit off and then back on If unit goes into Boost LD2 amp LD3 or Buck LD1 amp LD4 unit does not function and then goes into Normal mode LD2 LD4 Check wiring between transformer s and high voltage board Check transformer Check relay contacts Restart unit Take following readings when LD1 or LD3 should be on LD1 Line voltage should be read between J5 and J22 Replace high voltage board as required Turn unit off and then back on If unit goes into Boost LD2 or Buck LD4 unit does not function and then goes into Normal mode LD2 amp LD4 or LD3 does not turn on For LD3 measure voltage between U13 11 and J11 1 for LD1 measure between U13 13 and 1 1 on micro board If voltage is less
41. sing battery Visually look for battery Install battery Battery switch turned off Verify switch is Turn switch on after AC power is applied Connection Wires making connection Battery wired backwards Ensure connections are tight at the battery battery switch and micro board Verify the red wire is connected to the positive terminal Tighten and change wiring as needed Battery switch defective Verify continuity with multimeter Replace switch Battery Calibration Measure voltage at the battery and compare to the value displayed in hidden calibration Match values Battery voltage lt 12 1 during battery test Check voltage at the battery during battery test after 2 days 48 hours of operation If voltage lt 12 1 replace battery and continue to step 8 ON Micro board Battery test circuit Battery charging circuit Disconnect battery and measure voltage at the battery wires If 13 5 13 8 VDC is present replace battery If not present replace micro board and battery 2 8 Symptom Noise Order Possible Cause Verification Action 1 Loose screws panels or compressors Ensure all screws and bolts are tightly secure Tighten as needed Missing or no sound insulation Remove side panels to ensure insulation is present Inspect the bottom of cabinet to verify insulation is presen
42. t Add foam panels if necessary Start capacitor on compressor Ensure capacitor is not touching the compressor body and capacitor bracket securely holds the capacitor Adjust as needed Electrical cover on compressors Ensure cover is tight Tighten as needed Vibrating refrigeration lines Inspect for lines that are touching Adjust as necessary Nin By gt NO Solenoid Ensure that the solenoid base sits on presstite tape and is tie wrapped to the freezer base Replace presstite tape and tie wraps if necessary 2 9 Symptom Hot Condenser Alarm Order Possible Cause Verification Action 1 High ambient Measure ambient temperature Is ambient above 33 C Alarm will cycle with compressors If ambient is above 37 C alarm is on constantly Move to cooler location lower ambient Educate customer Restricted reduced airflow Check filter Change clean filter Check for condenser blockage Remove blockage Verify clearance specifications of 5 inches are met Install stand offs Check for open front panel Close front panel Fan s not running Confirm High stage is on fans should be running Start unit to continue if off Identify problem fan s Method tie wrap Confirm voltage to each fan by verifying voltage at pins J29 1 to J29 7 and J29 2 to J29 8 on the high voltage board If n
43. than 10 replace micro board If voltage was greater than 1OVDC for LD1 measure voltage from right side of D1 to right side of D2 for LD3 measure voltage from right D5 amp right side of D6 on high voltage board If the voltage is less than 1OVDC check ribbon cable If ribbon cable is OK Replace high voltage board If voltage between diodes was greater than 10 go to previous verification LD3 maybe defective Analog Output Reference Table Temp C 4 20 4 0 1V 0 5V mA with 250 Ohm resistor 50 20 000 5 000 1 000 5 000 49 19 893 4 973 0 993 4 967 48 19 787 4 947 0 987 4 933 47 19 680 4 920 0 980 4 900 46 19 573 4 893 0 973 4 867 45 19 467 4 867 0 967 4 833 44 19 360 4 840 0 960 4 800 43 19 253 4 813 0 953 4 767 42 19 147 4 787 0 947 4 733 41 19 040 4 760 0 940 4 700 40 18 933 4 733 0 933 4 667 39 18 827 4 707 0 927 4 633 38 18 720 4 680 0 920 4 600 37 18 613 4 653 0 913 4 567 36 18 507 4 627 0 907 4 533 35 18 400 4 600 0 900 4 500 34 18 293 4 573 0 893 4 467 33 18 187 4 547 0 887 4 433 32 18 080 4 520 0 880 4 400 31 17 973 4 493 0 873 4 367 30 17 867 4 467 0 867 4 333 29 17 760 4 440 0 860 4 300 28 17 653 4 413 0 853 4 267 27 17 547 4 387 0 847 4 233 26 17 440 4 3
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