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Technical Service Manual

1. NOTE Wiring diagram is positioned on inside cover d e Grommet e 4 Sta con connectors e New temperature control e Instructions _____STEPI Removing Power A Disconnect power to the unit Figure 2 Removing ballast box cover INSTALLATION INSTRUCTION TEMPERATURE CONTROL REPLACEMENT CONTINUED STEP 4 Relay Connection Mounting A With slotted screw driver and plastic mallet or hammer drive out knock out positioned on left side of ballast box See Figure 3 B Install the supplied grommet into the knockout hole See Figure 4 ie a Wo Figure 4 Installing the grommet C Mount relay to underside of unit on the left side of ballast box and 3 4 back from the front edge of the underside NOTE Mount relay next to the ballast box so that when the relay shield is installed it covers the relay and all exposed wiring Relay should be anchored with two self tapping screws supplied in kit as pictured in Figure 5 Figure 5 Anchoring relay we INSTALLATION INSTRUCTION TEMPERATURE CONTROL REPLACEMENT CONTINUED STEP 5 Relay Temperature Control Wiring i coil contacts 4 i white ink A Connect the wires included in kit to the relay as follows 1 Connect one black wire to one of the normally opencontacts of the relay meblack GS black 2 Connect the other black wire to the other normally open contact on Normally open contacts t
2. ni hrt l mia a i TT bone Ss PRR AE A ARAE n MEEPS E AASE a MAD D BRAE n Aena n arst n eT Figure 3 NOTE Length of door stop and number of screws determined by cooler model INSTALLATION INSTRUCTION gt LOCK INSTALLATION TD Models REQUIRED TOOLS e Phillips screwdriver STEP 1 STEP 2 STEP 3 Remove original lid handle and Close lid completely Slide ratchet Slide locking cylinder on ratchet replace with notched handle provided bar through notched handle so the bar until snug against handle Lid bar wraps around front rail assembly is now in locked position GENERAL INSTRUCTIONS In this section you find many different instructions from how to install castors to how to install vandal panels If there are any questions or we do not cover your needs in this section please call Technical Service 1 800 325 6152 INSTALLATION INSTRUCTION OVERSHELF OPTION TSSU TWT TUC Congratulations on your purchase of an accessory that has been designed to efficiently assist your food preparation The following instruction has been written to assist you in your overshelf installation KIT CONTENTS e Shelf 1 ea e Shelf supports 2 ea 60 models offer 3 ea e 1 4 20x1 Hex Head Bolt 4 ea e 1 4 20x1 1 2 Hex Head Bolt 4 ea 60 models offer 6 ea e 1 4 Flat Washer 4 ea 60 models offer 6 ea REQUIRED TOOLS e 7 16 Wrench INSTALLATION STEP I Place one flat was
3. Remove the door and carefully place door on a flat surface INSTALLATION INSTRUCTION TORSION SPRING REPLACEMENT SWING DOOR Continued STEP 8 Remove upper and lower brass bush ing from from the top and bottom of door with a slotted screwdriver or nee dle nosed pliers if required NOTE It may be necessary to verify stop pin location and door block material for some models Or call 800 325 6152 STEP 9 Using a needle nosed pliers remove the broken torsion spring from the bot tom of the door STEP 10 Insert the new spring from the top of the door ensuring that the end hooks into the cross in the bottom door block The gap in the hook should be wide enough to snugly fit STEP 11 Assemble top hinge Place the hinge washer over the door hinge shaft slide into brass bushing and fit into aluminum door block fig ure 1 NOTE The slot at the base of the hinge shaft must seat over the head of the door hinge spring STEP 12 Assemble bottom hinge Place the hinge washer over the bottom hinge bracket replace the thrust bear ing over the washer slide this assem bly into the brass bushing and fit into aluminum door bracket STEP 13 While holding bottom hinge in place lift door and slide top door hinge together Maintain vertical pressure by resting door bottom on your knee while squatting or have someone assist in order to re attach lower hinge to cabinet Fasten hinge with 3 8 bolts a
4. STEP 22 Plug the harness receptacle into the ballast receptacle and reinstall the louver grill STEP 23 Plug in the cabinet and test WIRE PAIRING Door harness to lamp holder The lamp holder combination will have two black wires and two white wires The door harness will have either two black and two white wires or one green one red one black and one white wire Below are the wire combinations for each Multi colored door _ harness to lamp holder Green wire to Black wire Red wire to Black wire White Wire to White Wire Black Wire to White Wire White Black door _harness _to lamp holder White Wire Black Wire White Wire to Black Wire to INSTALLATION INSTRUCTION SHIMMING THE GLASS INSERT gt Under normal circumstances your True Merchandiser won t require any type of adjustments except for the ones already outline in your installation instructions When install properly you will have a perfectly aligned piece of equipment There will be however some occasions in which it will be necessary to go a little deeper in order to accomplish a perfect alignment One of the most common problems at installation is the door s sagging or unaligned to correct this condition here are the recommended procedures 1 Make sure that there is no damage to the door s or the cabinet 2 Try to level the door s by adjusting the leveling legs Perform this procedure by adding castor shims if the unit is on castors 3
5. See Figure 2 STEP 15 Insulate the suction line where the line come out under the cabinet STEP 16 Place the cap tube suction line with the accumulator inside the cabinet STEP 17 Soder the capillary tube in to the evaporator as well as the accum ulator to the evaporator STEP 18 Solder the suction line down where the suction line meets with the below compressor pull out STEP 19 Solder the cap tube to the into the copper line that goes into the outlet of liquid line filter drier STEP 20 Pressurize the system using nitrogen to leak check If a leak is found repair the leak and repeat this step CAPILLARY TUBE REPLACEMENT INSTRUCTIONS Upright GDM T Series Equipment Continued STEP 21 Pull a vacuum on the unit NOTE The use of a micron gauge is recommended STEP 22 Reassemble the evaporator section Figure 2 STEP 23 Check the cabinet operation STEP 24 Place the cover over the new cap tube suction line assembly and secure it to the back wall using several small sheet metal screws or pop rivets STEP 25 Place the back guards back in the unit STEP 26 Finish reassembling the cabinet REFRIGERATION TROUBLESHOOTING CHART Refrigerator gt REFRIGERATION TROUBLESHOOTING CHART REFRIGERATOR PROBLEM Cabinet is running warm 1 Are lights and evaporator fan working NO Check to make sure cabinet is plugged in check to make sure circuit breaker is not tripped che
6. Technical Service Manual All Models Index Page Cabinet Installation and Set Up 4 Electrical Requirements 5 Conductors and Circuits 6 Cabinet Installation and Set Up Checklist 7 Cabinet Installation and Set Up Swing amp Slide Doors 8 GDM T Series Freezers 9 Remote Condensing Unit 10 Temperature Control Altitude Adjustment 11 Temperature Control Altitude Adjustment new temp control 12 Defrost Controls 13 14 Preventative Maintenance 16 Cabinet Maintenance Schedule 17 Condenser Cleaning 18 Refrigeration Section 20 Polyol Ester Lubricant The CFC Report 21 Service Contractors Attention Please 22 Basic Refrigeration The Capillar y Tube System 23 The Refrigeration Cycle 24 True s Remote System How it Works 25 Basic Refrigeration Control of Liquid Refrigerant Floodback 26 General Maintenance amp Repairs 28 Top Removal for TBB and TDD Units 29 Top Removal forTD and T GC Units 30 TPPCountertop Replacement Instructions 31 Top Removal for Various Coolers TSSU TWT TUC 32 Top Removal forTRCB 50 and 79 33 End Cap Replacement T Series Swing Door 34 35 Side Panel Replacement GDM Series 36 Side Panel Replacement GDM 33C PT 37 Floral Case Baffle Installation 38 GDM 23FC Mirror Retrofit Kit 39 Undercounter Refrigerator Freezer Perimeter Heater Wire Replacement 40 GDM amp T Series Freezer Perimeter Heater Wire Replacement 41 TD Series and Glass Chillers 42 Temperature Control Replacement for Cabinets Larger tha
7. Drill and pop rivet every 8 to 10 so that the extru sion remains straight gy INSTALLATION INSTRUCTION P lt SIDE PANEL REPLACEMENT GDM SERIES STEP 3 Attach the other plastic extrusion to the bottom side corner of the cabinet see illus tration Drill and pop rivet every 6 to 8 so that the extrusion remains straight STEP 4 If the cabinet will be placed outdoors the back side of the 3 4 wide flange should be silicone caulked to stop rain water from getting behind the panel STEP 5 Position and place artwork panel against cabinet so that the 3 4 wide flange is at the top and rear of the cabinet Slide panel into the slots provided in the plastic extrusions STEP 6 Check to see that there is no gap under the top and rear 3 4 wide flange STEP 7 Drill and pop rivet the artwork panel to the cabinet using the 3 4 wide flanges provid ed at the rear of the cabinet and the top STEP 8 Wipe off excess silicone caulking when sealing is completed CX TAUSION INSTALLATION INSTRUCTION SIDE PANEL REPLACEMENT GDM 33C PT POP AWET TOOL The procedure listed below will enable you to create a frame around the end panel and will secure your new replacement panel REQUIRED TOOLS e 1 2 drill e Rivet tool STEP 1 Peel backing on two way tape and attach as indicated in figure 1 Apply tape in two areas as shown this will secure replace ment panel when inserted into frame ST
8. Drill holes with 7 drill bit i or 201 Dia Install door on nha a e cabinet with black plastic i Pa l RE Ae p i spacer between hinge w oe bracket and counter top I Tee Pa oa op Scre S and run screws into new Mc Erap eet holes and remove spacer be blocks Evaporator Housing TOP REMOVAL FOR TRCB 50 and 79 TRCB 50 and 79 gt 1 Disconnect the power to the unit 2 Remove drawers 3 Remove condensing unit grill 4 Locate amp remove 2 2 3 4 inch screws in the black plastic trim in the top of each door or top drawer opening if necessary remove mullion 5 Break silicone seal around countertop inside and out 6 Lift front edge of counter top about 10 to 15 Push countertop toward back of cabinet to detach counter top from securing devise 7 To install reverse these procedures Make sure to replace screws and apply silicone seal around edge of counter top Mi z TES i n w m i Fa ini Top Pa a Top Screws End Bar ond Po Le A Mullion gt REQUIRED TOOLS e Phillips Head Screwdriver e 1 4 Hex Head Driver e Putty Knife e Two Way Tape e Rubber Mallet e 30 drill e Rivet Gun e Black Silicone optional e Silver Gray Silicone Caulk optional STEP I Disconnect power to unit STEP 2 Carefully lay cabinet on its back using 2x4 s etc to cushion and elevate from the floor S
9. Figure 1 INSTALLATION INSTRUCTION ANCHORING THE TSSU HOOD COVER gt This is True s recommended procedure for installing the fasteners required to connect the sandwich salad hood cover to the hood See callout 1 on the illustration ASSEMBLY STEP I Locate the hood cover packaged within the cardboard container on top of the salad sandwich unit and position under the hood STEP 2 Remove the slotted thumb screw from hood by backing out the factory installed slotted thumb screw See diagram of slotted screw and callout 2 STEP 3 Place hood cover into final position beneath hood align hood hinge pin with anchor hole on hood cover and re attach fastener by replacing thumb screw into hinge pin STEP 4 Repeat procedure for both ends of hood INSTALLATION INSTRUCTION INSTALLING THE TPP SERIES SERVICE SHELF prior to NSF 7 recessed pan design gt REQUIRED TOOLS b Remove the service shelf CAUTION e Pencil or Marker c Lightly punch a starter mark and PAMA RTM RA4 ee e Slotted Screwdriver drill a pilot hole in each of the will strip out e Center Punch two mounting areas be careful e Adhesive Tape or Equivalent not to drill beyond an inch and STEP 5 e Power Drill With 11 32 Bit three quarters e Adjustable Wrench c Turn hex nut in a counterclock e Pilot hole drill bit wise direction two full turns with a wrench while holding tool STEP I at right angles to the wor
10. If you are not sure of your cleaner s chloride content contact your cleaner supplier If they tell you that STAINLESS STEEL EQUIPMENT CARE AND CLEANING NAFEM North American Association of Food Equipment Manufacturers your present cleaner contains chlorides ask if they have an alternative They probably will Also avoid cleaners containing quaternary salts as they also can attack stainless steel and cause pitting and rusting 4 Treat your water Though this is not always practical softening hard water can do much to reduce deposits There are certain filters that can be installed to remove distasteful and corrosive elements Salts in a properly maintained water softener are your friend If you are not sure of the proper water treatment call a treatment specialist Keep your food equipment clean Use alkaline alkaline chlorinated or non chlo ride cleaners at recommended strength Clean frequently to avoid build up of hard stubborn stains If you boil water in your stainless steel equipment remember the single most likely cause of damage is chlorides in the water Heating cleaners that contain chlorides has a similar effect DON T USE Steel Pads Wire Brushes Scraper gt 6 Rinse Rinse Rinse If chlorinated cleaners are used you must rinse rinse rinse and wipe dry immediately The sooner you wipe off standing water especially when it contains cleaning agents the better After wiping the equipment down
11. YEARLY Check operation of all moving parts fan motors doors defrost timers amp IDL door cords Check all electrical connections make sure they are all tight and crimps in good condition Check defrost timer contacts make sure they are not pitted Check rear condenser coil screen clean if necessary gee gt ff ph ime aN A E H 7 DSIN PECES RAEE EAN a ne a DA TVA ai LCE eee eee Peete eee ey yy fee REQUIRED TOOLS e Phillips Screwdriver e Stiff Bristle Brush e Adjustable Wrench STEP 1 Disconnect power to unit STEP 2 Take off lower grill assembly by removing four 4 corner screws STEP 3 Remove bolts anchoring compressor assembly to frame rails and carefully slide out tube connections are flexible WL TH ynill MM j Ct N i w GENERAL MAINTENANCE CONDENSER CLEANING lj b STEP 4 Clean off accumulated dirt from condensing coil with a stiff bristle brush STEP 5 Lift cardboard cover above fan at plastic plugs and carefully clean condenser coil and fan blades STEP 6 After brushing condenser coil vacuum dirt from coil and interior floor STEP 7 Replace cardboard cover Carefully slide compressor assembly back into position and replace bolts When reinstalling condensing unit becareful not to crimp or damage the tubing between the con densing unit and the cabinet STEP 8 Reinsta
12. r A Capillary Tube Suction Line 5 8 Hole Figure 1 gt STEP 4 Remove all of the shelves STEP 5 Remove the wire back guards on the back wall of the cabinet NOTE These are in freezers models only STEP 6 Disconnect the evaporator drain line STEP 7 Drop down the evaporator housing by removing the 1 4 screws that hold it in place Remove the temperature control wires and allow the assembly to hang down on the right side of cabinet STEP 8 Locate the two 1 4 screws that hold the left side evaporator up and remove them STEP 9 Un solder the capillary tube from the evaporator NOTE The use of a heat shield is recommended STEP 10 Un solder the accumulator from the Evaporator and the suction line After the old suction lines cools down you can crimp it closed NOTE The use of a heat shield is recommended STEP 11 Drill a 5 8 hole in the floor as close to the Left rear corner of the cabinet as possible See Figure 1 STEP 12 Place the cap tube suction line assem bly in the cabinet STEP 13 Take the accumulator and hold it up inside the cabinet and mark the suc tion line where it needs to be cut You may have to cut some of the line coming from the accumulator STEP 14 Remove the suction line and cut it Using a 90 _ copper elbow join and soder the suction line and the accumulator NOTE This step is easier to preform outside of the cabinet
13. 2 Remove service shelf from box and place shelf legs on top of mounted cutting board Legs that measure 18 shorter legs are to positioned toward the front of prep table STEP 3 Center legs on elevated ingredient pan area left to right The shelf is not the exact width of the pizza prep table STEP 4 Using a level placed on top of the service shelf adjust raise or lower the rear legs for anchor posi tioning STEP 5 Using the pre drilled holes of the service shelf as a template place a pencil mark on the elevated surface Create a pilot hole with a nail or small drill bit Assemble riv nut tool provided and lubricate WD 40 etc the threads Ensure that the flange of the riv nut seats against the knurled edge STEP 7 Insert allen wrench into top of crimping tool and place entire riv nut assembly into recently drilled holes STEP 8 Secure crimping tool with a wrench and turn allen wrench in a clock wise rotation until resistance is felt overtightening will strip riv nut FIELD INSTALLING THE TPP SERVICE SHELF STEP 9 When minor resistance is felt riv nut has expanded to fill the drill hole Remove tape from sides Repeat these steps each of the four anchor positions and replace anchor bracket Use a slotted screwdriver to tighten thumb screws NOTE Hardware is tapped to rear leg of service shelf INSTALLATION INSTRUCTION SNEEZEGUARD OPTION TSSU m SNEEZE GUARD
14. A i Figure 1 LOCATING POWER CORD WIRING FOR CUTTING STEP 6 The power cord wiring is routed through the middle knockout in the cluster of three knockouts in the upper inside of the ballast box See Figure 1 6 gt LOCATING POWER CORD WIRING FOR CUTTING cont STEP 6 Locate the junction of tan pink and black wires coming from power cord area See figure 1 and Figure 2 If cabinet is sup plied with a European style cord the power cord black wire will be brown At this junction cut the pink wire several inches from the junction Strip each end of wire 1 2 See figure 2 ATTACHING THE SURGE PROTECTOR TO THE BALLAST BOX STEP 7 Position the surge protector on left side of ballast box toward back edge Allow for cover clearance See Figure 1 7 Using self drilling screws attach the surge protector on the ballast box as illustrated in Figure 1 step 7 NOTE For GDM 23 mount surge protector below flooring SPLICING INTERCONNECTING WIRING TO SURGE PROTECTOR STEP 8 a Route all interconnecting wires through newly created knockout hole See Figure 2 b Take one pre cut 15 pink wire and locating pink wire still connected to wire junction connect these together with an in line splice or butt splice On surge protector connect another end of pink wire to LINE IN marked on surge protector INSTALLATION INSTRUCTION SURGE PROTECTOR S FOR THE GDM SERIES Continued c Nex
15. ASSEMBLY KIT CONTENTS e Clear Plastic Shield 1 ea e Supports 2 ea e 1 4 20x1 1 2 Hex Head Bolt 4 ea e 1 4 Flat Washer 4 ea e 8 32 Knurled Waferhead Screw 4 ea REQUIRED TOOLS e 7 16 Wrench INSTALLATION STEP 1 Place one flat washer on each of the 1 4 20 hex head bolts STEP 2 Insert one 1 4 20 x 1 1 2 bolt into each of the two holes on the support component and position the support next to the two threaded inserts that are mounted to the outer edge on the back of the TSSU cabinet Figure 1 STEP 3 Screw the bolts into the threaded inserts until they are hand tight STEP 4 Repeat steps 2 and 3 for the remaining Support components which will be mounted to the other end of the cabinet back STEP 5 Remove the protective covering from the clear plastic shield so that it rests on top of the two support components Be careful not to scratch the plastic shield STEP 6 Secure the clear plastic shield to the supports by installing the four 8 32 knurled waferhead screws into the threaded inserts that are located one on the top and one on the rear surface of each support component Hand tighten these four screws STEP 7 Adjust the two support components so that they are positioned straight up and tighten the four 1 4 20 x 1 1 2 hex head bolts until the support com ponents are held firmly in position CLEANING AND CARE The support components are made of stainless steel and
16. Mount doors Top Screws E RES Evaporator Remount doors making sure spacing between doors 1s even To install new top change steps 7 8 and 9 to steps 1 2 amp 3 TOP REMOVAL FOR VARIOUS COOLERS TSSU TWT TUC gt 1 Disconnect power from cabinet 2 Remove door s by removing the screws securing upper hinge to the counter top and pull top of door towards you 3 Locate amp remove 2 2 3 4 inch screws in the black plastic trim in the top of each door or top drawer opening 4 Cut silicone seal with razor knife on inside and outside of cabinet break the silicone seal on both sides and along the front edge with a putty knife 5 Lift top upward two three inches and push backwards this will unhook top from lip in rear edge of cabinet 6 To install top apply a bead of black silicone to the top of the cabinet and hook top on lip at rear of the cabinet and pull forward press down firmly on the top and install screws through cabinet into top 7 Reinstall doors To Install New Top 1 Lay cabinet on its back amp align doors with edge of cabinet Pay attention to proper spacing of door along edge it should be approximately 5 8 Place new silicone beads inside amp out 2 When installing a new top use 5 8 spacers at outer edge of the door and cabinet to locate door properly 3 Push mounting plate on Top ZON KEIL hinge until parallel inn 7 with front of cabinet and mark center of hinge holes
17. Plug in the cabinet STEP 10 If lamp does not illuminate another problem may exist gt Glass Door Refrigerator Replacement Instruction See opposite page for freezer instruction REQUIRED TOOLS e Phillips Head Screwdriver 38 Wide Double Sided Tape NOTE For greater safety and ease of installation it is recommended that two persons assist in replacement procedure IT IS NOT NECESSARY TO REMOVE THE DOOR FROM THE CABINET STEP 1 Turn the cooler off STEP 2 Remove the rubber gasket from the perimeter of the interior side of the door INSTALLATION INSTRUCTION GLASS INSERT SWING DOOR Remove the door handle two screws STEP 4 Remove the screws that secure the four back plate pieces to the door Remove all four back plates STEP 5 Beginning at a corner carefully pry the broken glass loose from the frame If necessary use heat gun or hair dryer aimed in the space between glass insert and door frame to lessen resistance of double sided tape Carefully dispose of the damaged glass STEP 6 Remove any excess tape or glass from the lip on the door frame Replace with new double sided tape on the 1 2 lip GDM 49 STEP 7 To support glass insert use one sided tape to secure two plastic shims 3 32 x 7 8 x 2 1 2 on opposite ends of bottom door frame a few inches from the corners STEP 8 Remembering to keep the tempered glass to the handle side of the frame place the new gla
18. Try to align the door s by adjusting the bottom hinge left or right on the swing type door s Usually by performing these procedures the alignment of the door s is accomplished lf after performing these procedures the problem persists it is recommended to adjust the glass insert to square door by shimming it To shim the glass insert the recommended procedures are as follows WARNING SAFETY GLASSES SHOULD BE USED WHEN HANDLING OR WORKING WITH THIS OR ANY OTHER GLASS a Remove the gasket from the gasket base b Remove the screws holding the gasket base around the door and remove the gasket base c With a putty knife loosen up the glass insert around the door frame lt might be necessary to use a heat gun d With a two by four or a similar device proceed to lift the door frame by prying from the bottom outer corner See Photos 1 and 2 e Shim the glass insert wherever there is a space between the frame and the insert See photo 3 and 4 f Press the insert against the door frame and re install the gasket base and the gasket INSTALLATION INSTRUCTION SHIMMING THE GLASS INSERT CONTINUED gt REQUIRED TOOLS e tape measure e 1 4 drill e 2 saw drill hole saw e 3 4 saw drill hole saw e straightedge e tin snips e Phillips screwdriver e file e drill bit for screws on lock cup STEP I Drill 1 4 pilot hole 37 from the top of the cooler and 1 9 16 down from end panel edge Pierce through wall thickn
19. a decrease in temperature across the restriction due to the pressure drop in the line This will be true only if liquid refrigerant is in the line at the restricted point since any temper ature change due to restriction would be caused by the flashing of liquid into ity to ensure contact switching D Check to be sure defrost actuator pins are in proper position E Check all wires in the timer for tight ness to terminals and broken wires Defrost Control On The Evaporator Drain Pan A If the defrost time is always 35 min utes or whatever duration the elapsed time adjustment is set at and the fan motors do not delay after a defrost cycle and it has been deter mined that the solenoid in the defrost clock is functioning change the defrost control in the evaporator compartment in the top of the freez er This control is attached to the evaporator drain pan ble pull heater out of the plastic WILL NOT REFRIGERATE A Check timer motor to be sure it runs drain tube and replace Connect B Check contacts on the defrost timer heater to the electrical circuit in the 1 Check the refrigerant charge Check the C Check solenoid windings for continu evaporator compartment gt FIELD TROUBLESHOOTING FREEZER PERIMETER HEATER WIRE 7 REPLACEMENT 5 Cabinet Temperature Control A Remove the two screws on the right Drill out the pop rivet that was hidden by the stainless steel trim in the lower side of the evaporator
20. allow it to air dry for the oxygen helps maintain the stainless steels passivity film Recommended cleaners for specific situations STAINLESS STEEL EQUIPMENT CARE AND CLEANING NAFEM North American Association of Food Equipment Manufacturers 7 Never use hydrochloric acid muriatic acid on Stainless steel 8 Regularly restore passivate stainless steel Routine cleaning Medallion Arcal 20 Lac O Nu Ecoshine Fingerprints amp smears Cameo Talc Zud First Impression Stubborn stains amp discoloration Grease amp fatty acids blood burnt on foods Grease amp oil Any good commercial Apply with sponge detergent or cloth Easy off DeGrease It Oven Aid Restoration Passivation Benefit Super Sheen Soap ammonia detergent Apply with cloth or sponge Provides barrier film Rub in direction of polish lines Excellent removal on all finishes gt What does Corroded Stainless Steel Look Like Passive Film Breakdown If the passive film of your stainless steel has been broken your equipment will begin the long walk down the dark road of corrosion At it s end rust The first signs are on the microscopic level If you were to look at them under a microscope or through a magnifying glass you would see small pits and cracks staring back at you Given time these pits and cracks will grow and deepen while all the time exuding unsightly red orange rust More severe and visible
21. cabinet is not level this can cause performance problems that will not be cov ered as warranty repairs 5 When cabinet is set in its final location make sure the specific clearance guidelines are followed These are very important for ventilation in the condensing unit area If not followed can cause premature compressor failure 6 Follow altitude adjustment for temperature control if applicable 7 IF YOU HAVE ANY QUESTIONS ABOUT SET UP OR INSTALLATION OF YOUR NEW CABINET PLEASE CALL OUR TECHNICAL SERVICE DEPARTMENT AT 1 800 325 6152 INSTALLATION INSTRUCTION gt SWING DOORS _ ___ A Remove all other tape securing the doors to the cooler Remove the blue foam blocks approximate ly 1 x3 x1 2 5 x 7 6 x 2 5 cm that are between the door and the cooler One foam block is located on each side of the door frame left and right NOTE Your True Merchandiser has been secured for safe shipping During installation it is necessary to remove the door support bracket B Remove the two phillips screws that secure the bracket to the door see figure 1 C Remove bracket and save for future shipping D Replace screws securely into door figure 1 CABINET INSTALLATION AND SET UP SWING amp SLIDE DOORS SLIDE DOORS A Remove all transparent tape on the door area Remove the foam blocks in top channel in front on the right door approximately 1 x1 x20 2 5 x 2 5
22. consult True Manufacturing Technical Service at 800 325 6152 gt REQUIRED TOOLS e Drewel tool or sharp knife e 3 4 hole saw e Pop rivet tool e 7 8 deep well socket e Tape measure e Phillips screw driver e Slot screw driver e 32 drill bit INSTALLATION STEP I Use tape measure and mark a center line at 34 3 4 down from the top of the cabinet on the left end Mark second center line 7 8 from outside edge of cabinet This should locate the hole in the end of the cabinet STEP 2 Use 3 4 hole saw and drill hole on center mark STEP 3 Remove door jam gasket from left door jam STEP 4 Draw center line on black plastic fill in Align fill in center line with cabi net center line and mark a line along top and bottom to fill in STEP 5 Using drewel tool or sharp knife cut out black plastic breaker on marked lines Remove this section of breaker completely Some of the aluminum wall will need to be removed to create a large enough compartment to work in INSTALLATION INSTRUCTION BARREL LOCK INSTALLATION GDM slide door models 34 3 4 Front View STEP 6 Once the breaker is removed now the foam can be dug out to form the lock box Only enough foam should be removed to install lock STEP 7 Install lock assembly through 3 4 hole Place retainer plate and lock nut end tighten with 7 8 socket Install tumbler and latch assembly and tighten screw STEP 8 Install black plas
23. dis connected from cord Slide the door in both directions Look for binding in the channel area at the top and bottom Check the stain less insert holder the 1 4 3 8 foam tape the nylon buttons and the gasket Adjust or replace the v track to ease any binding Door Weights The door weight area This area includes the weight the nylon cord the assembly for holding the door open and the copper guides for the nylon cord a Remove the door and disconnect the cord Pull the cord and release it gradually Does the weight feel like it is binding Remove the knot in the weight Remove any excess cord at the knot The knot should be inside the weight to minimize the fric tion Is the weight dropping in the middle of the cover or to the front of the cabinet The weight dropping in the middle of the cover or to the front of the cabi net The weight should hang in a vertical position no angle Inspect the weight itself and the holes in it Replace the weight if holes are to far off center and are effecting the travel in the door weight area Gasket The gasket area This area includes the 3 plastic 1 3 8 plastic the gasket and the 11 16 gasket insert holder Inspect the door to make sure it is seating against gasket TO ELIMINATE GAPS ON SLIDE DOOR COOLERS 1 Adjust leg levelers to eliminate gap 2 Place shims between the roller brackets and the door 3 Remove gasket and shim needed locations 4 Sh
24. door black upper lamp holder Pin 2 Pigtail white to door white lower lamp holder Lamp Interior Pin 3 Pigtail red to door red heaters Pin 4 Pigtail green to door black upper lamp holder Pin 5 Pigtail brown to door white lower lamp holder Pin 7 Pigtail blue to door blue heaters 4 4 T Femaile plug for door cord 2 5 8 3 6 Q Black p7 Blaok POP 1 amp Interior 2 Door IDL Freezer Wiring 2 white and Y cord on 3 door cabinet 5 Door Frame Heater Yellow on VHO or Red on 24K ballast 1 ba 6 Blue 1 on VHO or 24K ballast J 2 Ea r WN Black from Org Blk in harness 3 fait 8 Yellow on VHO or Red on 24K ballast 4 loi 9 Door Glass Heater Blue 2 on VHO or Blue 1 from 24K ballast 5 ia Red 1 on VHO or Blue 2 on 24K ballast 6 White from neutral Bundle 7 JMi Red 2 on VHO or Blue 2 on 24K ballast 9 Boor me NEAN Door Glass Heater Red White Black Lamp Interior J UJ x O NUV ANONG O oo gt EQUIPMENT CARE AND CLEANING EQUIPMENT CARE AND CLEANING Cleaning Your Cabinet gt Cleaning Your Cabinet Cleaning Exterior Vinyl Clad Galvanized and Aluminum interior of cabinet True recommends the use of soap and warm water to clean these parts of the cabinet Warning Use of abrasive or chlorine based cleaners will damage your cabinet STAINLESS STEEL EQUIPMENT CARE AND CLEANING NAFEM North American
25. hole to allow connection to lamp holder wires STEP 13 Strip lamp holder wires and door har ness wires STEP 14 Match wires see wiring pairing and crimp on end connectors to each set STEP 15 Put the light channel back in its original position Be sure wires are not pinched within the frame Remove excess slack by pulling on door har ness STEP 16 Place the strain relief back into the door frame INSTALLATION INSTRUCTION IDL Harness Replacement Continued STEP 17 Replace the glass insert Make sure double sided tape is not bunched or lying outside of the door frame The insert should slide into the light chan nel first this may require force Once in the channel then lay within the frame opening STEP 18 Replace the back plastic Match up existing screw holes and use existing screws to fasten STEP 19 Replace the gasket and hang the door NOTE A test should be run before re hang ing the door Simply support the door and plug it into the ballast receptacle Plug the cooler in and see if the door light comes on STEP 20 See figures I amp 2 Route the door harness per figure 2 STEP 21 Place P clip as shown Be sure all the slack in the door harness is removed before tightening the clip Also be sure the clip is placed in plane with the binge bearing NOTE If larger cord is being used you will also have to replace the p clip This will be included in the replacement kit
26. insert into the lid rails sides only and trunions You will need to use your drill motor and a 29 drill bit drill 2 holes about 12 apart in each lid rail to install the 1 8 aluminum rivets 2 each in each lid rail cover Note Be sure to use only aluminum rivets as steel may rust sews INSTALLATION INSTRUCTION TEMPERATURE CONTROL REPLACEMENT For Cabinets With Larger Than 1 3 H P Compressors STEP 2 WARNING f l Slide Door Swing Door Failure to disconnect p lees tO Remove Louvered Grill Remove Louvered Grill the unit may result in electrocution to field personnel A To remove grill loosen upper A Remove screws as indicated by screw on each end of grill and arrows remove lower screws Gently swing Qualified Repair Personnel ea waaay These repairs should be performed by a qualified service technician Required Tools Phillips head Bit 1 4 Nut Driver Bit Wire Cutters Drill Needle Nose Pliers Wire Strippers Crimping Tool Voltmeter Figure 1 Removing louvered grill Figure 1A Removing louvered grill Plastic Mallet or Hammer slide door model swing door model Slotted Screw Driver STEP 3 Accessing Wire Connections Contents of Relay Kit e Relay and mounting screws e Relay Shield and mounting screws See Figure 2 e 4 Relay wires 2 blacks 1 pink 1 white with insulated female spade connectors on one end A Remove ballast box cover by backing out two hex head screws
27. of other vandal panel on back of cabi net Illustration 3 Vandal Panel a Mounting en Cabinet A Bracket should be facing the opposite direction from the Top Mounting Figure 1 REQUIRED TOOLS e Drill 1 4 Bit 3 16 Bit e Pop Rivet gun e Tape Measure STEP 1 Unplug the cooler STEP 2 Position bracket A directly under the sign panel trim with the lip down See figure 2 STEP 3 Center the bracket on the front of the cooler STEP 4 Drill five holes in the cooler front by transferring them through the pre drilled bracket INSTALLATION INSTRUCTION Vandal Panel GDM 69 STEP 5 Pop rivet the bracket in place STEP 6 The two brackets B will be mounted on the front of the cooler directly below the bottom door tracks IMPORTANT Check all dimensions carefully before drilling STEP 7 Position one bracket B so that the center of the bracket is 26 1 2 from the right hand edge of the cooler Located the second bracket B so that itis 26 1 2 from the left hand edge of the cooler See figure 2 STEP 8 Check the height of the brackets before drilling The dimension from the top of the lip on bracket A to the bottom of the lip on bracket B must be 53 See figure 2 gt STEP 9 When in place drill with 3 16 bit and fasten with rivets NOTE The right side of the cooler is determined when facing the cooler STEP 10 Two 1 4 hol
28. or ballast supply voltage Test at the black and white wires going to the ballast You should read approximately 118 volts High voltage Test between the red wires and anyone of the blue wires with the bulbs out You should read approximately 600 volts or 10 Preheat fluorescent light circuit Test voltage between pins on each end of the lamp You should get approximately 118 volts from one pin on one end to one pin on the other You can also check for continuity between the other pins on either end to the starter base To do this test make sure there is no voltage to the circuit and remove the starter from the base If both are ok change the bulb first and then change the starter FOR ANY INFORMATION OR HELP DIAGNOSING BALLAST PROBLEMS PLEASE CALL TRUE MANUFACTURING TECHNICAL SERVICE 1 800 325 6152 Revised 9 24 02 SB GDM amp T SERIES COOLERS DL CONNECTOR gt Black e Black _ m amp Interior 2 Door IDL Cooler Wiring 2 and Y cord on 3 door cabinet 5 6 White Blue 1 on R S or 24K ballast 1 7 Yellow 1 on R S or Red on 24K ballast 2 8 Blue 2 on R S or Blue 1 on 24K ballast 3 9 Yellow 2 on R S or Red on 24K ballast 4 5 Red 1 on R S or Blue 2 on 24K ballast 6 Yellow 2 on R S or Red on 24K ballast 7 E 9 Red 2 on R S or Blue 2 on 24K ballast 8 ne G 8 White Yellow 1 on R S or Red on 24K ballast 9 reen 7 6 a 4 Pin 1 Pigtail black to
29. terminated controls these systems have a temperature sensor that will disconnect the heaters to keep the cabinet from over heating However it won t restart the freezing cycle until the control completes the factory set time which in our case is usually 20 minutes These systems are also equipped with temperature sensors to delay the fan motors once the defrost cycle has been completed to pre vent the circulation of warm air inside the cabinet To adjust the defrost cycle time there is only one possible adjustment Once the cabinet has reach the design temperature pick the time of the day that you want the unit to defrost Turn the actuating gear clockwise until the contacts change position initiating the defrost cycle 3 Line 4 Compressor Actuating Gear PREVENTATIVE MAINTENANCE Please read these instructions Failure to follow maintenance guidelines may cause a non warranted cabinet repair service CABINET MAINTENANCE SCHEDULE Monthly Quarterly and Yearly gt CABINET MAINTENANCE SCHEDULE MONTHLY Check product temperature Brush off condenser coil 3 Inspect lamps and lamp holder connections NO m QUARTERLY Check physical condition of condenser coil and evaporator coil straighten fins if necessary Blow out condenser coil with compressed air Brush off evaporator coil if needed Check physical condition of gaskets and also make sure they are sealing correctly P ae ae oe
30. to remove any particles or moisture in the system Refrigerant then flows through the liquid line into the capillary tube The capillary tube is designed to allow a certain amount of refrigerant to flow through it to keep the evaporator evenly flooded The capillary tube is taped to the suction line to cool the liquid to allow the best heat transfer When the refrigerant enters the evaporator as a liquid warm air from inside the cabinet is circulated through the evaporator coil and the heat from the air is then absorbed in the refrigerant Evaporator As air is pushed through the evaporator by the fan motors liquid refrigerant absorbs heat through the walls of the evaporator coils and vaporizes thus becoming a low pressure gas Condensate Pan The resulting warm air from the condensor blows over the condensate pan and evaporates the water Color Chart Dark Blue Low pressure liquid Light Blue Low pressure gas Red High pressure gas High pressure liquid Hot air out EVaporater Drain Tube Suction Line luw pressure cas Cap liiary tube quid line an mA Compressor Fan Motor Compressor Combines heat absorbed in the evaporator coils with heat of compression from the piston stroke then pushes high pressure gas vapor on into the condenser Evaporator Fan Motor Thermostat Senses evaporator temperature 40 F cuts in starts compressor 18 F cuts ou
31. to the left and repeat process until all spring ten sion is relieved In some instances it is necessary to relieve spring pressure one hole posi tion at a time until spring pressure is relieved NOTE Operation is reversed for left side door gt NOTE If cabinet is equipped with integrated door light be sure to unplug from ballast box NOTE Freezer doors have heater wires which must be unplugged before doors can be removed STEP 6 In a squatted position rest the bottom of the open door on your left knee for right side door as you face the outside of the door Create an upward pressure and remove the two 3 8 bolts from the bottom hinge assembly Remove the bottom hinge assembly Figure 2 Glass Door Replacement Instruction STEP 7 Carefully place door on a flat surface INSTALLATION INSTRUCTION REMOVAL AND INSTALLATION OF A GDM SWING DOOR Continued REQUIRED TOOLS e Phillips Head Screwdriver e Two Drift Punches or two 1 8 drill bits NOTE It may be necessary to verify stop pin location and door block material for some models Or call 800 325 6152 for assistance STEP 1 Beginning with the top hinge assembly of the replacement door place the hinge washer over the hinge shaft and slide into top aluminum door block figure 1 NOTE The slot at the base of the hinge Shaft must seat over the head of the door hinge spring STEP 2 Insert the bottom hinge assembly
32. with 3 doors locate and adjust the blade to the back frame in the center door as needed making sure that the right door will operate freely and secure it with pop rivets Make sure that the wiper gasket does not drag against the door tracks gt Figure 1 REQUIRED TOOLS e Two Drift Punches or two 1 8 drill bits e Needle Nose Pliers e Phillips Head Screwdriver e Slotted Screwdriver NOTE For greater safety and ease of installation it is recommended that two people assist in replacement procedure STEP 1 Turn the cooler off STEP 2 Remove the four mounting screws from louvered grill and remove grill INSTALLATION INSTRUCTION Removal and Installation of GDM amp Old Style T Series Swing Door For models with the integrated door light feature unplug light from ballast box IMPORTANT Freezer doors have heater wires which must be unplugged before doors can be removed STEP 4 Locate the top hinge assembly STEP 5 Remove Door Stop Pin by placing a drift punch or 1 8 drill bit into the stop pin hole two holes to the left for right side door of the stop pin position With drill bit firmly anchored in posi tion apply back pressure to the left and remove the stop pin with a needle nosed pliers While firmly holding the drill bit with your left hand begin rotat ing the hinge shaft to the right reliev ing spring tension Insert second drift punch or drill bit into hole
33. x 50 cm B Remove both plastic brackets secured by tape from under the left door C Open the left door D Remove the foam block from the top channel behind the left door E Remove both plastic brackets from under the right door see figure 2 NOTE Door packing materials should NOT be removed until cooler is placed on location TRANSPORTATION OF THE COOLER WITHOUT THE DOOR PACKING MATERIALS IN PLACE CAN RESULT IN DAM AGE TO DOORS DOOR ROLLERS AND V TRACK gt Installing Castors Install castors in the bottom rail assembly on the underside of the cooler Castors with brakes should be installed in front To obtain maximum strength and stability of the unit it is important that you make sure each castor is secured with a 3 4 19mm open end wrench The bearing race on the castor must make firm contact with the rail Installing Leg Levelers Screw leg levelers into the four corners of the lower rail assembly larger models include levelers centered front and back also CAUTION To avoid damage to lower rail assembly raise unit slowly and carefully to upright position INSTALLATION INSTRUCTION GDM T Series Freezers LEVELING A Set unit in its final location Be sure there is adequate ventilation in your room Under extreme heat conditions 100 F 38 C you may want to install an exhaust fan Warning Warranty is void if ventilation is insufficient B Proper leveling of your True
34. 20 800325 800335 800340 800395 STEP 4 Use jeweler screwdriver and adjust control accordingly a Adjust screws clockwise for colder b Adjust screws counter clockwise for warmer Note 1 4 turn is equal approximately 4 degrees STEP 6 Re install control into housing Refer to Temperature Control Change Out Instructions page 39 41 When reinstalling freezer control make sure temperature control wires are being held up so they do not make con tact with evaporator heater STEP 7 Reset control to setting 5 A a ar STEP 8 Check control operation with ther mometer as done prior to adjustment to make sure control is functional as desired Calibration Instructions For 20DT Digital Thermometer STEP 1 Note that each unit is factory calibrat ed and a glyptol color coded seal is placed on the calibration potentiome ter to prevent calibration shift The color represents date of manufacturer STEP 2 Immerse the sensor in a known tem perature circulated liquid bath using a mercury glass thermometer to obtain the right temperature or have a mix ture of water and crushed ice slush to obtain 32 F 0 C STEP 3 To recalibrate the thermometer use a small phillips head screwdriver to adjust the potentiometer on the back of the 20DT Turn clockwise to adjust down and counter clockwise to adjust up To re seal the potentiometer you can use clear nail polish INSTA
35. 4 Check circuit for proper voltage at receptacle 10 115 Volt 5 10 208 230 Volt 5 Make sure that the wire gauge and breaker sizes are correct and comply with the min imum allowance for voltage drops WARNING FAILURE TO COMPLY WITH THESE REQUIREMENTS MIGHT RESULT IN PERSONAL INJURY AND OR PROPERTY DAMAGE AND WILL VOID WARRANTY gt CONDUCTORS AND CIRCUITS Wire Gauge for 2 Voltage Drop in Supply Circuits 115 Volt Distance In Feet To Center of Load Amps 20 30 40 50 60 70 80 90 100 120 140 2 14 14 14 14 14 14 14 14 14 14 14 3 14 14 14 14 14 14 14 14 14 14 14 4 14 14 14 14 14 14 14 14 14 12 12 5 14 14 14 14 14 14 14 12 12 12 10 6 14 14 14 14 14 14 12 12 12 10 10 7 14 14 14 14 14 12 12 12 10 10 10 8 14 14 14 14 12 12 12 10 10 10 8 9 14 14 14 12 12 12 12 10 10 8 8 10 14 14 14 12 12 10 10 10 10 8 8 12 14 14 12 12 10 10 10 8 8 8 8 14 14 14 12 10 10 10 8 8 8 6 6 16 14 12 12 10 10 8 8 8 8 6 6 18 14 12 10 10 10 8 8 8 8 8 8 20 14 12 10 10 8 8 8 6 6 6 5 25 12 10 10 8 8 6 6 6 6 5 4 30 12 10 8 8 6 6 6 6 5 4 4 35 10 10 8 6 6 6 5 5 4 4 3 40 10 8 8 6 6 5 5 4 4 3 2 45 10 8 6 6 6 5 4 4 3 3 2 50 10 8 6 6 5 4 4 3 3 2 1 230 Volts Distance In Feet To Center of Load Amps 20 30 40 50 60 70 80 90 100 120 140 5 14 14 14 14 14 14 14 14 14 14 14 6 14 14 14 14 14 14 14 14 14 14 14 7 14 14 14 14 14 14 14 14 14 14 12 8 14 14 14 14 14 14 14 14 14 12 12 9 14 14 14 14 14 14 14 14 12 12 12 10 14 14 14 14 14 14 14 12 12 12 10 12 14 14 14 1
36. 4 14 14 12 12 12 10 10 14 14 14 14 14 14 12 12 12 10 10 10 16 14 14 14 14 12 12 12 10 10 10 8 18 14 14 14 12 12 12 10 10 10 8 8 20 14 14 14 12 12 10 10 10 10 8 8 25 14 14 12 12 10 10 10 10 8 8 6 30 14 12 12 10 10 10 8 8 8 6 6 35 14 12 12 10 10 10 8 8 8 6 6 40 14 12 10 10 8 8 8 6 6 6 5 50 12 10 10 8 8 6 6 6 6 5 4 60 12 10 8 8 6 6 6 6 5 4 4 70 10 10 8 6 6 6 5 5 4 4 3 80 10 8 8 6 6 5 5 4 4 3 2 90 10 8 6 6 6 5 4 4 3 3 2 100 10 8 6 6 5 4 4 3 3 2 1 NADA CO mre DOD GO gt CABINET INSTALLATION AND SET UP CHECKLIST CABINET INSTALLATION AND SET UP CHECKLIST 1 Make sure cabinet is plugged into dedicated outlet Before plugging in cabinet check to make sure voltage is adequate for your cabinet Do not use an extension cord this will void cabinet warranty 2 Follow installation instructions for your specific cabinet Each cabinet is shipped with specific installation and set up instructions It is very important to read all information sent with your new cabinet 3 Make sure shipping blocks slide doors and door support brackets swing doors are removed Doors will not function correctly if this step is not followed 4 Make sure that your cabinet is leveled correctly Follow specific instructions with your cabinet and use castor shims were they are needed Make sure that legs and castors are installed per instruc tions If directions are not followed this may cause premature unwarranted failure of cabinet legs or castors If your
37. Assembly 89 TDD 1 CO Knock out 90 TDD 2 3 4 and Club Top models CO2 Knock out 91 Vandal Panel Installation for a GDM 33CPT 54 92 Vandal Panel GDM 69 93 94 Troubleshooting 96 Calibrate Temperature Control 97 98 Troubleshooting and Service Chart 99 100 Capillary Tube Replacement Instructions Upright GDM T Series Equipment 101 102 Refrigeration Trouble Shooting Chart Refrigerator 103 104 Refrigeration Trouble Shooting Chart Freezer 105 106 Capillary Tube Replacement Instructions Refrigerators and Freezers 107 Field Troubleshooting 108 110 Troubleshooting Fluorescent Lighting Circuits Rapid Start Electric and Preheat Fluorescent Light Circuits 111 GDM amp T Series Coolers IDLConnector 112 Equipment Care and Cleaning 114 Cleaning Your Cabinet 115 Stainless Steel Equipment Care and Cleaning NAFEM 116 120 CABINET INSTALLATION AND SET UP Please read these instructions Failure to follow maintenance guidelines may result in a non warranted service call ELECTRICAL REQUIREMENTS gt There are several factors that will affect the proper operation of your True unit Among these factors the electrical installation is the most important and should always be checked before connecting your True cabinet as follows 1 Make sure the circuit is dedicated exclusively to your True unit 2 Make sure the electrical installation complies with national state and local codes 3 Make sure the circuit is properly ground
38. Association of Food Equipment Manufacturers gt STAINLESS STEEL EQUIPMENT CARE AND CLEANING NAFEM North American Association of Food Equipment Manufacturers gt So what does all this mean At this very moment you re gritting your teeth and saying Well what am I supposed to do now The only way to get that crusted lasagna off my stainless steel is to use some kind of scouring pad and I certainly need to use a cleaner and the water in this town 1s hard enough to cut diamonds Don t Despair Here are a few steps that can help prevent stainless steel rust 1 Use the proper tools When cleaning your stainless steel products take care to use non abrasive tools Soft cloths and plastic scouring pads will not harm the steels pas sive layer Stainless steel pads can also be used but the scrubbing motion must be in the direction of the manufacturers polishing marks Step 2 tells you how to find the polishing marks 2 Clean with the polish lines Some stainless steels come with visible polishing lines or grain When visible lines are present you should always scrub in a motion that is paral lel to them When the grain cannot be seen play it safe and use a soft cloth or plastic scouring pad 3 Use alkaline alkaline chlorinated or non chlo ride containing cleaners While many traditional cleaners are loaded with chlorides the industry is providing an ever increasing choice of non chloride cleaners
39. Chillers Replacement of Lid Rails Lid Rail Trunions and Lid Gaskets Tools Required 1 4 Nut Driver Pop Rivet Gun Drill motor Phillips Head Screwdriver Utility Knife Duct Tape 29 Drill Bit Note For easier installation of new lid rails and lid trunions it s best to remove the top from the cabinet Note When changing out lid rails or lid trunions on a T 50 GC the trunion has a mullion heater looped through it STEP 1 Disconnect electrical power to cabinet _ STEP 2 a Remove top from cabinet See Top Removal instructions for TD amp T GC on page 30 __ STEP 3 Once top is removed turn top upside down and remove galva nized air deflector This will expose the hidden screws hold ing trunions and lid rails to top and any tape on the back side of the lid rails This will need to be cut or removed STEP 4 Remove old lid rails and lid trunions Note how the lid rails have a slot in the top edge which slides into the inside edge of the stainless steel top Once you have new lid rails in place you will need to re tape to secure them until top is re installed on cabinet Install new lid trunions and any lid gaskets that may need replacing _ STEP 5 Re install air deflector to top STEP 6 Re install top to cabinet See Top Removal instructions for proce dure STEP7 _ Once top has been installed you will need to install the new lid rail covers These will
40. Copeland s network of 800 authorized wholesalers The lubricant will be charged into our new produc tion compressors whenever a polyol ester is specified Currently certain approved compressor models sold to OEMs are available with this oil installed during manufacture Refrigeration service compressors charged with POE will be supplied in the near future SERVICE CONTRACTORS sane ATTENTION PLEASE SERVICE CONTRACTORS we ATTENTION PLEASE This is a Tecumseh hermetic compressor specifically designed for use with environmentally friendly HFC refrigerant R404A However it is acceptable to use this compressor as a service replacement with R502 The Tecumseh approved polyolester POE oil contained in this compressor is compatible with all internal component materials and is miscible mixes with R502 to effect proper oil return Using R502 with this R404A compressor will result in very similar performance to the replaced R502 compressor But the following precautions should be taken 1 Care must be taken to assure that most of the mineral oil is removed from the system before the new compressor is installed Small amounts of mineral oil up to 5 left in the system are acceptable but 1 or less if achievable is desired 2 POE oils are 100 times more hygroscopic ability to absorb moisture than mineral oils thus the utmost care must be taken to prevent moisture from entering the system The compressor or system should not be
41. EP 2 Peel backing away from two way tape and secure to black plastic extrusion Peel other side of tape and adhere extrusion to panel in the three locations indicated STEP 3 For the two longest extrusions drill six holes 1 2 deep through both the extru sion and the cooler end panel Drill three holes into the top extrusion and into the cooler top Place at equal distance Figure 1 STEP 4 Anchor all three plastic extrusions with poprivets 6 poprivets for the sides and three for the top panel STEP 5 Slide replacement panel into newly created frame and anchor bottom flange with three poprivets INSTALLATION INSTRUCTION gt FLORAL CASE BAFFLE INSTALLATION The baffle is installed on floral cabinets to slow the velocity of the air down This will make the flowers last longer because the pedals do not dry out as quickly 1 Trim a small square out of top left side of baffle to accommodate the suction line 2 Place baffle in place and install 6 x 1 2 screws into 1 2 lip of the baffle and top of cabinet 3 Install 6 x 1 2 screws into 1 2 lip and evaporator cover being careful not to puncture evaporator drain pan Evaporator Housing gt REQUIRED TOOLS e 1 16 Drill e 1 8 1 4 Shim 2 e Socket wrench STEP I Remove all products and shelving from interior of cabinet STEP 2 Disconnect power to the unit STEP 3 Wipe interior of cooler with a clean dry cloth to remove dir
42. Edge e Tin Snips e Phillips Screw Driver e File e Drill Bit For Screws on Lock Cup FIRST Before beginning installation remove front shelf standard from interior wall on handle side of cabinet INSTALLATION STEP 1 Drill 3 4 hole on outer cooler wall of foam Do not penetrate inner wall See diagram Center point of hole is 2 1 4 from front of cooler including plastic trim and 13 3 8 from bottom of cooler STEP 2 Drill 2 hole on inner cooler wall cen tered over 3 4 hole Drill just deep enough to accommodate white metal backing plate CAUTION Do Not Drill Too Deep STEP 3 Remove insulation so white metal backing plate will fit in hole INSTALLATION INSTRUCTION LOCK INSTALLATION GDM 5 amp GDM 5PT swing door models STEP 4 Check fit of locking cylinder after inserting through the outer cooler wall Fill any air space around cylinder and plate with insulation STEP 5 Place white metal backing plate over locking cylinder into 2 hole Attach lock nut to secure cylinder Drill holes and attach white metal backing plate to inner cooler wall this can be done with screws or pop rivets your option Parts not provided STEP 6 Attach lock arm to locking cylinder with 1 2 screw provided Tighten lock nut and screw Locking mecha nism on cooler wall should now be complete Check operation STEP 7 Remove rubber gasket from plastic door channel STEP 8 Determine proper h
43. INSTALLATION INSTRUCTION GDM AND T SERIES FREEZER PERIMETER HEATER WIRE REPLACEMENT of the plastic trim where the pop rivet was removed so that the stain less trim slides beneath it Drill out the two pop rivets in the top plastic trim which was hidden by the hori zontal piece of stainless trim STEP 6 Remove left and right vertical stainless steel trim pieces by sliding them out of the plastic trim Be sure to raise the top horizontal plas tic trim piece so that the stainless trim passes underneath it toward the top of the cabinet STEP 7 Drill out the pop rivet that was hid den by the stainless steel trim in the lower right corner of the vertical plastic piece so that the lower verti cal stainless trim slides beneath it for removal STEP Disconnect heater wires in the junc tion box Remove heater wire loop by unhooking at the corners where it is retained by the plastic trim pieces STEP 9 Replace inoperative heater wire loop being sure to hook under the corners of the plastic trim as observed during disassembly STEP 10 Reverse assembly sequence to replace trim Use the four 4 small sheet metal screws furnished with the heater wire in the same sequence as the pop rivets were removed STEP 11 Attach the heater wires to the power supply in junction box Replace all other assemblies in reverse sequence in which they were removed gt TD SERIES AND GLASS CHILLERS TD Series and Glass
44. LLATION INSTRUCTION CALIBRATE TEMPERATURE CONTROL Continued gt Temperature Control i Old Temperature Part Number Control Part Number 800345 e Currently being used in several freezer models gt COMPLAINT Compressor will not start no hum A Compressor will not start hums but trips on overload protector B Compressor starts but does not switch off of start winding Compressor starts and runs but short cycles on overload protector Unit runs OK but short cycles on oe lS i SOS gt ot oy eS a a a Oy ES ae CFC amp REFRIGERATION BASICS Trouble Shooting and Service Chart POSSIBLE CAUSE Line disconnect switch open Fuse removed or blown Overload protector tripped Control stuck in open position Control off due to cold location Wiring improper or loose Improperly wired Low voltage to unit Starting capacitor defective Relay failing to close Compressor motor has a winding open or shorted Internal mechanical trouble in compressor Liquid refrigerant in compressor Improperly wired Low voltage to unit Relay failing to open Run capacitor defective Excessively high discharge pressure Compressor motor has a winding open or shorted Internal mechanical trouble in compressor tight Additional current passing through overload protector Low voltage to unit or unbalanced if three phase Overload protector defective Run capacitor def
45. MIGRATION TO THE COMPRESSOR DURING PERIODS OF SHUTDOWN THIS CONDI TION CAN BE CONTROLLED BY THE APPLICATION OF A CRANKCASE HEATER A SUCTION LINE ACCUMULATOR DOES NOTHING TO PREVENT LIQUID MIGRATION AND A CRANKCASE HEATER DOES NOTHING TO PREVENT LIQUID FLOODBACK EACH WITHOUT THE OTHER IS HALF A JOB BOTH TOGETHER PROVIDE BALANCED COMPRESSOR PROTECTION GENERAL CABINET MAINTENANCE AND REPAIRS Using the following instructions you will be able to make cabinet exterior repairs along with other general cabinet repairs TOP REMOVAL FOR TBB amp TDD UNITS TOP REMOVAL FOR TBB amp TDD UNITS Disconnect the power to the unit Locate and remove screws on the inside of the cabinet going through the evaporator housing and into the bot tom of the counter top Locate and remove the screws securing the line set cover to the top located to the left of the evaporator housing Remove the two screws inside the door jamb going through the jamb into the bottom of the top There will be two screws in each door on multiple door units Cut the silicone seal that runs along both ends and along the back of the unit Silicone seal is wrapped around the front wall of multiple door units To remove top lift front up approximately 2 3 inches and push backward to unlock lip in back of top To reinstall top carefully align the groove in the back with lip on cooler base Slide forward reinstall all screws and re silicone around cabinet edge
46. Replace which proper capacitor Reset control Use larger valve Add surface or replace Improve air movement Readjust valve or replace with smaller valve Clean valve of foreign particles replace 1f necessary Determine reason and correct Correct charge Replace part Open valve fully Find and tighten Reform to be free of contact Replace blade Replace motor WARNING ELECTRICAL POWER MUST BE DISCONNECTED WHEN TERMINAL PROTECTIVE COVER NOT IN PLACE TO PROTECTAGAINST ELECTROCUTION OR VENTED TERMINAL gt TOOLS REQUIRED Drill Hole Saw _ Copper Coupling Two _ 90 Copper Elbow Torch Heat Shield Tube Cutter Foam Insulation Cap Tube Suction Line Assembly Supplied Liquid Line Filter Drier Supplied Cover Supplied Wire Back Guards GDM T 23 Freezer Model only require ordering part number 8729777 STEP 1 Inspect supplied cap tube suction line assembly The kit should include one _ suction line cap tube accumula tor section shipped loose NOTE You may have to secure the cap tube to the suction line with the supplied foil tape Be sure to use all of the supplied cap tube The excess cap tube should be coiled up and left inside the evaporator section STEP 2 Remove the power supply to the cabinet STEP 3 Recover the refrigerant from the unit CAPILLARY TUBE REPLACEMENT INSTRUCTIONS Upright GDM T Series Equipment Accumulator Evaporator Coll lw ee
47. TEP 3 Take off lower grill assembly by remov ing four front corner screws Loosen do not remove two screws in grill bracket on the side to receive replacement panel FIGURE 1 STEP 4 Take off top grill assembly by removing three screws along the rear edge on top two screws in the front underside and single screw on right side into top hinge bracket INSTALLATION INSTRUCTION END CAP REPLACEMENT T SERIES SWING DOOR Gently lift grill and slide away from side to receive replacement panel Be careful not to disconnect wiring to thermometer FIGURE 2 STEP 5 If replacement is on the hinge side of the cooler remove the door and hinges see instruction on page 3 STEP 6 Drill out rivet in stainless gasket base on right side top with a 30 bit no rivet on left side and bottom FIGURE 3 STEP 7 Install 5 strips of two way tape vertical ly the length of the side being capped STEP 8 Remove replacement panel from masonite box replacement panel may be used on either end 1 2 lip faces front STEP 9 Carefully bend 1 3 4 rear lip inward slightly in order to create an angle less than 90 to produce a snug fit while installing STEP 10 Peel plastic film away from 1 2 front lip only Install panel by working the top front 1 2 lip in slot between cabinet and plas tic gasket base and continue down the cabinet and under bottom grill frame It may be necessary to use a putty kn
48. To make the adjustment insert the appropriate tool in each adjustment screw and turn 1 4 of a revolution clock wise to the right This proce dure will adjust both the cut in and cut out about 2 F warmer STEP 3 Make sure to re connect the pink wires to the proper spade terminal when re installing Cut out Adjustment Screw Allen 5 64 or 2 mm Cut in Adjustment Screw Torx T 7 Compressor Connection pink Compressor Connection pink gt DEFROST CONTROLS Defrost Time Clock Adjustment Recommended Defrost Settings True Manufacturing has factory set your defrost time clock to a recommended time and duration defrost scenario All refrigeration equipment operating below 30 F will accumulate frost on the evaporator coil and will require routine defrost Your True equipment has been designed for three defrost periods 8 00 a m 12 00 p m and 4 00 p m If you decide to deviate from these defrost time settings please follow the procedures and adjustment below REQUIRED TOOLS e Slotted Screwdriver Locating The Defrost Timer Take off lower grill assembly by removing four 4 corner screws Single door models Defrost timer is located in the lower right corner behind the louvered grill Two door models Defrost timer is located in the middle of the cabinet behind the louvered grill Timer is mounted to the left of the centered ballast box Three door models Defrost timer is located on the
49. Top Screws gt TOP REMOVAL FOR TD amp T GC UNITS TOP REMOVAL FOR TD amp T GC UNITS Turn unit off and remove lids Remove screws along back of cabinet top Remove screws on each side going through lid slide rails inside cooler Remove screws along front of top under inside ledge also remove the two screws holding center trunion on units with more than one door Lift top to approximately 45 degrees while pushing top forward at same time Top will lift off lip in front T 50 GC has heater wire looped through center trunion Please becareful when removing top Before reinstalling inspect heater wire to make sure it is not damaged To reinstall top while holding top at 45 degree angle hook top on lip at front of cabinet and lay down while pushing backwards on top when laid completely down press firmly on top to provide a good seal Reinstall all screws along inside of cabinet and along back of top on outside of cabinet Reinstall doors and turn unit on Lid Trunion Top Screws gt AEs i TPP COUNTERTOP REPLACEMENT INSTRUCTIONS gt Unscrew top door hinges from countertop and remove doors Locate amp remove 2 2 3 4 inch screws in the black plastic trim in the top of each door or top drawer opening Remove front louvered grill Remove screw from L bracket that connects countertop to cabinet Remove screws from the following parts inside of cabinet A Airduct which extends from e
50. URE LOW PRESSURE HIGH PRESSURE GAS GAS LIQUID LIQUID CFC amp REFRIGERATION BASICS Liquid floodback during operation can be caused by fan failure or dirty clogged filters that can reduce the heat transfer rate to such a point that the liquid refrigerant floods through instead of vaporizing When this situation occurs liquid refrigerant may enter the compressor under conditions which result in separation of the oil and refrig erant This separation may result in an accumulation of the refrigerant under the oil Thus when the compressor is started the first liquid to be pumped to the bearings will probably be refrigerant not oil Even if this oil refrigerant separation does not occur the large amount of liquid refrig erant in the crankcase will instantly vaporize and boil away the oil charge when the compressor starts Thereby leaving the compressor oil starved for many seconds Liquid floodback can be prevented by the application of a properly designed and sized suction line accumulator Using a totally new concept Tecumseh engineers have designed a suction line accumulator available in eight basic sizes covering a full range of system applications and refrigerant When properly selected based upon system charge a Tecumseh suction line accumulator will improve compressor reliability and endurance by preventing dam aging liquid refrigerant floodback LIQUID REFRIGERANT ACCUMULATION IN THE COMPRESSOR CAN ALSO BE CAUSED BY LIQUID
51. a new suction line capillary tube assembly up the rear of the cabinet and drill a hole above the evaporator housing to bring the tubing inside the cabinet to pipe back to the evaporator 2 Cut the suction line a couple of inches below where it enters the cabinet also cut it a couple of inches from the evaporator coil Install new capillary tube inside of the existing suction line Now use Tee s to reconnect suction line while feeding capillary tube out of the other side of the Tee FREEZERS The above methods of replacing capillary tubes on refrigerators can also be used on freezers There is also one other option that is used only on freezers 1 Drill a hole in the rear left hand corner through the floor on the inside of the cabinet run the new assembly up the rear left hand corner and reconnect to the evaporator After re piping cover the assembly up with a corner cover that can be ordered from True s parts department Remember that P O E oil is now being used and it is very hygroscopic You should only have the system open for no more than 15 minutes and then replace drier and pull a 200 micron vacuum through both sides of the system gt FIELD TROUBLESHOOTING IF THE COMPRESSOR WILL NOT RUN 1 If there is no voltage at the compressor terminals follow the wiring diagram and check back from compressor to the power supply to find where the cir cuit is interrupted If power is available at the compressor terminals and th
52. acitor should be replaced Substitute a known to be good start capacitor if available If compressor then starts and runs properly replace the original start capacitor If a capacitor tester is not available an ohmmeter may be used to check run and start capacitors for shorts or open circuits Use an ohmmeter set to its highest resistance scale and connect prods to capacitor terminals a With a good capacitor the indicator should first move zero and then grad ually increase to infinity b If there is no movement of the ohm meter indicator an open circuit is indi cated c If the ohmmeter indicator moves to zero and remains there or on a low resistance reading a short circuit is indicated Defective capacitors should be replaced 4 If the correct voltage is available at the compressor terminals and no current is drawn remove all wires from the terminals and check for continuity through the motor windings On sin gle phase motor compressors check for continuity from terminals C to R and C to S On compressors with line break inherent protectors an open overload protector can cause a lack of continuity If the compressor is warm wait one hour for the compressor to cool and recheck If continuity cannot be established through all motor wind ings the compressor should be replaced Check the motor for ground by means of a continuity check between the common terminal and the compressor shell If the
53. an gea geg grejem EEE Tin aa min aoa ee ee ee a a as arn aon ana ara suopean s m n ao ann nen ang ang ee ea ee ans nrn a n e TT 2 REQUIRED TOOLS L N Contro ace Bulb e Permagum e Phillips Head Screwdriver ae Ly Mee C a e Hex Head Driver lilies way etl yi ii ceve STEP I panii Brrr nns Insert the control bulb into the copper Pa ee aN sleeve Before insertion be sure there are cc fe no kinks in line figure 2 et ps ARERR EREES STEP 2 a Permagum n IMPORTANT Figure 3 IIIe T f Seal the end of the sleeve with permagum E oea e to keep moisture out figure 3 sT ae e Dar T TIe a a STEP 3 STEP 6 er ae Connect the two wires to the new tem Replace black control knob and turn the oe cal perature control control to the 5 setting e STEP 4 STEP 7 Fasten the control onto the mounting plate Plug the Cooler in with two screws Item A STEP 5 NOTE If it becomes necessary to remove the Fasten the mounting plate to the cooler housing be sure to tape off any interior with two screws Item B panel at risk of being scratched CAUTION Wait at least 12 hours before re adjusting control This allows the Cooler to stabilize cycle y INSTALLATION INSTRUCTION Temperature Control STEP 1 Unplug Cooler and turn temperature control to off 0 position STEP 2 Pull off the black control knob from the control STEP 3 Remove the mounting plate from the evaporator hous
54. before searching for a solution Place a level on the center of the lower chan nel and on the v track in several places The different areas involved with the closing of the door are as fol lows Plastic Channel The plastic channel area This includes the top bottom v track and bumpers a Inspect the top and bottom chan nels for blockage Inspect the v track for dents or movements that may be causing the door to bind The v track may be adjusted slightly by bending the v with a number amp r vise grips The v track can be realigned or replaced Shims under the door can be adjusted or added to to improve the seal and speed of closing of the door Door The door This area includes v roller bracket assembly stainless insert hold er slot on top of door where cord is fastened the foam tape on the door and the plastic buttons on the inside of the door a Inspect the v rollers clean realign and lubricate the rollers should spin freely or replace Be sure the roller bracket screws do not touch the v track b Check to make sure door is square If not loosen stainless insert holders then retighten insert holders Push on glass insert and break the seal between insert and 2 sided tape Square the door by INSTALLATION INSTRUCTION Slide Door Instruction To improve slide door closing placing shims between frame and glass insert and then reinstall the insert holders c Replace the door with door
55. ck to see if temperature control is set on 5 YES Remove the grill covering the condensing unit 2 Is the condenser coil looks like a car radiator clean If not clean this with a brush and either a vacuum or condensed air Wait and let the cabinet run with a clean coil and see if that solves problem CONDENSER COILS SHOULD BE CLEANED MONTHLY 3 Can you here the compressor and condenser fan motor running NO Check the voltage at the compressor receptacle It should be 115 volts 10 Using a remote reading thermometer check the evaporator coil temperature If the temperature control is set on 5 and the coil tem perature is above 40 degrees the control should be closed calling for the compressor to run If the coil tem perature is above 40 degrees and the temperature control does not close A remove the temperature control from the evaporator housing and either calibrate or replace control e Verify on yourwiring diagram but most models have a pink wire that is connected to the power cord black wire in the electrical box This feeds one side of the temperature control and the other pink wire is connected to the other side of the control to bring power to the compressor receptacle when the switch closes on a call for refrigeration YES Is the evaporator coil frozen Check to see if temperature control is operating correctly If the evapo rator coil is not iced up and the compressor and condenser fan is running please install piercing valv
56. cooler is critical to operating success Effective condensate removal and door operation will be effected by leveling C The cooler should be leveled front to back and side to side with a level see figure 4 Place the level in the interior floor of the unit in the four positions illustrated For Castored Models Four shims have been provided in warran ty packet for leveling castored units posi tioned on uneven floors Shims must be positioned between rail end and bearing race see figure 3 If the cabinet is not level use a 3 4 19mm open end wrench to turn the anchoring bolt under the bearing race counter clockwise until the cabinet is level Install the desired number of shims making sure the slot of the shim is in contact with the threaded stem of the castor If more than one shim is used turn the slot at a 90 angle so they are not in line Turn the anchoring bolt clockwise with a 3 4 19mm open end wrench to tighten and secure the castor Leg Levelers For GDM Models If the cabinet is not level adjust leg levelers by first relieving weight to leveler and adjusting by either hand or wrench Repeat with all leg levelers until cabinet is level in all directions D Ensure that the drain hose or hoses are positioned in the pan IMPORTANT Make certain the metal strap holding the compressor during shipment is removed Failure to cut strap could result in excessive noise and vibration freezer E Fr
57. cracking can also take place STAINLESS STEEL EQUIPMENT CARE AND CLEANING NAFEM North American Association of Food Equipment Manufacturers Contrary to popular belief Stainless Steels ARE susceptible to rusting Corrosion on metals is everywhere We recognize it quickly on iron and steel as unsightly yellow orange rust Such metals are called active because they actively corrode in the natural envi ronment Stainless steels are passive metals because they contain other metals like chromium and nickel 400 series stainless steels contain chromium while 300 series contain both chromium and nickel Metals are crystalline solids made up in atom arrangements like tinker toys With 12 30 chromium an invisible passive film covers the steels surface acting as a shield against corrosion The metal becomes passive toward corrosion As long as the film is intact not broken or con taminated the metal is passive and stainless gt Enemies of Stainless Steel There are three basic things which can break down your stainless steels passivity layer and allow cor rosion to rear its ugly head 1 Mechanical abrasion 2 Deposits amp Water 3 Chlorides Mechanical abrasion means those things that will scratch the surface Steel pads wire brushes and scraper are prime examples Water comes out of our tap in varying degrees of hardness Depending on what part of the country you live in you may have hard or soft wat
58. e compressor does not run check the voltage at the com pressor terminals while attempting to start the compressor If voltage at the compressor terminals is below 90 of the nameplate volt age it is possible the motor may not develop sufficient torque to start Check to determine if wire sizes are adequate electrical connections are loose the circuit is overloaded or if the power supply is inadequate On single phase compressors a defec tive capacitor or relay may prevent the compressor starting If the compres sor attempts to start but is unable to do so or if there is a humming sound check the relay to see if the relay con tacts are damaged or fused The relay points should be closed during the ini tial starting cycle but should open as the compressor comes up to speed Remove the wires from the starting relay and capacitors Use a high volt age ohmmeter to check for continuity throughout the relay coil Replace the relay if there is not continuity Use an ohmmeter to check across the relay contacts Potential relay contacts are normally closed when the relay is not energized current relay contacts are normally open If either gives an incorrect reading replace the relay Any capacitor found to be bulging leak ing or damaged should be replaced Make sure capacitors are discharged before checking Check for continuity between each capacitor terminal and the case Continuity indicates a short and the cap
59. e is risk of electrocution if they are not followed correctly a qualified service technician must be used when following these steps For diagnosing unusual problems or if there are questions regarding these instructions please call Technical Service 1 800 325 6152 gt REQUIRED TOOLS e Accurate Remote Reading Thermometer e 1 4 Nutdriver e Jeweler Screwdriver ___ Refrigerator Instructions __ For cooler calibration install ther mometer in evaporator coil Shut door and get true reading of where control is opening and closing Watch to see at what temperatures compressor cycles on and off Compare these to design temperature of the control and adjust accordingly Freezer Instructions For freezer calibration install ther mometer next to temperature control bulb this is an air sensing control Shut door and get a true reading of where control is opening and closing Watch to see at what temperature the compressor cycles on and off Compare these to the design temperature of the control and adjust accordingly Calibration STEP 1 Unplug the cabinet STEP 2 Set control to setting 9 STEP 3 Remove control from evaporator hous ing and locate cut in and cut out screws Refer to Temperature Control Change Out Instructions page 39 41 INSTALLATION INSTRUCTION CALIBRATE TEMPERATURE CONTROL A tere ooo eee hezearen See HW NoSTH BCR STBTRT ST BTE STATS asenaan 800303 800306 800312 800313 8003
60. e system to complete the charging process Add the correct amount or until the sight glass indicates a full charge with a clear window bubbles indicate more refrigerant 1s required Care should be taken not to overcharge the system at this point The evaporator fans must be operational while charg ing cooler fans must run continuous ly freezer fans will be delayed by the fan control Make sure freezer fans are running during final charging process Keep a close check on suction and discharge pressures After system has stabilized check for excessive liquid floodback to the compressor If flooding occurs less than 8 super heat in freezers 12 in coolers adjust expansion valve Clockwise 1 2 a turn at a time recheck before leaving installation Check full load amps on the com pressor this can be found on the com pressors nameplate Check compres sor oil level Normal charge is indi cated by 1 2 of the sight glass having oil in it Final Check Check high and low pressure control settings Set thermo stat to desired cabinet temperature Check defrost timer settings if appli cable Check voltage this must be 100 of the nameplate rated voltage for operation Anything more or less should be corrected immediately Replace all service valve caps and secure all unit covers INSTALLATION INSTRUCTION TEMPERATURE CONTROL ALTITUDE ADJUSTMENT Figure Ti oo ee CCW ee Adjustment based on 360 comple
61. e used to preform these tests using extreme care because of the risk of electrocution if tests are not preformed correctly There are different types of lighting systems being used in True cabinets so there will be different types of troubleshooting techniques that need to be used The one common aspect in all of the lighting circuits is that the bulbs being used must be the same as the bulbs that were originally installed in the cabinet To test ballast determine which lighting system you are working on and follow steps below Electromagnetic rapid start fluorescent light circuit There are three different voltage tests Incoming or ballast supply voltage Test at black and white wires going to ballast You should read approximately 118 volts Filament voltage Tested between red to red wires or blue to blue wires Depending on which ballast you have you should get a reading between 2 and 5 volts with the bulbs out Please call technical service with the ballast number to get the correct voltage reading High voltage Test between either red wire and either blue wire Again depending on which ballast you are checking the voltage can range between 205 and 310 volts with the bulbs out Please call technical service with the ballast number for the correct voltage reading Instant start electronic fluorescent light circuit Note A high impedance meter is required for testing this ballast There are two different voltages to test Incoming
62. ective Excessive discharge pressure Suction pressure too high Compressor too hot return gas hot Compressor motor has a winding shorted Overload protector Thermostat High pressure cut out due to a Insufficient air b Overcharge c Air in system Low pressure cut out due to a Liquid line solenoid leaking b Compressor valve leak c Undercharge d Restriction in expansion device ae eS oo St eee Sia aa Ao Os ae Nag 3a 3b 3c Aa Ab Ac Ad REPAIR Close start or disconnect switch Replace fuse Refer to electrical section Repair or replace control Relocate control Check wiring against diagram Check wiring against diagram Determine reason and correct Determine reason and replace Determine reason and correct replace if necessary Replace compressor Replace compressor Add crankcase heater and or accumulator Check wiring against diagram Determine reason and correct Determine reason and correct replace if necessary Determine reason and replace Check discharge shut off valve possible over charge or insufficient cooling on condenser Replace compressor Replace compressor Check wiring diagram Check for added fan motors pumps etc connected to wrong side of protector Determine reason and correct Check current replace protector Determine reason and replace Check ventilation restrictions in cooling medi um restrictions
63. ed outside at the bottom of the frame STEP 9 Install gasket back plates and gasket STEP 10 Mount door and tighten torsion spring Refer to Removal and Installation of GDM and T Series Swing Door Instructions on page 46 47 gt Tools Required Phillips Head Screwdriver 3 8 Socket Set Awl Wire Strippers Crimper Needle Nose Pliers Note For greater safety and ease of installation it is recommended that two persons assist in the replacement procedure Note It may not be necessary to remove the door from the cabinet if two persons are assisting in the replacement procedure STEP 1 Disconnect electrical power to cabi net STEP 2 Remove door from cabinet and lay on a flat surface Refer to Removal and Installation of GDM and T Series Swing Door Instructions on page 46 47 STEP 3 Remove door gasket from the perimeter of the interior side of the door STEP 4 Remove door handle 2 screws STEP 5 Remove the screws that secure the four back plates to the door STEP 6 With your Awl pry out plastic shims wedged between glass insert and door frame STEP 7 Before removing glass insert discon nect the electrical wiring to door frame heater and heater inside glass insert Note Wiring harness connection for your info 2 whites go to 2 whites on lower lamp socket 2 blacks go to 2 blacks on upper lamp socket 1 red is 115v lead to both frame and insert heaters 1 b
64. ee plug and cord from inside the lower rear of the cooler do not plug in F The unit should be placed close enough to the electrical supply so that extension cords are never used Warning Compressor warranties are void if the unit is more than 6 12 ft 2m from plug in connection gt For cabinet installation use instal lation instructions with cabinet Receiving Upon receiving this piece of equipment remove all outer packaging and inspect for concealed damage If damage is found indicate such on the carriers Bill of Lading for claim to be filed In order to minimize damage to this equipment it is recommended that the packaging remains in place until it is in its final location Condensing units located indoors or in confined areas must have ade quate ventilation Condensing units require 1000 cfm of air per ton of refrigeration True Manufacturing Company strongly recommends the use of compressor crankcase heaters and headmaster valves be used at all times with a remote compressor unit Not using these components may void the compressor warranty Refrigerant Lines All refriger ant piping should be ACR type It is recommended that all brazed joints be made with hard solder such as Silphos or Unibraze Solder such as 95 5 or other soft solders are not recommended All suction lines must be insulat ed with at least 1 2 wall insula tion Keep all lines as short as pos sible Always pitch suc
65. eight for strike plate extension to be engaged by lock arm Then determine location for two drill holes to attach strike plate to door frame Drill two 3 16 holes for strike plate through door frame and inner most plastic channel CAUTION Make sure strike plate is positioned on the door so when the door is closed it will pass as close to the edge of the opening as possible without hitting STEP 9 Remove portion of the plastic channel wall where the strike plate will be located STEP 10 Securely attach strike plate to metal frame through plastic channel with 3 4 screws provided STEP 11 Replace rubber gasket in plastic door channel STEP 12 Check for proper operation STEP 13 Install split standard 2 pieces in place of original one piece standard Use original mounting holes and secure NOTE Shorter piece should be at top INSTALLATION INSTRUCTION gt RATCHET LOCK amp PLASTIC DOOR STOP SLIDE DOOR Figure I REQUIRED TOOLS STEP 4 e Drill With 1 8 Bit Using an Exacto knife or razor blade e 1 4 Nut Driver carefully cut rubber gasket along the e Exacto Knife or Razor Blade Knife edges of the ratchet bar STEP 1 STEP 5 Remove left side door by lifting up and Replace left side door and check slide out of bottom track operation STEP 2 ALOY Wk Ratchet bar may have to be bent in Position ratchet bar over left side of slightly so not to impede right hand door centered top to bot ope
66. er Hard water may leave spots Also when heated hard water leaves deposits behind that if left to sit will break down the passive layer and rust your stainless steel Other deposits from food preparation and service must be properly removed Chlorides are found nearly everywhere They are in water food and table salt One of the worst perpe trator of chlorides can come from household and industrial cleaners STAINLESS STEEL EQUIPMENT CARE AND CLEANING NAFEM North American Association of Food Equipment Manufacturers Review 1 Stainless steels do rust when Passivity film shield breaks down by scrapes or scratches by deposits and chlorides 2 Stainless steel rust starts with pits and cracks 3 Use the proper tools Do not use steel pads wire brushes or scraper Step 1 4 Use non chlorinated cleaners at recommended concentrations Use only chloride free cleaners Step 3 5 Soften your water Know the hardness of your water Use filters and softeners whenever pos sible Step 4 6 Wipe off cleaning agent s and standing water ASAP Prolonged contact will cause eventual problems Step 6 To learn more about chloride stress corrosion and how to prevent it contact the manufacturer of your equipment your cleaning materials supplier or NAFEM NAFEM N American Association of Food Equipment Manufacturers 401 N Michigan Avenue Chicago Illinois 60611 4267 312 644 6610 E mail NAFEM hq_sba com Deve
67. es need to be drilled in both the left and right vertical door tracks Lay the left side template against the front and inside edge of the cooler The bottom edge of the tem plate must rest on the top of the lower plastic door track See figure 3 Transfer the holes from the template into the side wall of the cooler Drill the holes only 1 deep Do not drill through the walls 53 Le 26 7 Figure 2 Bracket s B INSTALLATION INSTRUCTION Vandal Panel GDM 69 continued Repeat this operation for the right side templates are marked left and right and the top is also indicated To Mount The Panels STEP 1 STEP 2 Hang the lip of the center panel on the lip on bracket A Slide the right hand panel into place by guiding the two pins into the drilled holes in the vertical door track Push the panel to the right and back until the foam tape rest against the center door Repeat for the left panel NOTE Panels may be shipped in the locked position in this case turn lock to fit panel over bracket B STEP 3 Lock in place by turning the key locks to engage brackets B Hole Locator Strip PETES TETTETETT TETTETETT soe oe 2 Bottom Door Track aa E Pad PaP a a eee as TROUBLESHOOTING This section provides troubleshooting instructions that will help a qualified service technician diagnose any problem you may be having with your cabinet Because ther
68. es on both the suction and discharge process tubes 1 If pressures are equalized high suction pressure low head pressure and compressor is running low amp draw compressor has bad valves replace compressor 2 If you have low suction pressure and low discharge pressure first check to make sure there are no kinks in the compressor pullout or the suction line after doing this you have a few options A Add a few ounces of refrigerant and see what happens B Recover charge and weigh in correct amount of refrigerant REFRIGERATION TROUBLESHOOTING CHART Refrigerator continued gt If the pressures rose and the cabinet began to function correctly the cabinet was low on charge This means that there is a leak in the refrigeration system that must be located A technician can raise system pressure up to 200 psi with nitrogen to aid in the leak search Remember that the foam insulation with in the cabinet will make a leak detector sniffer type react AFTER LEAK IS LOCATED IT IS VERY IMPORTANT THAT THE SYSTEM DRIER IS CHANGED AND THAT A 200 MICRON VACUUM IS PULLED THROUGH BOTH THE HIGH AND LOW SIDE ACCESS FITTINGS When leak is found recover refrigerant at this time the technician may want to remove piercing valves and solder on access valves to pull vacuum and recharge system After charging system both service valves should removed from the system If the head pressure rises but falls right back down after you stop adding gas and t
69. ess and then rock slightly to create a vertical slot approximately 1 2 STEP 2 Using a 2 hole saw insert drill into existing hole and align top of bit with the coolers black tank plastic Drill far enough to pierce the interior skin stop at the insulation STEP 3 Insert 3 4 hole saw into original exte rior pilot hole and drill through INSTALLATION INSTRUCTION Lock Installation GDM model 23 26 single swing door insulation Remove insulation from created hole and smooth burs with a file Outside of Cooler STEP 4 Using straightedge pencil mark a straight line parallel to the lock cup knockout opening With tin snips trim off top of lock cup STEP 5 Insert lock cup into drilled opening interior wall while inserting lock Trimmed with f Tin Snips assembly from the exterior wall Fasten assembly by attaching hex nut Anchor lock cup with three self tapping screws STEP 6 Install latch and secure with phillips washer head screw STEP 7 Pull gasket away from door trim Using masking tape as a center point Score interior door trim using the lock Lock Assembly to measure top and bottom width With tin snips cutaway door trim in order to accommodate lock plate amp nd FE Latch front view Cabinet Side View Lock plate iin e i k F i E5 Lf i T i id Lock assembly exploded view Note Other single swing door cabinets please
70. field install locks on cabinets gt INSTALLATION INSTRUCTION GLASS INSERT SLIDE DOOR REQUIRED TOOLS e Phillips Head Screwdriver e 3 Wide Double Sided Tape STEP 1 Slide left door door positioned on out side track to the right Lift door up and pull out at the bottom Right door door positioned on inside track can be removed in the same manner STEP 2 Remove the nylon cord from the top of the door STEP 3 Set the door handle side down on a flat surface STEP 4 Remove the screws that secure the four glass insert holders to the door Remove all four aluminum pieces STEP 5 Beginning at the corners carefully pry the broken glass loose from the frame If necessary use heat gun or hair dryer aimed in the space between glass insert and door frame to lessen adhesion of double sided tape Carefully dispose of the damaged glass STEP 6 Remove any excess tape or glass from the lip on the door frame Replace with new double sided tape on the 1 2 lip STEP 7 Remembering to keep the tempered glass to the handle side of the frame place the new glass insert inside the frame and press against the two way tape The etched TRUE logo is posi tioned on the tempered glass side STEP 8 Replace the four Aluminum glass insert holders STEP 9 Reconnect the nylon cord to the top of the door and replace the door as origi nally removed gt Check the cooler to see that it is level
71. g element If necessary use heat gun or hair dryer aimed in the space between glass insert and door frame to lessen resistance of double sided tape It is recommended that one person support the damaged glass insert while the other releases the wires from the two self stripping con nectors Carefully dispose of the damaged glass Follow steps 6 7 of refrigerator glass insert installation STEP 8 Rejoin heater wires using self stripping connectors black to black amp white to white as shown in figure 2 a Place self stripping connectors on heater wire leads as shown in dia gram a leads from bottom of replacement glass into appropriate self stripping connectors black to black amp white to white as shown iagram b interior electrical box self stripping connec 1 in diagram c 8 13 of refrigerator sert installation med es m i ea Ps A ph mm tlet ao oa H gt EAEE TETTE ee Ee p Required tools Phillips head screwdriver 3 8 Wide double sided tape 1 16 Drill Bit Drill Silicone STEP Slide left door door positioned on outside track to the right Lift door up and pull out at the bottom Right door door positioned on inside track can be removed in the same manner Remove the nylon cord from the top of the door STEP 3 Set the door handle side down on a flat surface STEP 4 Remove the screws that secure the four glass in
72. he relay 3 Connect the pink wire to one side of the relay coil 4 Connect the white wire to the Figure 6 Relay Wiring Diagram other side of the relay coil NOTE Each relay has a wiring diagram on the side of it See Figure 6 B Feed wires into the ballast box through the knockout See Figure 7 C Using the Sta Con connectors in the relay kit make the following con nections inside the ballast box 1 Locate the pink wire coming from the temperature control and connecting to the black compressor receptacle wire Cut this connection and connect this pink wire from the temp control to the pink wire going to the relay 2 Connect one black wire on relay to the black wire cut from the compressor receptacle 3 Connect the white wire com ing from the relay to the white wire bundle that is connected to the white on the main power cord 4 Connect one black wire to the black wire bundle that is connect ed to the outgoing terminal on the main power switch located on the ballast box INSTALLATION INSTRUCTION TEMPERATURE CONTROL REPLACEMENT CONTINUED gt STEP 6 Replace existing temperature control with new Danfoss control in repair kit See Figure 8 A Connect one pink wire from old control to double terminal 4 on new temperature control B Place the plastic coated spade clip on secondary 4 terminal C Connect other pink wire from old control to terminal 3 on new Danfoss
73. he suction pressure stays low there may be a restriction in the system Recover the charge and cut out the drier also cut about 1 off of the capillary tube Circulate nitrogen through the system to clear any restrictions in the evaporator Evacuate the system and recharge If the problem still exists capillary tube may need to be replaced REFRIGERATION TROUBLESHOOTING CHART Freezer gt REFRIGERATION TROUBLESHOOTING CHART FREEZER PROBLEM Cabinet is running warm Can you hear the compressor running NO If nothing is running and cabinet is warm check to make sure cabinet is plugged in and then check circuit breaker GDM cabinet lights will not come on until cabinet reaches 20 degrees but on T series cabinets lights will work when you open the door at any temperature All freezers have a fan delay that will not allow the evaporator fans to start before the coil gets to 15 degrees Remove the grill covering the condensing unit Check the defrost timer to see if cabinet is in defrost Do not turn dial on defrost timer take a pencil and mark a spot on the outer dial and watch this to see if timer is working This should take no more than 10 minutes to verify While waiting look to see if the condenser coil looks like a car radiator is clean If coil is dirty clean with a brush and a vacuum or compressed air CONDENSER COILS SHOULD BE CLEANED MONTHLY If cabinet is not in defrost and the compressor and condenser fan motor is not r
74. head pressure your compressor has bad valves replace compressor 2 If you have a low suction pressure and a low head pressure you may have one of a few different things happening with your system A Kinks in the suction line or compressor pullout 1 Check for kinks and repair tubing if needed B CRO valve not functioning correctly 1 Install a line tap in suction line to verify pressure upstream of valve replace valve if needed C Evaporator or accumulator may be logged with oil 1 Disconnect termination switch from timer and run system through an extended defrost cycle to warm oil and get it to return to the compressor after putting back in freeze cycle 2 Allow evaporator to warm up and remove capillary tube from evaporator then blow nitrogen through evaporator You may also want to poke a hole in the accumulator with a scratch awl to add in the oil removal D You may also have a system that is low on refrigerant charge or have a capillary tube or drier that is restricting refrigerant flow 1 Add a few ounces of refrigerant to system 2 Recover the charge and weigh in the correct amount of refrigerant With either of these options used if the pressures rise and the cabinet begins to function correctly we know that the cabinet was low on charge This means that there is a leak in the refrigeration system that now must be located A technician can raise the system pressure up to 200 psi with nitrogen to aid in the leak search Remember that
75. her on each of the 1 4 20x 1 1 2 hex head bolts and insert one of these assemblies into each mounting hole located on the longer section of the square shelf support STEP 2 Hold the shelf support next to the threaded holes that are located along the edge on the back of the cabinet 60 models have a third shelf support that is located near the center of the cabinet back STEP 3 Carefully thread the 1 4 20 x 1 1 2 bolts into these threaded holes until the supports make contact with the cabinet and the bolts are hand tight STEP 4 Repeat steps 2 and 3 to install the sec ond shelf support for 60 models repeat steps 2 and 3 for the third sup port STEP 5 Hold the shelf up between the two mounted shelf supports and thread one 1 4 20x1 hex head bolt into each of the two threaded holes that are located on the inside surface of each shelf sup port for the 48 and 60 models have someone help hold the shelf in posi tion Thread each bolt until the shelf is drawn against the shelf support and the bolt is hand tight Figure 1 STEP 6 Adjust the shelf assembly so that the shelf supports are vertical and the shelf is flat STEP 7 Firmly tighten each bolt using the 7 16 wrench CAUTION Do not place more than 100 lbs of weight upon the overshelf and never stand on the overshelf INSTALLATION INSTRUCTION gt CRUMB CATCHER TEMPLATE INSTALLATION PE PEN STEP 2 This instructio
76. hinge bracket hinge washer thrust bearing into aluminum door block and brass bushing inside bottom frame figure 1 STEP 3 While holding bottom hinge in place lift door and slide top door hinge together Maintain vertical pressure by resting door bottom on your knee while squatting or have someone assist in order to re attach lower hinge to cabinet Fasten hinge with 3 8 bolts and washers STEP 4 Replace the louvered grill on the cool er with the four screws STEP 5 Adjust the spring by rotating the door hinge shaft to the left using two drift punches or 1 8 drill bits hole by hole to the desired tension approximately one half turn Replace the stop pin in the door hinge shaft NOTE If cabinet is equipped with integrated door light be sure to plug into ballast box NOTE Freezer doors have heater wires which must be plugged in before operation To adjust door hang Loosen bolts from bottom hinge assembly and lightly tap with plastic or rubber hammer When door hangs true tighten bolts gt INSTALLATION INSTRUCTION TORSION SPRING REPLACEMENT New Style T Series amp GDM Radius Front SWING DOOR NOTE If the torsion spring is broken there is no need for steps 1 4 Figure 1 REQUIRED TOOLS e Drift Punch or 1 8 drill bit e Needle Nose Pliers e Phillips Head Screwdriver e Slot Head Screwdriver e Wrench 3 STEP I Turn the cooler off STEP 2 Locate the to
77. housing that holds the control mounting plate Reach behind the evaporator housing on the control side of the cabinet and pull the control bulb out of the recepta cle in the roof of the cabinet A Pull switch downward out of the square hole overriding the holding tabs Remove wires and replace the switch Disconnect the power supply unload contents of cabinet and lay cabinet on its back Remove the lower louvered grill the plastic trim Be sure to raise the top horizontal plastic trim piece so that the stainless trim passes underneath it toward the top of the cabinet right corner of the vertical plastic piece Raise this corner of the vertical plastic piece so that the lower vertical stainless trim slides beneath it for removal Disconnect the wires from the control Remove the stainless steel skirt around 8 Remove three 3 screws on each side Check control for continuity replace if the louvered grill of the center mullion and raise mullion defective out of the cabinet and slide the stainless Remove the sign or the louver section trim past the top of the cabinet 6 Evaporator Fan Motor above the door s A Remove fan blade guard from the evap 9 Disconnect heater wires in the junction orator housing Remove the blade Remove hinges and door s box Remove heater wire loop by Remove screws holding the evaporator unhooking at the corners where it is motor Disconnect wires by removing Drill out pop rivet on right top co
78. ife to widen gap A Lif 4 t pe O p He sided Tape Replacement Panel FIGURE 4 When cap is in position gently tap fold ed edge with a rubber mallet until flush STEP 11 Tighten screws in bottom grill frame STEP 12 Smooth replacement end over two sided tape and around rear edge Remove protective film INSTALLATION INSTRUCTION gt END CAP REPLACEMENT T SERIES SWING DOOR continued STEP 13 Drill pilot holes for rivets using 30 drill bit Four down the front edge and three across top and bottom edges see figure 5 STEP 14 Install rivets Replace drilled out pop rivet in top right side gasket base STEP 15 FIGURE 5 Carefully lift cabinet to upright position Drill 3 holes one at top one in middle one at the bottom see figure 6 Install rivets STEP 17 If necessary use black silicone to create a good seal where front corner meets plas tic gasket molding Use silver gray sili cone caulk to seal rear raw edge STEP 18 Reinstall doors and louvers FIGURE 6 REQUIRED TOOLS e 1 8 drill e Rivet Tool e Silicone Caulk STEP I Make sure that both sides of the cabinet are free from dirt Clean if necessary STEP 2 Attach the plastic extrusion to the front side corner of the cabinet side see illustra tion Use a 1 8 drill bit to drill through the extrusion and the cabinet Use pop riv ets provided to fasten extrusion
79. im v track gt INSTALLATION INSTRUCTION Wiper Gasket Installation REQUIRED TOOLS e Drill e 1 8 Drill Bit e Pop Rivet 2 Per Door Top View of Wiper Gasket The short side of the gasket is what seals between the doors SHOULD YOU HAVE ANYADDITIONAL QUESTIONS PLEASE FEEL FREE TO CONTACT THE TECHNICAL SERVICE DEPARTMENT STEP 1 Before removing the doors from the cabinet mark each door in the area where the wiper gasket will be applied at the point of the center leg on the top and bottom door channels See 1 Use the reference marks for the vertical positioning of the wiper gasket STEP 2 Remove the doors by lifting the left door up and swing the bottom out Remove the door cord attached to the top of the door Repeat these steps for right door Place the left door with the handle down and place the right door with the handle up STEP 3 Drill out the rivets that secure the wiper Gasket and remove all residues from the door surface where the wiper gasket will be applied STEP 4 Peal off the adhesive tape on the back side of the gasket and apply one wiper gasket to the back of the out side left door Position the wiper gasket at least 3 8 in from the door frame on the inside right door STEP 5 Drill one 1 8 hole through the top and Bottom of the wiper gasket hold er and in to the door frame about _ from the top of the blade and replace the pop rivets STEP 6 On coolers
80. in refrigeration system Check for possibility of misapplication Use stronger unit Check refrigerant charge fix leak add if necessary Replace compressor See D above Differential set too close widen Check air or water supply to condenser correct Reduce refrigerant charge Purge Replace Replace Fix leak add refrigerant Replace device WARNING ELECTRICAL POWER MUST BE DISCONNECTED WHEN TERMINAL PROTECTIVE COVER NOT IN PLACE TO PROTECTAGAINST ELECTROCUTION OR VENTED TERMINAL p gt COMPLAINT Unit operates long or continuously Start capacitor open Shorted or blown Run capacitor open shorted or blown Relay defective or burned out Space temperature too high Suction line frosted or sweating Liquid line frosted or sweating Unit noisy L aa PARLAR Noo e na Se R CFC amp REFRIGERATION BASICS Trouble Shooting and Service Chart Continued POSSIBLE CAUSE Shortage of refrigerant Control contacts stuck or frozen closed Refrigerated or air conditioned space has excessive load or poor insulation System inadequate to handle load Evaporator coil iced Restriction in refrigeration system Dirty condenser Filter dirty Relay contacts not operating properly Prolonged operation on start cycle due to a Low voltage to unit b Improper relay c Starting load too high Excessive short cycling Improper capacitor Improper ca
81. ing STEP 4 Remove the temperature control from the plate and disconnect the 2 wires STEP 5 Remove the lamp from the front of the cooler and remove the front panel New Copper Sleeve Extension Replacing Temperature Controls in GDM 7 GDM 10 and GDM 12 Models Standard Copper Sleeve __ Parmagum Evaporator STEP 6 Reach in to the side of the evaporator coil and remove the permagum from around the control bulb Then remove the old thermostat control bulb from the sleeve completely STEP 7 Insert the new thermostat control bulb into the new copper sleeve exten sion until about 1 2 inch protrudes from the swaged end Using a low temperature lubricant on the control bulb is advisable STEP 8 Using the protruding end of the con trol bulb as a guide insert it into the copper sleeve elbow in the rear of the evaporator Then push the sleeve extension over the end of the elbow to lock the two tubes together STEP 9 Gently push the control bulb through the joined sleeves in 1 2 inch incre ments until it reaches the end inside the evaporator taking care not to kink the line STEP 10 Seal both ends of the new control sleeve with permagum to keep mois ture out STEP 11 Remove the mounting plate from the evaporator housing Connect the 2 wires to the new control the control to the mounting plate the plate to the cooler and replace the control knob STEP 12 T
82. ing tool at a 30 Remove black knockout plug with angle this should line up with a a pair of pliers pre punched hole in the compressor compartment STEP 3 Snake CO line through knockout hole and newly drilled hole and route through rear grill louvers STEP 4 Seal hole around CO line with sil icone sealer to prevent cold air leakage gt Kit Materials 1 16 Pop Rivets 2 8 Mounting Brackets 3 2 Vandal Panel STEP 1 Two Mounting Brackets need to be positioned on the upper left and right hand corners of the cabinet The Mounting Brackets must be off 1 16 down from the top of the cab inet See Illustration one Drill holes with 7 32 drill bit and attach bracket via pop rivets Illustration 1 INSTALLATION INSTRUCTION Vandal Panel Installation for a GDM 33CPT 54 STEP 2 The two other Mounting Brackets are mounted 32 7 8 from the top of the cabinet to the bottom of the Mounting Bracket The two bot tom brackets must be installed fac ing the opposite direction from the top two brackets already installed in Step A See Illustration 2 STEP 3 The Vandal Panel slides down on top of the Top Mounting Brackets see Illustration 3 Then the bot tom brackets lock onto the Vandal Panel Center Mounting Bracket on side of end panel Bracket Bottom Mounting Bracket 1 16 32 7 8 From top of cab inet to base of Mounting STEP 4 Repeat Procedure for installation
83. k area SURFACE PREPARATION d Break nut loose with a clockwise movement and remove both wrenches from the tool Mask off the mounting surface of your Pizza Prep or Sandwich Salad unit with adhesive tape this will pre vent scaring on the cabinet surface e Remove rivnut tool from the rivnut by revolving entire tool in counter clockwise direction Figure 1 STEP 6 FINAL POSITIONING a Remove masking tape and replace shelf Seal bracket if STEP 2 required d Using a 11 32 drill bit complete Remove service shelf from box and the hole b Align mounting holes of shelf place 3 from the rear of the cabinet with rivnut holes and screw 1 4 for sandwich salad units and 3 STEP 4 20 round head bolts into 3 4 from the front for pizza prep threaded rivnuts units rivnut will strip out a Thread the 1 4 20 rivnut on the pull up stud of the rivnut tool STEP 3 until tight and insert into drilled hole a Using the predrilled holes of the service shelf as a template place b Place hex wrench in the socket of a pencil mark in each of the the jackscrew and hold stationary mounting holes gt REQUIRED TOOLS e Pencil or Marker e Slotted Screwdriver e Center Punch e Power Drill e Masking tape SURFACE PREPARATION STEP 1 Tape off both sides of the elevated ingredient pan area where the over shelf legs will be anchored this so that errant drilling will not mar the side of the cabinet STEP
84. left open to the atmosphere for longer than 15 min utes maximum 3 The appropriate new drier provided must be installed in the system 4 Established industry procedures for recovery evacuation refrigerant charging and leak testing should be followed TRUE MANUFACTURING COMPANY CFC amp Refrigeration Basics BASIC REFRIGERATION gt THE CAPILLARY TUBE SYSTEM Evaporator ERENLER AAJN AIID Lt TT tt tb Heat Exchanger Suction Line LOW PRESSURE GAS Starting at the Capillary Tube refrigerant flows into the evaporator and changes from a liquid to a gas As it absorbs heat after leaving the evaporator it flows through the accumulator The accumulator is a part that is designed like a reservoir to allow any refrigerant that has not changed from a liquid to a gas space to do so before returning to the compressor After flowing through the accumulator refrigerant flows through the suction line as a low pressure gas into the compressor The compressor pumps the refrigerant from a low pres sure gas to a high pressure gas and forces it into the condenser In the condenser with a fan circulating air over it the refrigerant condenses from high pressure HIGH PRESSURE GAS Accumulator Condenser Filter Drie Motor Compressor LOW PRESSURE HIGH PRESSURE LIQUID LIQUID gas to high pressure liquid After leaving the condenser refrigerant flow through the drier which is designed
85. left upright post behind the louvered grill Adjusting The Defrost Control time initiated temperature terminated Your True freezer contains a defrost system that is temperature terminated however the time clock has been designed with a time termination back up so that the defrost period will not exceed twenty minutes While True recommends 3 defrost periods not to exceed 20 minutes the procedure below should be followed to customize your specific needs Graduated Time Disk Time Indicator Duration Indicator Warning Always follow the manufactures recommended settings when program ming the amount and duration of the defrost cycles STEP 1 Referencing the outer graduated time disk position the current time of day to align with the TIME indicator To move the graduated time disk grasp the adjusted knob and turn counter clockwise until the current time of day aligns with the TIME indicator Adjusting Knob Trip Pin Extra Trip Pin Trip Pin Hole STEP 2 In order to program the time to begin the defrost cycle insert threaded trip pins into the graduated time disk hole that corresponds to your customized defrost needs STEP 3 True recommends a 20 minute defrost cycle three times per day Changing the recommended duration requires pressing down and sliding the copper duration indicator DEFROST CONTROLS gt 2 TIME INITIATED TIME TERMINATED Like in the time initiated temperature
86. ll louver assembly onto unit with appropriate fastener and clips Tighten all screws STEP 9 Connect unit to power and check to see if compressor is running REFRIGERATION SECTION In this section you can find information that is helpful for the customer and the service technician to help you understand how our refrigeration system works along with how to diagnose and correct any problems that might arise gt POLYOL ESTER LUBRICANT THE CFC REPORT LEADING THE WAY INTO A NEW AGE Polyol Ester Lubricant After exhaustive research and testing Copeland has determined that PolyolEster POE lubricants pro vide the best combination of characteristics for use with the new generation of chlorine free refrigerant In addition to providing superior lubrication POE has other advantages which increase its attractive ness for use in refrigeration Polyol Ester is a synthetic lubricant used primarily for jet engine lubrication It is manufactured by numerous companies and there are various types and grades available Therefore it is important to recog nize that all POE s are not the same Since POE is synthetic it has better resistance to high temperature degradation than refrigeration min eral oils POE is also made from more expensive base stocks making it significantly more expensive than other refrigeration oils Furthermore POE is compatible with common refrigerant and mineral oil Therefore a compressor containi
87. loped for NAFEM by an independent testing laboratory Packer Engineering of Naperville Illinois
88. lue is neutral to both frame and insert heaters STEP 8 Remove glass insert by pushing on insert in upper corner of the handle side If necessary use a heat gun or hair dryer aimed in the space between glass insert and door frame to lesson resistance of double stick tape Note For safety gloves and eye protec tion should always be worn when handling glass STEP 9 Once glass has been removed this REPLACEMENT OF DOOR FRAME HEATER ON IDL FREEZER DOORS will expose the heater wires inside door frame Remove old heater and replace with new heater cable STEP 10 Remove any old tape from the lip on the door frame Replace with new double sided tape on the 1 2 lip STEP 11 Re install glass insert by first installing two of the plastic shims to opposite ends of bottom door frame a few inches from the corners Remember to keep the tempered glass to the handle side of the frame and press against the two way tape Note The etched TRUE logo is positioned on bottom corner of the tempered glass side STEP 12 Square glass insert to door frame by adding shims to the handle side STEP 13 Replace backplates door handle and gasket STEP 14 Re install door on freezer if removed Refer to Removal and Installation of GDM and T Series Swing Door Instructions on page 58 61 STEP 1 Unplug the cooler and door harness and remove louver grill Remove P clip STEP 2 Take the door off the c
89. may be cleaned with any food service stainless steel cleaner The clear plastic shield should be cleaned only with mild soap warm water and a soft cloth CASTOR OR LEG FRAME INSTALLATION GDM amp T Series Castor or Leg Frame Installation _ m r g T ea iie mm i 5 Bia a i ae Eie a os B a GDM 61 69 72 will utilize 3 castor or leg frame assemblies INSTALLATION INSTRUCTION GDM 33CPT Castor Mounting Assembly gt T Hex Nut JA Castor With Threaded Stem INSTALLATION INSTRUCTION TDD 1 CO Knock out gt Knockout Plug j This instruction is True s y recommended procedure for installing a remote CO container REQUIRED TOOLS STEP 2 e Pliers e Power Drill Use drill and bit to bore hole straight e Silicone Sealer back through wall into compressor e Drill bit 1 2 compartment STEP I STEP 3 STEP 4 Remove black knockout plug with a Snake CO line through hole down and Seal hole around CO line with sili pair of pliers around exiting behind rear castor cone sealer to prevent cold air leakage underneath rear grill INSTALLATION INSTRUCTION TDD 2 3 4 and Club Top models CO Knock out gt This instruction is True s recommended procedure for installing a remote CO container REQUIRED TOOLS e Pliers e Power Drill e Silicone sealer e Drill bit 1 2 STEP 2 STEP 1 Use drill to bore hole through insu lation while hold
90. n remove stainless steel strip by lifting plastic trim and slide out the bottom STEP 8 Remove evaporator cover to access wiring connection of the heater wires STEP 9 Disconnect wires and remove defective heater s from cabinet pay close atten tion to how wiring is attached around the perimeter and the mullion s VIEW PLASTIC TRIM STEP 10 Reinstall heater in the same manner The splice in the heater wire is to be just below the plastic trim inside the acrylic tubing Any section of the heater wire can not be inside of acrylic tubing STEP 11 Insert heater wire through acrylic tub ing in to the cabinet and reconnect with wire nuts STEP 12 Reinstall the stainless steel plates and pop rivet corners STEP 13 Stand unit upright and let stand 2 to 4 hours before plugging it in gt REQUIRED TOOLS e Phillips Head Screwdriver e Drill e 1 8 Drill Bit STEP I Disconnect the power supply unload contents of cabinet and lay cabinet on its back STEP 2 Remove the lower louvered grill Remove the stainless steel skirt around the louvered grill STEP 3 Remove the sign on the louver sec tion above the door s STEP 4 Remove hinges and door s STEP 5 Drill out pop rivet on right top cor ner of plastic and stainless steel mullion trim Remove the top hori zontal stainless steel strip by sliding it to the right of the tracks in the plastic Be sure to raise the corner
91. n 1 3 HPCompressors 43 47 Temperature Control Change Out GDM 48 Temperature Control Change Out GDM amp T Series 49 Replacing Temperature Controls in GDM 7 GDM 10 amp GDM 12 models 50 Surge Protector s for the GDM Series 51 52 Door and Lock Repair 54 Glass Insert Slide Door 55 Slide Door Instruction To improve slide door closing 56 Wiper Gasket Installation 57 Removal and Installation of GDM Swing Door 58 59 Torsion Spring Replacement Swing Door 60 61 IDLLamp Replacement 62 Index Page Glass Insert Swing Door 63 64 Glass Insert Gas Release High Altitude Installation 65 GDM amp T Series IDLGlass Insert Replacement 66 Replacement of Door Frame Heater on IDL Freezer Doors 67 IDL Door Wire Harness Replacement 68 69 Shimming the Glass Insert 70 71 Lock Installations GDM Single Swing Door GDM 23 26 72 Barrel Lock Installation GDM Slide DoorModels 73 Slide Barrel Lock Top View 74 Slide Barrel Lock Front View 75 Lock Installation GDM 5 amp GDM 5PT Swing Door Models 76 Ratchet Lock amp Plastic Door Stop Slide Door 77 78 Lock Installation TD Models 79 General Instructions 80 Overshelf Option TSSU TWT TUC 81 Installing The Crumb Catcher 82 Field Installing The TSSU Series 19 Cutting Board 83 Anchoring the TSSU Hood Cover 84 Installing the TTPSeries Service Shelf 85 Field Installing the TPPService Shelf 86 Sneezeguard Option TSSU 87 Castor and Leg Frame Installation 88 GDM 33C PT Castor Mounting
92. n be caused by low damage defective running capacitors or a defective starting relay 4 If all operating conditions are normal the voltage supply at the compressor termi nals balanced and within limits the com pressor crankcase temperature within normal limits and the amperage drawn within the specified range the motor pro tector may be defective and should be replaced If the operating conditions are normal and the compressor is running excessive ly hot for no observable reason or if the amperage drawn is above the normal range and sufficient to repeatedly trip the protector the compressor has internal damage and should be replaced vapor as the pressure changes Any abnormal restriction in the system must be corrected 3 Check the compressor discharge pressure An abnormally high discharge pressure can cause a loss of capacity and can be caused by a dirty condenser a malfunc tioning condenser fan or air in the sys tem If the suction pressure is high and the evaporator and condenser are function ing normally check the compressor amperage draw An amperage draw near or above the nameplate rating indicates normal compressor or unit may have damaged valves An amperage draw considerably below the nameplate rating may indicate a bro ken suction reed or broken connecting rod in the compressor 3 Coil Defrost Heater A Lower the evaporator cover Disconnect the coil heater by remov ing the wi
93. n is True s recommend ed procedure for installing the crumb catcher option REQUIRED TOOLS Place the crumb tray on the cabinet counter top so that it is equally positioned at each end Pencil or Marker STEP 3 Phillips Screwdriver Adhesive Tape or Equivalent Power Drill and 1 4 drill bit Use adhesive tape to temporarily hold the crumb tray in position while you mark with a pencil the hole location on the stainless steel counter top INSTALLATION INSTRUCTION STEP 4 STEP 1 Remove the crumb tray and drill each hole using the 1 4 diameter drill bit Be careful not to allow the drill to wan Remove the white plastic cutting board der and scar the countertop provided with the cabinet from the counter top ANCHORING INSTALLING THE CRUMB CATCHER ACCESSORY FOR THE TSSU SERIES THE CRUMB CATCHER STEP 5 Remove any small burs from around the holes that have been drilled STEP 6 The plastic inserts are now ready to be installed Push the plastic insert into one of the 1 4 diameter holes STEP 7 With all the plastic inserts installed place the crumb catcher on the count er top and fasten using the screws pro vided STEP 8 Place the 3 4 thick cutting board pro vided with this kit on the cabinet counter top Figure 1 gt This instruction is True s recommend ed procedure for installing the 19 cutting board option REQUIRED TOOLS e Pencil or Marker e Fla
94. n line cover and up 2 from the bottom edge of the mirror Mark center point see figure 3 NOTE If the drain line cover edge at the tank bottom is difficult to locate measure the distance from the side wall to the center point at the top of the mirror and use that measurement for the bottom center point STEP 10 Drill pilot holes at both center points with a 1 16 drill bit through the mirror and drain line cover STEP 11 Fasten 10 16 x 1 2 hex knurled head screw included in both pilot holes snug against mirror WARNING Do not over tighten screw to avoid cracking mirror STEP 12 Remove shims replace shelving and reconnect power to cabinet Figure 3 drain line cover gt INSTALLATION INSTRUCTION TWT TUC TSSU and TPP PERIMETER HEATER REPLACEMENT POP RIVET REQUIRED TOOLS e Phillips Head Screwdriver e Pop Rivet Tool e Drill e 30 Drill Bit STEP I Disconnect power cord unload contents of cabinet and lay cabinet on its back STEP 2 Remove doors by removing upper door hinges STEP 3 Drill out pop rivet in the top right hand corner STEP 4 Lift plastic trim and slide upper stain less strip out HEATER SPLICE 4 a PLASTIC TRIM HEATER STEP 5 Drill out pop rivet in the bottom right corner and move vertical stainless strip up STEP 6 Lift plastic trim and slide bottom stain less strip out STEP 7 Remove bottom 3 screws on each side of mullio
95. n one circuit a TRUE S REMOTE SYSTEM HOW IT WORKS Refrigeration Schematic Diagram Suction Line i Evaporator Feed ned Coil Tubes distributor is used which evenly distributes refriger ant to each circuit The TXV is made to open and close by its sensing bulb which senses suction line temperature on the other side of the evaporator The sensing bulb has the same refrigerant that is used in the refrigeration system When hot air passes over the evaporator coil and warms the refrigerant the sensing bulb senses the warm condition and pushes the sensing valve open When too much refrigerant flows into the evaporator the sensing bulbs refriger ant cools and contracts allowing the diaphragm to ease away the needle valve thus closing the valve The external equalizer is another sensing element which helps the sensing bulb to more accurately feed refrigerant The external equalizer line must be down stream of the TXV bulb The TXV bulb should be insulated with corktape gt Control of Liquid Refrigerant Floodback To The Compressor During Operation BASIC REFRIGERATION Expansion Device Compressor LOW PRESSURE HIGH PRESSURE LOW PRESSURE HIGH PRESSURE GAS GAS LIQUID LIQUID MNI TD AMEN TLD Didi ibhiger TTT ann punu aii TTT CULE ORY Expansion Device p Accumulator J 7 a Crankcase Heater Compressor LOW PRESSURE HIGH PRESS
96. nd washers STEP 14 Adjust the spring tension by turning counter clockwise right door to the desired tension approx 1 2 turn Again use a 1 8 drill or drift punch to adjust and replace stop pin NOTE If cabinet is equipped with integrated door light be sure to plug into ballast box NOTE Freezer doors have heater wires which must be plugged in before operation STEP 15 Replace louvered grill and secure with four screws To adjust door hang Loosen bolts from bottom hinge assembly and lightly tap with plastic or rubber hammer When door hangs true with cabinet tighten bolts gt STEP I Unplug the cooler STEP 2 Remove lamp cover by squeezing it in the center twist and pull outward STEP 3 The lamp can then be removed by pushing it up and then out This will release the lamp from the lower lamp holder At this point the lamp can be totally removed INSTALLATION INSTRUCTION IDL Lamp Replacement STEP 4 Install the new lamp by placing the lamp terminals in the upper lamp hold er first STEP 5 Push up on the bulb to recess the upper holder STEP 6 With the upward pressure applied line up the terminal on the lower end of the bulb with the lamp holder Once aligned the lamp will snap into place Figure 1 STEP 7 Pull on bulb to make sure it is seated properly STEP 8 Replace lamp cover by squeezing and snapping into retainer on lamp assem bly STEP 9
97. ng the oil can be installed in a system containing HCFC s or HFC s In short POE provides significant flexibility in the face of changes brought on by the CFC issue HFC refrigerant require the use of POE for all Copeland compressors This is necessary for two specific reasons First mineral oils are not readily miscible in HFC s When using HFC s conventional oils will not return to the compressor Secondly the chlorine contained in CFCs and HCFCs aids in the lubricity of mineral oil One drawback from using POE is that they absorb moisture from the air at a much greater rate than do mineral oils As a result they must be handled and packaged with much more care than conventional oils Copeland has not tested all types of compressors or all combinations of refrigerant and con Industry knowledge of POE must rapidly increase in order to maintain and improve expected reliability After conducting extensive tests for both compressor durability and reliability on more than 40 refriger ant oil combinations Copeland identified Mobil Oil Corporation as our preferred U S supplier of polyol ester oil in terms of both the oil itself and Mobil s ability to package and deliver the oil with acceptable low moisture levels Because of its technical superi ority Copeland has approved Mobil s EAL Artic 22 CC polyol ester oil for use in our compressors To serve our customers Copeland will distribute EAL Artic 22 CC to the after market through
98. ooler and place on a flat stable surface Refer to Removal and Installation of GDM and T Series Swing Door Instructions on page 58 61 STEP 3 Remove door gasket STEP 4 Remove back plastic This will require a phillips screwdriver STEP 5 Remove the glass insert This can be done by placing a putty knife between frame and the insert Then pry the insert up and out of the frame The insert will stick due to double sided tape that is used to hold STEP 6 Remove the strain relief bushing on the underside of the door frame STEP 7 Pull light channel to expose lamp hold er and door harness connection INSTALLATION INSTRUCTION IDL Door Wire Harness Replacement FRONT VIEW Sirain Relief With door closed all stack in the harness should be pulled out before fastening ihe P clip P clip showd hold harness in place with the hinge bearing 30 Match plug pin to those on the ballast receptacle R p a Door Harness Bearing Spacer Harness Plug Louver Frame Ballast Receptacle Figure 2 STEP 8 C SSTTEP D Cut the lamp holder wires directly Remove the door harness above the lamp connectors gt STEP 10 Check the physical dimension of the new cord If the new cord is thicker it is necessary to enlarge the hole in the door frame Enlarge the hole using a 5 8 drill bit STEP 11 Place strain relief around the new door harness STEP 12 Route door harness through frame
99. p hinge assembly STEP 3 If spring remains taut relieve tension by placing a drift punch or 1 8 drill bit into the stop pin hole two holes to the left for right side door of the stop pin position Hinge a eee oF 4 2 Brass uae e Bushing Thrust Bearing Hinge Washer Bottom Door Hinge J Bracket With drill bit firmly anchored in posi tion apply back pressure to the left and remove the stop pin with needle nosed pliers While firmly holding the drill bit with your left hand begin rotating the hinge shaft to the right relieving spring tension Insert second drift punch or drill bit into hole to the left and repeat process until all spring tension is relieved In some instances it is necessary to relieve spring pressure one hole posi tion at a time until spring pressure is relieved NOTE Operation is reversed for left side door gt STEP 5 Remove all 4 anchor screws from lou vered grill and remove grill NOTE If cabinet is equipped with integrated door light be sure to unplug from ballast box NOTE Freezer doors have heater wires which must be unplugged before doors can be removed STEP 6 In a squatted position rest the bottom of the open door on your left knee for right side door as you face the outside of the door Create an upward pressure and remove the two 3 8 bolts from the bottom hinge assembly Remove the bottom hinge assembly figure 2 STEP 7
100. pacitor Excessively high line voltage 110 of rated max Incorrect relay Incorrect mounting angle Line voltage too high or too low Excessive short cycling Relay being influenced by loose vibrating mounting Incorrect run capacitor Control setting too high Expansion valve too small Cooling coils too small Inadequate air circulation Expansion valve passing excess refrigerant or is oversized Expansion valve stuck open Evaporator fan not running Overcharge of refrigerant Restriction in dehydrator or strainer Liquid shut off king valve partially closed Loose parts or mountings Tubing rattle Bent fan blade causing vibration Fan motor bearings worn tt a COND 2a 2b 2C Ne cae aed E e T aS E N e a ad REPAIR Fix leak add charge Clean contacts or replace control Determine fault and correct Replace with larger system Defrost Determine location and remove Clean condenser Clean or replace Clean contacts or replace relay if necessary Determine reason and correct Replace Correct by using pump down arrangement if necessary Determine reason for short cycling E above and correct Determine correct size amp replace Determine correct size and replace Determine reason and correct Check and replace Remount relay in correct position Determine reason and correct Determine reason See E above and cor rect Remount rigidly
101. ration of left hand door tom see figure 1 STEP 3 STEP 6 Drill through pilot hole in ratchet bar To lock cabinet slide ratchet lock onto and into door frame with 1 8 drill bit ratchet bar through slot lock should be Anchor by installing 1 4 hex head oriented with slot towards top of lock screw provided see figure 2 Figure 2 CAUTION Do not drill beyond 3 4 to avoid hitting glass insert INSTALLATION INSTRUCTION gt RATCHET LOCK amp PLASTIC DOOR STOP SLIDE DOOR Continued Plastic Door Stop Installation Instruction Unnecessary if factory installed REQUIRED TOOLS e Drill With 1 8 Bit e Phillips Head Screwdriver STEP I Remove left side door by lifting up and out of bottom track STEP 2 Position the plastic door stop cen tered in the front door channel and mark it Center within the confines of the door that was removed STEP 3 Peel backing from double sided tape and position on previously marked spot STEP 4 Drill 1 8 holes using the pre drilled holes of the plastic door stop as a template STEP 5 Install phillips counter sunk screws provided see figure 3 STEP 6 Replace left side door and check Slide operation If door stop impedes closing of left hand door remove door detach plastic door stop and remove one layer or piece of the door stop and reinstall perem p TT aa aaa n nET aia a aa i mia
102. re is a ground replace the compressor 5 If the compressor has an external pro tector check for continuity through the protector or protectors All external inherent protectors on compressors can be replaced in the field IF THE MOTOR COMPRESSOR STARTS BUT TRIPS REPEATEDLY ON THE OVERLOAD PROTECTOR 1 Check the compressor suction and dis charge pressures while the compressor is operating Be sure the pressures are within the limitations of the compres sor If pressures are excessive it may be necessary to clean the condenser purge air from the system replace crankcase pressure regulating valve An excessively low suction pressure may indicate a loss of charge On units with no service gauge parts Where pressures can be checked check condenser to be sure it is clean and fan is running Excessive temper atures on suction and discharge line may also indicate abnormal operating conditions 2 Check the line voltage at the motor terminals while the compressor is operating The voltage should be within 10 of the nameplate voltage rating If outside those limits the voltage supply must be brought within the proper range or a motor compres sor with different electrical character istics must be used 3 gt FIELD TROUBLESHOOTING Check the amperage drawn while the compressor is operating Under normal Operating conditions the amperage drawn will seldom exceed 110 of the nameplate amperage High amperage ca
103. re nuts at the point where the heater joins the electrical circuit of the freezer in the evaporator com partment Check heater for continu ity with an ohmmeter If the heater is defective cut the bale wires holding the heater to the coil and remove the heater Replace with a new heater using bale wires provided 4 Drain Tube Heater A Lower the evaporator cover Disconnect the drain tube heater by removing the wire nuts at the point where the heater joins the electrical circuit of the freezer in the evapora tor compartment Check the drain tube heater with an ohmmeter B If the drain tube heater is defective disconnect the drain tube from the rigid plastic drain bend the tabs that hold the evaporator drain pan to the DIAGNOSIS AND REPLACEMENT OF FREEZER CABINET COMPONENTS 1 Defrost Time Clock evaporator cover and raise the drain pan so that the flexible heater is visi IF THE COMPRESSOR RUNS BUT evaporator surface to determine if it is evenly cold throughout or if partially starved A lack of charge may be indi cated by light fluffy frost at the evapora tor inlet Add refrigerant if necessary Check the compressor suction pressure An abnormally low pressure may indi cate a loss of refrigerant charge a mal functioning capillary tube a lack of evaporator capacity possibly due to icing or low air flow or a restriction in the sys tem Often a restriction in a drier or strainer can be identified by frost or
104. rner of retained by the plastic trim pieces wire nuts plastic and stainless steel mullion trim Remove horizontal top stainless steel 10 Replace inoperative heater wire loop 7 C R O Valve strip by sliding it to the right on the being sure to hook under the corners of A Remove the refrigerant from the system tracks in the plastic Be sure to raise the plastic trim as observed during dis to an equalized 0 pounds pressure the corner of the plastic trim where the assembly Remove securing strap holding the pop rivet was removed so that the stain valve to the condensing unit base less trim slides beneath it Drill out the 11 Reverse assembly sequence to replace Replace the valve Evacuate the sys two pop rivets in the top plastic trim trim Use the four 4 small sheet metal tem to 100 microns and recharge the which was hidden by the horizontal screws furnished with the heater wire system piece of stainless trim in the same sequence as the pop rivets were removed Fan Door Switch and lights on T Remove left and right vertical stainless Models steel trim pieces by sliding them out of 12 Attach the heater wires to the power supply in the junction box Replace all other assemblies in reverse sequence in which they were removed TROUBLESHOOTING FLUORESCENT LIGHTING CIRCUITS Electromagnetic Rapid Start Instant Start Electronic and Preheat Fluorescent Light Circuits gt WARNING A qualified service technician must b
105. rp To avoid personal injury use adequate protection for your eyes and hands when working or handling this or any other glass component Required tools Phillips head screwdriver 3 8 Wide double sided tape Side cutters Gf working with freezers Butt connectors if working with freezers Crimping tool Gf working with freezers STEP 1 Disconnect power to the cabinet STEP 2 Disconnect IDL plug from cooler STEP 3 Loosen up the tension from torsion spring and remove door Refer to Removal and Installation of GDM and T Series Swing Door Instructions on page 46 47 STEP 4 Remove doors handle and place door on a flat surface STEP 5 Remove door gasket and back plates from the top bottom and handle side STEP 6 Beginning at the upper corner in the handle side carefully pry the bro ken glass loose If necessary use a heat gun or hair dryer to loosen up the insert from double sided tape Note Do not forget to disconnect the glass insert heater wires before pulling it out and reconnect them before sliding the new glass insert in STEP 7 Remove any excess tape and glass from the lip on the door s frame and replace with new double sided tape GDM amp T SERIES IDL GLASS INSERT REPLACEMENT STEP 8 Install the new glass insert by push ing it into the light channel first and then work out wards toward the handle side NOTE Make sure the TRUE logo on the insert is locat
106. sert holders to the door Remove all four aluminum pieces a n a im eet in Ts cae oe ou EE on am on an n ata at Pe oo aa Papen 7 a Be ae aaa a na Pa n a a ces inst INSTALLATION INSTRUCTIONS Glass Insert Gas Release High Altitude Installation Top View of Glass Insert Step 6 7 S V Three panes of glass STEP 5 Beginning at the corners carefully pry the broken glass loose from the frame If necessary use heat gun or hair dryer aimed in the space between glass insert and door frame to lessen resistance of double sided tape STEP 6 Carefully use the drill with a 1 16 drill bit to drill through the spaces between the glass STEP 7 After gas is released from in between both panes use the silicone to reseal drill holes STEP 8 Remove any excess tape or glass from the lip on the door frame Replace with new double sided tape on the 1 2 lip AO Holes to be drilled with 1 16 drill bit STEP 9 Remembering to keep the tempered glass to the handle side of the frame place the new glass insert inside the frame and press against the two way tape The etched TRUE logo is positioned on the tempered glass side STEP 10 Replace the four Aluminum glass insert holders STEP 11 Reconnect the nylon cord to the top of the door and replace the door as originally removed gt Warning The Edges on the glass insert are very sha
107. ss insert inside the frame and press against the two way tape The etched TRUE logo is posi tioned on bottom corner of the tem pered glass side STEP 9 Square up door by adding shims between glass insert and the handle side of the door frame gt STEP 10 Place double sided tape on all edges of glass insert to create a seal with the back plate STEP 11 Replace bottom back plate then top and side plates Tighten all screws STEP 12 Replace the handle STEP 13 Snap the gasket back into the back plate Figure 2 INSTALLATION INSTRUCTION GLASS INSERT SWING DOOR CONTINUED Freezer Glass Door Replacement Instruction REQUIRED TOOLS e Phillips Head Screwdriver e 3 Wide Double Sided Tape e 2 Self Stripping Connectors NOTE For greater safety and ease of installation it is recommended that two persons assist in replacement procedure IT IS NOT NECESSARY TO REMOVE THE DOOR FROM THE CABINET Follow steps 1 4 of refrigerator glass insert installation STEP 5 Freezer doors have heater wires running through the door frame and around the rear side of the glass insert which junc tion at the lower inside corner and plug into the compressor area The glass insert must be carefully pried loose start ing from the top corner and working down to gently free the glass insert A Door frame heater wires ae Self stripping connectors b Insert without damaging the heatin
108. t shuts compressor off Capillary Tube Meters the amount of liquid refrigerant into the evaporator where it absorbs heat a a DA Dai 0M7 oe amp a Cool air in Condenser High pressure gas is condensed into a high pressure liquid when the heat is removed By pulling air in the front of the condenser by means of the fan motor The air will be used to evaporate the drain pan water gt Liquid and Suction Tubing P Trap e TXV Bulb External Equalizer xy eT g m L Distributor Liquid Line E with Nozzle Solenoid j The suction line will exit the evaporator coil as usual for self contained models except it shall include an Oil P trap This is used to trap oil in low velocity suction gases at a point just prior to a vertical rise Whether the compressor is to be located above or below the evaporator True does not have control over this the suction will always have a P trap in case the compressor is installed overhead The liquid line shall enter the cabinet and go direct ly to the liquid line solenoid this is a normally closed refrigerant valve which will be energized and wired in series with the thermostat When the ther mostat is closed requires refrigeration the solenoid will be energized to open allowing refrigerant to pass to the thermal expansion valve TXV The TXV allows refrigerant through to the evaporator coil If the evaporator has more tha
109. t locate other loose pink wire in ballast box connect the remaining pink wire with in line splice or butt connector d On surge protector connect other end of pink wire to LINE OUT e Now create a 15 long white wire Strip both ends 1 2 On one end put 1 4 quick connect insulated slip on connector f Locate junction of white wires in bal last box if cabinet is supplied with a European style cord this wire will be blue g Cut end connector off junction re strip wires and add white wire Re crimp the connection using a large closed end connector h On surge protector connect other end of white wire to NEUTRAL ENCLOSING WIRING AND UNIT START UP RECEPTACLE Figure 2 Ballast Box Before Surge Protector NOTE Ou STEP 9 Neatly replace wires into ballast box and replace lid Plug in cabinet Green light on surge protector should be off Cabinet now has power There will be a 3 minute delay before the pump will start Test voltage After start up delay cabinet should operate normally Replace louvered grill cover and secure with four phillips head screws SURGE PROTECTOR Figure 3 Ballast Box Before Surge Protector Check all wiring to make sure it is correct Connections should be verified against Figures 3 and 4 DOOR AND LOCK REPAIR In this section you will find instructions on how to replace or repair door assemblies along with how to
110. t and moisture Surface must be clean and dry for adhe Sive on extru sions mirror support strips L 5 16 STEP 4 Measure 15 16 from rear interior wall for ward and mark the side wall for the mirror support strip location Select two shims of equal height between 1 8 1 4 one for each side of the cabinet Measure and mark the height of the shim against the side wall Repeat on the opposite wall see figure amp 3 STEP 5 Locate two channel extrusions mirror support strips Remove paper strip cov ering adhesive from one of the mirror support strips STEP 6 Carefully secure mir ror support strip against the side wall the height of the shim mark and along the mark 15 16 from the back wall INSTALLATION INSTRUCTION GDM 23FC Mirror Retrofit Kit Repeat on the opposite wall adhesive backing is the only anchor for the mirror supports STEP 7 Place shims on the interior floor in line to support the mirror when in position STEP 8 Slip one edge of the mirror in the mirror support strip channel bow mirror and feed into the other mirror support strip Work until mirror fits flat inside support strips and rests on top of the floor shims see figure 2 STEP 9 Locate left edge of the drain line cover at the rear of the cabinet At the top edge of the mirror measure in 1 and down 2 Mark center point Figure 1 At the bottom edge of the mirror measure in 1 from the drai
111. te turn 2000 3000 4000 9000 6000 7000 8000 9000 10 000 Figure 2 This scale may be used as a guide for measuring degrees of rota tion required for altitude correction The arrows indicate STEP 1 direction of screw rotation Unplug the cooler STEP 5 _sCSTEEP2 Tum screws counterclockwise CCW REQUIRED TOOLS See Chart and figure 2 Turn the temperature control to the 9 e Phillips Head Screwdriver position STEP 6 e Hex Head Driver e Jewelers Screwdriver _ CO STEPS ___________ Reassemble to cooler housing and return the temperature control to the Remove the screws that secure the 5 position IMPORTANT mounting plate to the evaporator top OSM A R AI s A CA See figure 1 Altitude temperature controls are pre calibrated and do not _ STEEP 4 require adjustment Pull control down gently from housing Danfoss Temperature Control Adjustment for High Altitude Applications INSTALLATION INSTRUCTION Terms Cut out Temperature sensed by the controller that shuts the compressor off Cut in Temperature sensed by the controller that turns the compressor on Instructions STEP I Mechanical temperature controllers are affected when functioning at high alti tude The cut in and cut out tempera tures will be colder than when the con troller function closer to sea level STEP 2 For installations above 2 000 ft it may be necessary to warm up the set points
112. temperature control See Figure amp 9 STEP 7 Anchor the Relay Shield See Figure 10 A Secure the new relay by attaching the relay shield B Relay shield includes two self tapping screws When installing shield place shield in position to cover relay and all exposed wiring Figure 10 Anchoring Relay Shield gt STEP 8 Unplug the cooler STEP 9 Checking Relay Operation A Unplug the condensing unit from the compressor receptacle located on the ballast box B Turn the new control to the 0 zero position by aligning the zero indication on control knob with the arrow stamped into the evaporator housing Ensure that control is off by listening for an audible click This will indicate an off position C Plug voltmeter into compressor receptacle D Plug cabinet into power source Securing Ballast Box A Reinstall ballast box cover B Anchor cover with two screws F Check voltage at compressor receptacle Voltage should equal voltage at wall outlet G If voltage is correct turn temper ature control to 0 zero H Plug condensing unit cord back into the compressor receptacle INSTALLATION INSTRUCTION TEMPERATURE CONTROL REPLACEMENT CONTINUED STEP 10 Replacing Louvered Grill A Reinstall grill by reversing earlier procedure STEP 11 Re connect Power Cord STEP 12 Return Temp Control to normal setting and check cabinet operation Fig
113. the foam itself will make a leak detector sniffer type react AFTER LEAK IS LOCATED IT IS VERY IMPORTANT THAT THE SYSTEM DRIER IS CHANGED AND THAT A 200 MICRON VACUUM IS PULLED THROUGH BOTH THE HIGH AND LOW SIDE ACCESS FITTINGS When leak is located recover refrigerant at this time the technician may want to remove any line taps they might have installed and solder on access fittings to pull the vacuum and recharge the system After charging the system both of the access valves must be removed from the system If the head pressure falls right back down after you stop adding refrigerant and the suction pressure stays low there may be a restriction in the system Recover refrigerant and cut out the drier along with about of the capillary tube Circulate nitrogen through the system to clear any restrictions in the evaporator Evacuate the system and recharge If the problem still exists the capillary tube may need to be replaced CAPILLARY TUBE REPLACEMENT INSTRUCTIONS Refrigerators and Freezers gt Depending on what model cabinet you may have you will always have a couple of options when it comes to replacing the capillary tube REFRIGERATORS Some model cabinets for example GDM slide door cabinets have capillary tube suction line assembly behind the rear center shelf standard These are easy to access and change On refrigerator cabinets that do not have a rear center shelf standard here are you options 1 You can run
114. thead Screwdriver e Adhesive Tape or Equivalent e Power Drill e Adjustable Wrench LOCATION Align the predrilled cutting board holes with the locating pins positioned on the stainless working surface SURFACE PREPARATION STEP I Tape off both sides of work surface so that errant drilling will not mark the side of the cabinet STEP 2 Place the anchor bracket over the top of the cutting board edge pulling for ward until bracket backstop is seated firmly against the cutting board edge Use bracket screw holes as a template for drilling STEP 3 Pencil mark drill hole Using the 2 or 15 64 bit provided drill through the metal thickness stop and pull out STEP 4 Assemble riv nut tool provided and lubricate WD 40 etc the threads Ensure that the flange of the rivnut seats against the knurled edge STEP 5 Insert allen wrench into top of crimp ing tool and place entire rivnut assem bly into recently drilled holes STEP 6 Secure crimping tool with a wrench and turn allen wrench in a clockwise INSTALLATION INSTRUCTION FIELD INSTALLING THE TSSU SERIES 19 CUTTING BOARD rotation until resistance is felt over tightening will strip rivnut STEP 7 When minor resistance is felt rivnut has expanded to fill the drill hole Remove tape from sides Repeat steps 2 through 7 for each of the four anchor positions and replace anchor bracket Use a slotted screwdriver to tighten thumb screws
115. tic fill in plate work ing lock to make sure latch will move through the slot When components Operate properly fasten fill in with black pop rivets REMINDER Remember to install left door gasket Top View STEP 9 With left door installed mark rear of door where the notch in the latch meet the door frame Drill a 32 hole on the mark Install screw and latch tube assembly into drilled hole Latch should drop onto tube assembly and lock left door STEP 10 Install lock bar assembly to rear edge of right door Install so the bar is 2 from the top of the door in the storage position use 32 drill bit STEP 11 Lower bar into locking position It should be positioned against 3 break er strip Install third SS clip so locking bar will fall into it as a pocket This will hold bar in the locking position use 32 drill bit SLIDE BARREL LOCK TOP VIEW gt Aluminum interior wall ___ Foam Insulation a ssembly Screw me Latch Barrel Lock Me _ s E Lock Nut a a Vinyl end i to Fi a 3 4 Round hole 3 Black plastic gt breaker strip al Retainer plate SLIDE BARREL LOCK FRONT VIEW gt 34 34 Screw and latch tube Install in to back of door frame Door Frame Jamb Gasket eS 75 gt REQUIRED TOOLS e Tape Measure e 1 4 Drill e 2 Saw Drill Hole Saw e 3 4 Saw Drill Hole Saw e Straight
116. tion lines down ward in the direction of flow Generally 1 2 pitch for each 10 ft of line is adequate for good oil return Field installation vibration eliminators should be field installed INSTALLATION INSTRUCTION Remote Condensing Unit parallel with the compressor crank shaft and as close to the compressor as possible Leak Check and Evacuation After all refrigerant line connections have been complete the entire sys tem should be leak checked This includes field and factory connec tions Charge system with refrigerant vapor and add enough nitrogen to raise pressure to 150 PSIG maxi mum Leak check the entire system Make repairs as necessary Evacuation Process To obtain the proper level of dehydration in the refrigeration system a vacuum of at least 500 microns must be drawn Do not use the system s compressor as a vacuum pump and do not operate compressor while system is in a vac uum Open all system service valves to discharge any pressure in the system Connect vacuum pump to high and low side of system Pull vacuum Break the vacuum with system refrigerant Pull vacuum again down to 500 microns or lower Shut valves before charging Charging Process When initially charging a system that is in a vacuum liquid refrigerant can be added direct ly into the receiver tank without compressor running If you have difficulty charging the correct amount of refrigerant into the system you may start th
117. unning unplug the condensing unit and check the voltage at the compressor receptacle The voltage should be within 10 on a 115 volt compressor and within 5 on a 208 230 volt compressor Any voltage less than that unplug cabinet and remove the temperature control from the evaporator housing and check out control Control could be stuck open or be pitted due to low voltage or short cycling Refer to Temperature Control Change Out Instructions page 39 41 e There is a wiring diagram on the back of the electrical box cover plate Use this to help you troubleshoot YES The compressor is running and cabinet is warm Does the evaporator coil have an ice build up on it If so follow above directions on how to verify if timer is advancing If it is manually turn timer and put freezer into defrost to check defrost heaters After ice build up is gone restart cabinet if box starts to freeze properly cabinet may not have enough defrost times Set timer for 4 defrosts a day You may also want to check out defrost heater voltage and amperage at this time to verify that there is not a heater or voltage problem If the compressor is running and there is no ice build up on the evaporator coil install gauges on the suction and discharge side of the system and check the system operating pressures REFRIGERATION TROUBLESHOOTING CHART Freezer Continued gt 1 Ifcompressor is running and you have a low amp draw with a high suction pressure and a low
118. ure 1 Temperature Control REQUIRED TOOLS e Phillips Head Screwdriver e Hex Head Driver iC STEEP 1 Unplug the cooler STEP 2 Turn the temperature control to the OFF position 0 STEP 3 Remove the black control knob on the temperature control It pulls off STEP 4 Remove the screws that secure the mounting plate to the evaporator top Item A STEP 5 Remove the two screws that hold the control to the mounting plate Item B INSTALLATION INSTRUCTION TEMPERATURE CONTROL CHANGE OUT GDM Permagum JEF ATL l l j i i F oO F l NOTE If it becomes necessary to remove the housing be sure to tape off any interior panel at risk of being scratched STEP 6 Disconnect the two wires from the tem perature control Items 1 and 2 STEP 7 Reach to the side of the evaporator coil and remove the permagum from around the control bulb Completely remove the control bulb from the sleeve and pull straight out after removing the permagum Danfoss Temperature Control Change Out Connect one wire to terminal 3 and the other wire to terminal 4 Note Spare terminal 4 should be covered with insulated female connector sent with new control INSTALLATION INSTRUCTION TEMPERATURE CONTROL CHANGE OUT GDM AND T SERIES Installing The New Control mom sea mna ata Pa na a a ge a a a ajalina EE Eo m e n a non noa n ngoa g p jaina EE EN a a noa nna ann a ee Poi apn a m aon
119. urn the control knob to the 5 set ting STEP 13 Reassemble front of cooler and plug it In gt SURGE PROTECTOR INSTALLATION This instruction is True s recommended procedure for installing surge protection part no VD SI6P A REMOVING POWER STEP 1 Disconnect power before installing surge protector REQUIRED TOOLS e Multimeter e Adjustable Wrench e Phillips Screwdriver e Wire Strippers e Wire Cutters e Crimper LOUVERED GRILL REMOVAL STEP 2 Remove louvered grill by removing the four phillips head screws as shown in Figure 1 2 INSTALLATION INSTRUCTION SURGE PROTECTOR S FOR THE GDM SERIES BALLAST BOX ACCESS STEP 3 Remove ballast box cover by un screwing two 1 4 hexhead screws center posi tioned on both sides of cover plate See Figure 1 3 KNOCKOUT LOCATION AND BUSHING INSTALLATION STEP 4 Locate 5 8 knockout positioned on the inside upper left of ballast box Figure 1 4 Tap out 5 8 knockout with a screw driver and hammer See Fig 1 4 If available install a 5 8 snap bushing in knockout hole CREATING WIRE CONNECTION FOR SURGE PROTECTOR STEP 5 NOTE Installer will need to provide 16 wiring for splicing From this installer supplied wiring cut two pink 15 pieces and strip both ends 1 2 from ends On one end of each wire crimp on a 1 4 quick connect insulated slip on connector N Y yvy a N UY rAr j x i J
120. vaporator housing to far left end of cabinet After all screws are removed lower duct into cabinet floor B Fan area housing after air duct is lowered screws connecting this housing to the countertop will be exposed remove these screws Cut silicone seal that seals countertop to cabinet Lift up on front of countertop and push towards rear of cabinet Countertop slips into groove on rear of cabinet Clean all excess silicone from cabinet before reinstalling countertop To reinstall onto cabinet sliding it to front of cabinet so it will catch in the lip on the rear of cabinet Countertop should be flush with the rear of the cabinet when installed correctly Reinstall screws through the top of the door openings Holes in top should align with holes in frame Reinstall all L brackets 10 Reinstall screws into interior parts first the pan area housing and then the air duct 11 Set cabinet upright and silicone seam between countertop and cabinet The following steps help to install the Fa Hood lt gop new counter top EEE EH Follow step 8 vut you will have to pre drill 5 28 holes to reinstall 2 3 4 3 aed Se a 5 a screws through the door drawer opening 2 89 S3 k Air Duct Screws ee ee Uai EEGA BEEN aa E eS ee m Lay the cabinet on its back place doors amp E a g i E 7 into position Mark holes for top a A m i R hinges Pre drill these holes with a at an f 7 32 drill bit

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