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Pro-Series (Model 648PRO - AKA PRO48)

1. 1 WATER FILTER SW REFRIGERATOR REF VARIABLE SPEED 4 PWR SUPPLY COMPRESSOR COMPRESSOR pc power Ed STARTING RELAY GLASS DOOR ONLY GREENVELLOW BLACK 5 YES a FURPLE ils duce gd ee ao i EM RIBBED ESE M E Ses Se EMEN UE 08 C2 g E 8 z ICEMAKER E WATER VALVE WHITE ah MAIN SE mE 8 CONTROL E x AWECO creen CONDENSER 8 BOARD E REF VALVE iS SEEN FAN 2924 MOTOR BH 5 284 TAN 4 sug WATE E eae CRE 5 2 BLACK 3 uud di z z nm 3 du 8 PURPLE DA E 85 Bas dd FRE VARIABLE SPEED 8 ee Baad J COMPRESSOR lo 4 44542244344 25598855158 2 veuow TITTI WIBITE RED tay TENTE RED amm ik WHITE TOP ACCENT LIGHT EE BLUE GREERITELLG 5 FRE DOOR SWITCH PRANGEMETE 5 TANO E YELLOW PENG A 8 ORAN
2. NOTE Variable speed compressors evapo NEUTRAL rator fans and the condenser fan will V V run a great majority of the time This is normal These components will 0000000 AWECO REF VALVE 2 2950 only cycle off during defrost also cycle off for short periods of time if the ambient temperature is low ren ts PIZ 20 2 enough P Initial speed command from invert Das Al er to a compressor are always for 1 High speed LIO rs z AC power supplied to variabl d The refrigerator compressor will not CP upp i 3b gt Ms be variable speed on solid door units _ MAIN compressor IVE ERE i CONTROL cooling is called for 3 phase high DC The refrigerator service replacement ue BOARD il compressor is non variable speed P as voltage is then supplied to variable sa speed compressor If compressor load regardless of the unit configuration i SPARE ROP AaS dll a glass door or solid door is high medium
3. d 2 2 E z z m 8 9 5 u 8 CONTROL 2 BOARD 3 3 2 ur mre N H H sensor JACKET CABLE MARK o o 0121819019919 Nor REF WITH 1 BLACK STRIPE N DEI no NEAR SENSOR END SENSOR FRE COND JACKET CABLE o M SENSOR JACKET CABLE MARK HH AMBIENT WITH 1 BLUE STRIPE NEAR SENSOR END REDI RED Waite 2 p WHITE gl UPPER REF EVAP FAN 3 MOTOR Q JACKET CABLE MARK WITH 2 BLUE HE STRIPS NEAR SENSOR END 53 i 3 SENSOR JACKET CABLE MARK aes ul REFEVAP WITH 2 BLACK STRIPS 377 SENSOR JACKET CABLE MARK NEAR SENSOR END FRE EVAP WITH 2 GREEN STRIPS NEAR SENSOR END SENSOR FRE CAB SENSOR JACKET CABLE MARK WITH 1 BROWN STRIPE REF CAB NEAR SENSOR END amp 834 E 181 884 L DOOR 253 3 3 ajd HEATER 8 8 8 WHITE BLACK 5 FRE EVAP FAN MOTOR IN HINGE eine ALCUN BLUE o S BLUE WHITE O Mec REDI RED YELLOWPURPLe 4
4. Drain Trough Heater Loop j R E Figure 7 49 Drain Trough Heater 3758440 Revision A October 2005 Component Access Removal Compressor Area Mechanical Components Water Filter Removal The water filter is located behind the grille assembly To remove the water filter 1 Lift Louvered section of grille assembly up 2 Rotate filter counterclockwise to remove it See Figure 7 50 clockwise to install it NOTE The water filter timer will reset to a one year countdown when the filter is replaced If the water filter was removed only to service other components press the filter switch five times within five seconds to allow the filter timer to continue the original countdown A beep will be emitted indicating the original countdown has been resumed Water Valve Removal The water valve is attached to the back side of the water valve bracket located behind the grille assembly NOTE Before continuing disconnect or switch off water supply To remove the water valve See Figure 7 51 Lift Louvered section of grille assembly up Rotate water filter counterclockwise to remove it Extract mounting screws from mounting bracket Disconnect wire leads from valve Disconnect water lines from valve Extract mounting screws from valve mounting bracket
5. NOTES If both condenser outlet temperatures evans wr are lt 90 F 32 C no power is sup ES socveies NEUTRAL plied to the condenser fan motor regardless of compressor operational state Currently the condenser fan operates at 1350 RPM whenever it is ener aan JAR CONDENEER FAN MOTON gized In the near future the con e E E denser fan will operate at a variable 1 speed as follows Das 3 Condenser fan energized 1 Compressor running and con denser outlet temperature gt 0 90 F 32 C condenser fan speed will be Low 1100 RPM M CONTROL 2 Compressor running and con Mes ua denser outlet temperature gt 95 F 35 C condenser fan JU d aga will be High 1350 I 1 Compressor s energized If a condenser outlet thermistor is nane verro rem mne defective the condenser fan will run dai at high speed whenever a compres sor is energized STARTING RELAY f VSPEED oy 1 BOX REF_ ETATK DOOR ONLY DC POWER LOW VOLTAGE E 2 Condenser outlet temper 1 m atures gt 90 F 32 EE qn mU non es sos qus m CONTROL son ZONE e ex i POP M BOARD PANE H H H a Ei CU Figure 3 22 Signal Trac
6. P16 MAIN 24 m CONTROL BOARD P18 i P19 I sa 7 1 Temperatures nina displayed ET t sH User Displays ES 3 Evaporator fan s energized Figure 3 19 Signal Trace Regulating Temperatures 3 13 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO Peus zenod Assist in Control of Variable Speed Compressors As mentioned on the previous page temperature signals from the thermistors in the zones compartments are moni tored by the microprocessor and then displayed on the User displays When a zone reaches high offset calling for cooling a start command is sent to the inverter which is supplied with AC power at all times The inverter then provide high DC voltage 3 phase 50 150 Hz outputs to the compressor The inverter in turn senses the compressor load If the the compressor load is high the speed compand from the inverter will be for high speed compessor operation if medium compressor load speed compand from the inverter will be for medium speed if low compressor load speed compand from the inverter will be for low speed If when a zone reaches low offset a stop command signal is sent to the inverter which then cuts DC power to the compress Sor
7. CIRCUIT DESCRIPTION FUNCTION COLOR CIRCUIT DESCRIPTION FUNCTION COLOR 120 VOLT CIRCUITS LOW VOLTAGE CIRCUITS CONTINUED P13 NEUTRAL NEUTRAL INTO BOARD WHITE 4 1 12 VDC POWER 12 VDC POWER RED 14 DEFROST HEATER 1 POWERS DEF HTR 1 BLUE 4 2 12 VDC RETURN 12 VDC RETURN WHITE P15 POWER IN POWER INTO BOARD BLACK 16 MAIN LIGHTS POWERS MAIN LIGHTS YELLOW P6 1 VERTICAL LED REF 12V TO LED BLACK WHITE P17 COMPRESSOR REF POWERS REF COMPRESSOR GRAY P62 UNUSED UNUSED UNUSED P18 COMPRESSOR FREEZER POWERS COMPRESSOR FRZ PURPLE P6 3 VERTICAL LED REF COMMON VERTICAL LED RETURN WHITE P19 UNUSED UNUSED UNUSED P6 4 GLASS DOOR 2 12 V TO 2 BLACK P6 5 GLASS DOOR HTR 2 COMMON HTR 2 RETURN WHITE P12 1 UNUSED UNUSED UNUSED P122 UNUSED UNUSED UNUSED P8 l EVAPORATOR FAN ZONE 1 TACHOMETER INPUT BLUE WHITE P12 3 UNUSED UNUSED UNUSED P8 2 UNUSED UNUSED UNUSED 12 4 WATER VALVE INPUT SENSES WATER VALVE ACTIVATION P8 3 EVAPORATOR FAN ZONE 3 TACHOMETER INPUT BLUE P12 5 ZONE 4 DRAWER INPUT SENSES IF ZONE 4 DRAWERS ARE OPEN UNUSED 8 4 EVAPORATOR FAN ZONE 4 TACHOMETER INPUT BLUE BLACK 12 6 ZONE 3 DOOR INPUT SENSES IF ZONE 3 DOOR OPEN UNUSED P8 5 EVAPORATOR FAN ZONE 1 PWM DRIVE OUTPUT YELLOW BROWN P127 ZONE 1 DRAWER UNUSED UNUSED P8 6 UNUSED UNUSED UNUSED P12 8 ZONE 1 DOOR UNUSED UNUSED P8 7 EVAPORATOR FAN ZONE 3 PWM
8. To allow ice to freeze fully and reduce effects of low water pressure power 1 to the ice making system is interrupt Des Power to water valve solenoid is ed for forty five 45 minutes after Des monitored by microprocessor each ice harvest This can be coNTROL 7 If energized longer than 15 seconds bypassed for service diagnostic pur un power to ice making system is cut poses by switching the icemaker sys Um for 12 hours If this occurs 5 con tem OFF then back ON using the gt secutive times making system is ICE MAKER key N By disabled When in Sabbath Mode the ice mak 1 ing system is disabled Sabbath Mode will be covered later LOW VOLTAGE ra 5 m 1 Ca 71 3 Je n Figure 3 28 Signal Trace Schematic of Icemaker Electrical System L Fw JE 0590 F duo Figure 3 29 ICE amp SERVICE Flashing Solenoid Energized 15 sec every 12 hrs 5 Consecutive Times 3 21 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO cc Monitor Water Filter Time in Use and Display When it s Time to Replace it The microprocessor observes the switch behind the wate
9. fe LIGHT FREEZER ZONE UNIT POWER DOOR AJAR UPPER REFRIGERATOR SET POINT ON OFF KEY ALARM ON OFF ZONE SET POINT ADJUSTMENT KEY ADJUSTMENT KEYS KEYS ICE MAKER ACCENT LOWER REFRIGERATOR SYSTEM ON OFF LIGHT ZONE SET POINT KEY ON OFF ADJUSTMENT KEYS Figure 3 4 648PROG Series Control Panel Layout NOTE Figure 3 4 represents the 648PROG with glass door The control panel for the 648PROS with solid door does not have the LIGHTS on off key 3 5 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO Jreus zenog BASIC ELECTRONIC CONTROL INPUT OPERATIONS The following pages describe the basic input operations performed at the control panel switching unit ON and OFF adjusting set point temperature adjustment switching ice maker system ON and OFF enabling and disabling door ajar alarm feature and in models with glass doors only accent lighting system ON and OFF Please note that though possible to display temperatures in Fahrenheit or Celsius in most cases Fahrenheit readings are shown Unit ON OFF All units are shipped the OFF Mode When power is supplied to the unit the word OFF is visible in the right User Display By pressing the POWER key See Figure 3 5 power is allowed past the main
10. Figure 7 17 Slide Bin Removal Figure 7 18 Refrigerator Shelf Pegs Side Wall N Ce Figure 7 19 Light Diffuser Removal Pro Series 648PRO Component Access Removal LED Accent Lighting Side Lights Removal To access and remove the accent lights 1 Use a small flat bladed screwdriver to pry accent 6 light diffuser out of the breaker strip taking care not to damage the edges of diffuser or the breaker strip See Figure 7 20 NOTE On earlier models the side light diffusers Side were glued in place In this case the glue must be Light broken loose in order to remove the diffuser Diffuser 2 Bow the diffuser out then extract both ends from the top and bottom of the breaker strip 3 With the diffuser removed use a needle nose pli ers starting at bottom of light strip to depress the Figure 7 20 Side Light Diffuser Removal plastic tabs securing light strip to pocket in breaker strip 4 Now pull the light strip past the tabs See Figure 7 6 21 Control Keypad Interface Control Panel Removal wan The Control Keypad Interface AKA Control Panel is Tab located on the top front of the refrigerat
11. 8 5 3758440 Revision October 2005 Troubleshooting Pro Series 648PRO lt gt SEALED SYSTEM DIAGNOSTICS TABLES Before entering sealed system see Service Mode information starting on page 8 2 By initiating Service Mode and observing temperatures error codes etc it may be discovere that it is unnecessary to enter the sealed system The table on following page also provides a quick reference for temperature pressure correlation NOTE Always use solder on process valves Do NOT use bolt on process valves as they are prone to leak NOTE Whenever servicing the sealed system the high side filter drier must be replaced NORMAL OPERATING PRESSURES Modell Normal Low Side Pressures Normal High Side Pressures 648PRO Refrigerator XX psi to XX psi XX psi to XX psi 648PRO Freezer XX psi to XX psi XX psi to XX psi 3758440 Revision A October 2005 8 6 Pro Series 648 Troubleshooting EVAPORATOR TEMPERATURE SEALED SYSTEM LOW SIDE PRESSURE CORRELATION NOTE The temperature pressure table at right is for reference only A unit s temperature pressure correla Pressure tion may differ from those listed due to variations in evaporator thermistor location set points where the sealed system is in the refrigeration cycle ambient tem perature etc If a unit is experiencing temperature problems it is rec ommended that you reference the General Troubleshooting Guide before ac
12. 115VOLTS E NEUTRAL 60 CYCLES ATER FLTER SW 0000000 AWECO REF VALVE 2 wem 2950 ORANGE MITE i WATER VALVE GRANT 1 0000000 wee ORANGE PME IM WHITE esas fp CONDENSER FAN MOTOR wn n D PI 1 2 P2 P13 1 ORANGERED IN WHITE pi veuow wins 0 Pu CONTROL Lu BOARD a pum orancennne P18 1 5 2300 29000 FILL TUBE HEATER P 7 DEF HEATER 1 ud 1 sue WHITE uo DE a 5 BI METAL 1 TROUGH HEATER 1 Em m CONTROL BROWN UT FIVE suck BOX FZ FOR NON GLASS BLACK DOOR ONLY REFRIGERATOR COMPRESSOR LT BLUE STARTING RELAY VSPEED GRAY CONTROL BROWN BOX REF BLACK FOR GLASS DOOR ONLY we n DC POWER LOW VOLTAGE SUPRIY 1 pa de 1 P12 20 2 E THERMISTER 1 R Aent U owe 7 THERMISTER 2 Pl BROWN COND aT j 117 wwe KRX SEF CABINET HERMISTER n Iw snow COND BIS awe WT mE rs mown ap REF EVAP Brown AT REF LWR CABINET r1 Wm e Vue AVA Vis awe 7 me 7 E 7 2724 THERMISTER Wen wom SHEEP P 020202 CONTROL 4 3 BOARD 8 8 THERMISTER 8 i i sow Por 5 Pag 1 awe EO i z 8 3 8 3 p R3 zo TT T BLUE BLACK T 7 Hig E i 3 E GLASS DOOR HTR 2 Pn PTEITEITTEN E
13. Figure 3 11 Converting Temperature Units of Measure to F within first minute after switching unit ON Press and Hold ALARM Key and POWER Key for five 5 seconds 3758440 Revision A October 2005 3 8 Jreus zenog Pro Series 648PRO Electronic Control System Showroom Mode Showroom Mode was incorporated into the electronic control system so that these appliances could be displayed in a showroom setting When in Showroom Mode all cooling defrosting and ice making functions are disabled but the lighting system displays and door ajar alarm are operational Set points will appear on the User Displays and Showroom will appear on the Technician Display To initiate Showroom Mode the unit must first be switched OFF using the POWER key See Figure 3 12 then press and hold any pair of WARMER and COLDER keys then the POWER key then release all three keys See Figure 3 13 To return the unit to normal operation repeat the steps above NOTES Always check set points after returning unit to normal operation One unique operation that is possible when in Showroom Mode is to force the REPLACE FILTER icon to appear Do this by pressing and holding the ICE MAKER key for five seconds but only if the filter is in place And to deactivate the REPLACE FILTER icon the filter must be removed then replaced FF COLDER WARMER ALARM LIGHT COLDER WARMER
14. Loosen Screws Figure 2 19 Horizontal Drawer Adjustment Installation Information Pro Series 648PRO 3758440 Revision A October 2005 2 12 sue 2enod Pro Series 648PRO Electronic Control System SECTION 3 ELECTRONIC CONTROL SYSTEM INFORMATION Electronic Control System Pro Series 648PRO Jreus zenog ELECTRONIC CONTROL TERMINOLOGY amp COMPONENT DESCRIPTIONS The model 648PRO utilizes an electronic control system which monitors regulates controls and displays a variety of functions and operations in the appliance The table below defines some of the basic electronic control system terminology Term Component Main Control Board Control Panel Assembly Membrane Switch Keys Function Keys User Display Module Technician s Display Module LCD Liquid Crystal Display Indicators Error Codes Temperature Units of Measure Set Point High Offset Cut in Low Offset Cut out Definition Description Also referred to as the Main Controller Board is the printed circuit board PC Board which contains a microprocessor relays triacs and electrical connections that monitor and control all functions of the appliance An electrical component on the control board which receives electrical signals from other components processes the information then sends electrical signals to relays and triacs on the board to open or close switching components in the
15. 10 4 Model 648PRO Control Board Layout 10 5 Model 648PRO Control Board Summary Table 10 5 Pro Series 648PRO General Information WARRANTY INFORMATION This page contains a summary of the 2 5 amp 12 Year Warranty that is supplied with every Model 648PRO unit This is followed by a summary of the two special warranties The Non Residential Warranty which applies to units installed in non residential applications and the Display Model Home Warranty which applies to distributor or dealer display units and units in model homes sold three years after date of manufacture The last entries on this page are details and notes about the warranties TWO FIVE amp TWELVE YEAR Warranty Summary Two year TOTAL PRODUCT warranty parts and labor Five Year SEALED SYSTEM warranty parts and labor Sixth through Twelfth year LIMITED SEALED SYS TEM warranty sealed system parts only ONE amp FIVE YEAR Non Residential Warranty Summary Example Office Yacht etc One Year TOTAL PRODUCT warranty parts and labor Five year LIMITED SEALED SYSTEM warranty sealed system parts only ONE amp FIVE YEAR Display Model Home Warranty Summary Display units sold three years after date of manufacture One Year TOTAL PRODUCT warranty parts and labor Five year LIMITED SEALED SYSTEM warranty sealed system parts only Serial Number FREEZE 648PRO
16. ZONE 4 CABINET SENSOR L1 ZONE 3 CABINET SENSOR RIGHT CONDENSOR LEFT CONDENSOR AMBIENT GND J NEUTRAL FRONT OF UNIT WATER VALVE INPUT ZONE 4 DRAWER INPUT ZONE 3 DOOR INPUT ZONE 1 DRAWER INPUT ZONE 1 DOOR INPUT ZONE 1 DEFROST BI METAL INPUT REFRIGERANT VALVE CONDENSER FAN ICEMAKER ICE ACCESSORIES WATER FILTER INPUT Figure 3 2 Control Board Layout CIRCUIT DESCRIPTION FUNCTION COLOR CIRCUIT DESCRIPTION FUNCTION I COLOR 120 VOLT CIRCUITS LOW VOLTAGE CIRCUITS CONTINUED P13 NEUTRAL NEUTRAL INTO BOARD WHITE 4 12 VDC POWER 12 VDC POWER RED 14 DEFROST HEATER 1 POWERS DEF HTR 1 BLUE P4 2 12 VDC RETURN 12 VDC RETURN 15 POWER IN INTO BOARD BLACK P16 MAIN LIGHTS POWERS MAIN LIGHTS YELLOW 6 1 VERTICAL LED REF 12V TO LED BLACK WHITE P17 COMPRESSOR REF POWERS REF COMPRESSOR GRAY P6 2 UNUSED UNUSED UNUSED P18 COMPRESSOR FREEZER POWERS COMPRESSOR FRZ PURPLE P6 3 VERTICAL LED REF COMMON VERTICAL LED RETURN WHITE P19 UNUSED UNUSED UNUSED P64 GLASS DOOR HTR 2 12V TO HTR 2 BLACK 6 5 GLASS DOOR 2 COMMON HTR 2 RETURN WHITE 12 1 UNUSED UNUSED UNUSED 12 2 UNUSED UNUSED UNUSED P8 1 EVAPORATOR FAN ZONE 1 TACHOMETER INPUT BLUE WHITE P12 3 UNUSED UNUSED UNUSED P8 2 UNUSED UNUSED UNUSED P12 4 WATER VALVE INPUT
17. Condenser Fan Removal The condenser fan is mounted to the condenser fan shroud with three 3 fan brackets that hook into grom meted holes in the fan shroud Screws passing through these brackets secure the fan motor to the brackets To remove the condenser fan See Figure 7 52 1 Disconnect electrical leads from fan motor 2 Extract screws securing motor to brackets NOTE Brackets will unhook from grommeted holes in condenser fan shroud after screws are removed 3 To remove fan blade from fan motor a Grab blade and motor while turning nut coun terclockwise b Pull blade from the motor shaft 3758440 Revision A October 2005 Pro Series 648 Water Filter A Ss Figure 7 50 Water Filter Removal Water Valve Screws m Water Connection Water Connection A Figure 7 51 Water Valve Removal Rear View J Screws 3 Bracket 3 Nut Condenser Fan shroud Figure 7 52 Condenser Fan Removal Top View Pro Series 648PRO Component Access Removal Sealed System Components NOTE When entering the sealed system always use solder on process valves Do NOT use bolt on process valves as they are prone to leak NOTE Whenever servicing the sealed system the high side filter drier must be replaced Freezer High Side Filter Drier Re
18. 2 LWR REF EVAP FAN MOTOR SENSOR REF LWR EVAP JACKET CABLE MARK WITH 1 RED STRIP NEAR SENSOR END L SENSOR JACKET CABLE MARK WITH 1 GREEN STRIPE NEAR SENSOR END REF LWR CAB 1 2 EC 10 3 3758440 Revision A October 2005 Wiring Diagrams Schematics Pro Series 648PRO WIRING SCHEMATIC MODELS PRO48 WHITE L1 115 VOLTS BLACK 60 CYCLES NEUTRAL WATER FILTER SW E V 8 0000000 AWECO REF VALVE 2 2950 ORANGE WHITE WAT
19. Unit Shroud Removal The unit shroud houses the sealed system and techni cian display To remove the unit shroud See Figure 7 16 1 Remove the grille assembly 2 Extract screws along left side and rear flange of unit shroud 3 Extract screws from top of unit shroud above con denser 4 Lift stroud from top of unit Y I 1 Figure 7 16 Top Cover Removal 7 7 3758440 Revision A October 2005 Component Access Removal Refrigerator Slide Bin Removal Slide bins fit into guideways under either side of any of the refrigerator shelves To remove a slide bin pull it forward out of the guide ways See Figure 7 17 Refrigerator Shelf Adjustment and or Removal To adjust and or remove a refrigerator shelf lift up at front slightly then lift back up and out of shelf ladders See Figure 7 18 Upper Refrigerator Light Diffuser Removal The refrigerator light diffuser is located at the top of the compartment The light diffuser is held in place by C shaped clamps fitting over pegs protruding from the side walls See Figure 7 19 To remove the light diffuser push diffuser toward rear of unit to disengage C shaped clamps from the pegs in the side wall then lower the diffuser down and pull from the compartment 3758440 Revision A October 2005 Pro Series 648 Refrigerator Interior Cosmetic and Mechanical Components 7 8
20. low speed com Al mand will adjust accordingly 5 snl VSPEED colesson mE ware CONTROL ROM EOR NON GLASS DOOR ONLY a LT BLUE controL GROWN BOX REF Om BLACK DOOR ONLY LOW VOLTAGE ES lel 120 qe WHITE Un TE son E a son son tin MAIN Ta Wee uas sensi TEXT i a nom Gitta e Pd i Um BOARD em H qu oll 9 7 WHITE Figure 3 20 Signal Trace Variable Speed Compressor Control 3758440 Revision A October 2005 3 14 Pro Series 648 Electronic Control System Control Refrigerator Dual Refrigerant Solenoid Valve The electronic control senses refrigerator zone temperatures via thermistors one in each of two refrigerator zones Zones 3 and 4 If either zone reaches high offset calling for cooling then two parallel circuits on the control board 1 relay per circuit with 1 common triac are used to control the dual refrigerant valve Depending on which zone is calling for cooling its corresponding relay supplies power to the triac a positive polarity or a negative polarity pulse signal 500ms 30 pulses per 1 2 second is delivered to the dual refrigerant valve frocing the bead inside the valves T connection to one side or the other If the pulse signal is positive
21. 1 From control board side of condenser extract screws which hold condenser side brackets to con denser 2 Cut cable ties holding thermistors to condenser out let tubes 3 Using a tube cutter cut condenser inlet and outlet tubes NOTE It is not recommended to sweat tubing apart Doing so will induce moisture into the sealed system 4 Lift condenser off of unit 3758440 Revision A October 2005 Pro Series 648PRO Bolts Cut Here Cut Here Bolts Electricals Figure 7 56 Compressor Top View 7 22 Cut Tubes Figure 7 57 Condenser Removal Extract Screws Pro Series 648PRO Evaporator Removal Evaporators are attached to rear walls of the compart ments with screws behind evaporator covers which must be removed first NOTE When replacing an evaporator the high side fil ter drier must also be replaced NOTE When removing a freezer evaporator the evap orator thermistor defrost terminator and defrost heater must also be removed and reused on new evaporator After capturing the refrigerant from the sealed system See Figure 7 58 1 Extract screws which hold evaporator to rear wall of compartment 2 Pull and rotate evaporator so heat exchanger is accessible 3 With a file score a line around capillary tube 1 or less from evaporator inlet then fatigue capillary tube at this line until it separates 4 With a
22. Lower the light assembly down disconnect the wire leads 3 Now push the communication cable grommet from the hole at the left end and remove the communica tion cables from the hole NC Figure 7 33 Light Diffuser Removal Upper Freezer Evaporator Duct Cover The bottom of the upper freezer duct cover is secured by slots in the side flanges that fit over pegs at the bot tom of each shelf ladder The top is secured by screws holding it to the back wall To remove the upper freezer duct cover the light dif fuser must be removed first then See Figure 7 34 M 09 1 Extract screws from top of duct cover 1 e 2 Tilt duct cover forward and lift off of locating pegs 4 Extract Screws at top then lean forward and lift up n Figure 7 34 Upper Freezer Duct Cover Removal 7 15 3758440 Revision A October 2005 Component Access Removal Freezer Bottom Shelf Assembly Removal At the bottom of the upper freezer compartment is a shelf separating the top compartment from the drawer compartments To remove the shelf lift the front up then lift the back off of the locating pegs in the rear side walls of the compartment See Figure 7 35 Freezer Zone 1 Compartment Thermistor Removal The freezer thermistor is located behind the upper duct cover and attached to the back wall with a screw and tube clamp
23. 3758440 Revision A October 2005 Pro Series 648 7 6 Bolts 7 16 11 Grille Panel Figure 7 12 Grille Assembly Removal Cylinder Mount A Figure 7 13 Cylinder Valve Removal Communication Cables Mounting Screws SJ Figure 7 14 User Display Removal Rear Vie w Pro Series 648PRO Component Access Removal Main Controller Board Removal DC Power Supply NOTE Electrical shock hazard Refer to WARNING at beginning of sectioN The main control board is located on top of the unit behind the grille assembly to the right of the condenser and is covered by a control cover To remove the main controller board See Figure 7 15 1 Extract screws along front flange of cover 2 Work wire leads and grommets down and out through key hole slots in sides of cover while lifting front of cover up 3 Disconnect wire leads from DC power supply locat ed inside the control cover Control cover is now free to be removed 4 Disconnect all wire leads from main controller board Figure 7 15 Control Board Right Side View 5 Extract mounting screws securing control board to unit top then lift board out SS Sr Sa f ila S To DC Power Supply
24. D shaped to fit into the D shaped hole in the timing cam It has eight blades which rotate and sweep the ice from the mold cavities during the ejection phase of the cycle Ice Stripper The stripper is attached to the dumping side of the mold serving as a decorative side cover and it also prevents ice from falling back into the mold Bearing Inlet The bearing inlet is attached to the ice mold opposite the support Water enters the bear ing inlet and is directed to the ice mold The bearing inlet also supports the ice ejector at the end opposite the timing cam Thermostat The thermostat is a single pole single throw bi metal switch At 15 F 3 F it closes starting the ice ejection phase Thermal Mastic substance similar in appearance to grease that is applied between the thermostat and the ice mold Its purpose is to increase thermal con ductivity between the mold and the thermostat Lever Arm and Shut off Arm The lever arm is moved side to side by two revolutions of the timing cam As it moves it raises and lowers the shut off arm and operates the shut off switch to control quantity of ice production If shut off arm comes to rest on top of the ice in the storage bin during either revolution the shut off switch will remain open stopping ice production at the end of that revolution Water Valve Solenoid Switch single pole double throw type switch that allows electricity to the water valve
25. NOTES It is possible to force the appliance to run self diagnostics when in Service mode Service Mode is explained later in this section A Service Technician should always initiate Service Mode and view Error Code History when the SERVICE icon is flashing Service Mode is explained later in this section wure T HN5VOUS 60 CYCLES WATER FILTER SW Jt V V m E 1000000 AWECO REF VALVE 2 ware 2950 x 0000000 WATER VALVE 1 1600 IM ORANGERED ade wuss CONDENSER FAN MOTOR sus at 720 22 eu P12 D wine n a ja rsuo
26. 51 and it is now possible to toggle down through the software version information ceo JV WARMER COLDER ICE MAKER POWER ALARM LIGHT COLDER WARMER COLDER WARMER Press ALARM key 1 time Figure 3 51 Key Strokes and Tech Display Version Information 3 35 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO Peus zenod 3758440 Revision A October 2005 3 36 sue 2enod Pro Series 648PRO Sealed System Information SECTION 4 SEALED SYSTEM INFORMATION Sealed System Information Pro Series 648PRO Jreus zerog HFC 134a REFRIGERANT SERVICE INFORMATION The Pro Series sealed systems contain HFC 134a refrigerant This section provides general rules for working with 134a and procedures to be followed while servicing the sealed system This is followed by diagrams illustrating sealed system operation then model specific refrigerant flow diagrams A CAUTION 134a refrigerant requires Synthetic Ester oil in the compressor and does not tolerate contamination from other refrigerants moisture petroleum based lubricants silicone lubricants cleaning compounds rust inhibitors leak detection dyes or any other type of additive General Rules for Working with 134a Refrigerant Use equipment dedicated to 134a sealed system ser
27. F SERVICE Flashing Multiple Possibilities See Error Code History 3758440 Revision A October 2005 Pro Series 648 Electronic Control System POSSIBLE ERROR INDICATORS This page contain diagrams illustrating what a customer may see on the User Displays alerting them that there is a problem with the appliance NOTE A Service Technician should always initiate Service Mode and view Error Code History when error indicators are observed NOTE For thermistor errors described below thermistors can be tested by submersing them in a glass of ice water for two 2 to five 5 minutes and checked for 30 000 to 33 000 ohms tti RW SERVICE JL TG F Figure 3 34 EE in Left User Display SERVICE Flashing in Right Freezer Zone Thermistor Fault See SERVICE lt E I rs wm Figure 3 35 EE at Left of Right User Display amp SERVICE Flashing Upper Ref Zone Thermistor Fau t t li SERVICE sh dU t Fig 3 36 EE at Right of Right User Display amp SERVICE Flash ing Lower Ref Zone Thermistor Fault lil 9 0590 E Fig 3 37 Ice Making Icon amp SERVICE Flashi
28. REFRIGERATOR 0000000 Bo Warranty Details Total Product Parts includes but is not limited to the following Electronic Control System Components Fan amp Light Switches Fan Motors amp Blades Defrost amp Drain Heaters Defrost Terminator Drain Pan Drain Tubes Wiring Light sockets amp bulbs Icemaker Water Valve Door hinges Door closers amp Cams Compressor Electricals Sealed System Parts includes the following Compressors Condenser Evaporators Filter Driers Heat exchangers All Tubing that Carries the Freon NOTE Condenser Fan Motors Freon Solder and com pressor electricals are NOT considered sealed system parts Warranty Notes All warranties begin at the time of the unit s initial installation All Warranty and Service information collected by Sub Zero is arranged and stored under the unit serial number This information is now also stored under the customer s last name Sub Zero requests that you have the model and serial number available whenever contacting the factory or parts distributor The serial number tag on SIDE BY SIDE models is located by the top door hinge in the freezer compart ment The serial number tag on OVER AND UNDER models is located by the top door hinge in the refrigerator compartment The serial number tag on ALL REFRIGERATOR and ALL FREEZER models is located by the top door hinge in the refrigeration compartment Manufactu
29. See directions below to clearing Error Codes Electronic Control System WARMER 4 cower 4 COLDER WARMER ICE MAKER POWER ALARM LIGHT COLDER WARMER COLDER WARMER Figure 3 43 Key Strokes and Tech Display Error History Before attempting to clear Error History the cause must first be corrected If this is not done the Error Codes will be re logged After repairs follow the steps below to clear Error History 1 After initiating Service Mode press ALARM key once Press the COLDER key once Press ALARM key once Press the COLDER key once Press ALARM key once Press the COLDER key once and Clear Error History Yes gt appears See Figure 3 44 7 Press ALARM key now and all Error Codes will be cleared from memory n comen Lb COLDER WARMER ICE MAKER POWER ALARM LIGHT COLDER WARMER COLDER WARMER Figure 3 44 Key Strokes and Tech Display Clearing Error History 3 29 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO Jreus zenog Error Code Table CODE ZONE SERVICE INSTRUCTION Zone X Cabine
30. gt of each of four possible zone s run time based on 50 cycles and duration 5 Comp Cycles gt Total number of compressor cycles for left and right compressor 6 Defrost gt Last defrost interval in hours and minutes Last defrost duration in minutes 7 Average Temps gt Average temperature of Ambient left right condenser 4 cabinet amp evaporators 8 Door Open Tim gt Greatest non cumulative duration of light switch open readings four possible zones 9 10 WARMER 4 cower JV COLDER WARMER ICE MAKER POWER ALARM LIGHT COLDER WARMER COLDER WARMER Figure 3 47 Key Strokes and Tech Display Statistics 3758440 Revision A October 2005 3 32 Jreus zenog Pro Series 648PRO Electronic Control System Service Mode 2 Operational Status Sub Mode There are two levels under Op Operational Status Mode they are 1 Zone Status Accessing Operational Status Zone Status will show a zone s cooling and defrost status 2 Ice Maker Accessing Operational Status Maker shows ice maker status as Harvest or Production The next few pages explain the steps for working through the two levels of Op Status Mode For sake of space the directions that follow will not explain or show what is seen in the
31. where the process begins again De Y A Y Capillary Tube s 3 A Y a Fig 4 10 Tube s Part of Heat Exchangers 5 gt Y Evaporator s Y T Connection gt Heat Exchanger s Suction Tube s NS 4 Figure 4 11 Evaporator s 4 7 Figure 4 12 Suction Tube s amp Heat Exchanger s 3758440 Revision A October 2005 Sealed System Information Pro Series 648PRO Psus zenoy REFRIGERANT FLOW DIAGRAMS Suction T Connection Refrigerator Compressor Refrigerator Drier Freezer Compressor Condenser Freezer Drier Dual Refrigerant Freezer Heat Exchanger Valve ood Refrigerator Heat Exchanger Upper Refrigerator Evaporator Freezer Heater Loop Lower Refrigerator Heat Exchanger Freezer Evaporator Lower Refrigerator Evaporator Drain Pan Heater Refrigerator Heater Loop Figure 4 13 Models 648PRO Refrigerant Flow 3758440 Revision A October 2005 4 8 J
32. 648PRO freezer sealed system The components are listed in order of refrigerant flow with an explanation of their fundamental role as part of a sealed system 1 Compressor Figure 4 1 The compressor creates a high side and low side pressure difference in the sealed system by compressing the refrig erant gas thus raising the pressure and temperature The compressor pushes this high pressure high heat gas through the discharge tube to the condenser 2 Condenser Figure 4 2 The high pressure high heat gas travels through the con denser where the heat is dissipated by cooler air being drawn over the condenser tubing by the condenser fan This changes the gas into a high pressure warm liquid that is then routed through the door gasket seat heater loop to prevent sweating and through the drain pan heater loop to help evaporate water in the drain pan The high pres sure high heat gas then enters the high side filter drier 3 High Side Filter Drier Figure 4 3 The high pressure warm liquid travels through the high side filter drier which removes moisture from the refriger ant before it enters the capillary tube Figure 4 1 Compressor c 5S Condenser Seui E 2 High Side Filter Drier 3 Door Gasket YS Seat Heater Loop A V lt D
33. REF UPPER CABINET ZONE 3 SENSES TEMPERATURE BROWN LOW VOLTAGE CIRCUITS 5 8 REF UPPER CABINET ZONE 3 SENSES TEMPERATURE BLUE P2 1 UNUSED UNUSED UNUSED P5 9 REF LOWER CABINET ZONE 4 SENSES TEMPERATURE BROWN 2 2 UNUSED UNUSED UNUSED P5 10 REF LOWER CABINET ZONE 4 SENSES TEMPERATURE BLUE P2 3 UNUSED UNUSED UNUSED 5 REF UPPER ZONE 3 SENSES TEMPERATURE BROWN 2 4 UNUSED UNUSED UNUSED 5 12 REF UPPER EVAP ZONE 3 SENSES TEMPERATURE BLUE P2 5 UNUSED UNUSED UNUSED P5 13 REF LOWER EVAP ZONE 4 SENSES TEMPERATURE BROWN 5 14 REF LOWER ZONE 4 SENSES TEMPERATURE BLUE 5 15 FRE CABINET ZONE 1 SENSES TEMPERATURE BROWN 5 16 FRE CABINET ZONE 1 SENSES TEMPERATURE BLUE P5 17 FRE EVAP ZONE 1 SENSES TEMPERATURE BROWN 5 18 FRE EVAP ZONE 1 SENSES TEMPERATURE BLUE 5 19 UNUSED UNUSED UNUSED P5 20 UNUSED UNUSED UNUSED 648PRO CONTROL BOARD SUMMARY P521 UNUSED UNUSED UNUSED P5 22 UNUSED UNUSED UNUSED P5 23 UNUSED UNUSED UNUSED 5 24 UNUSED UNUSED UNUSED Figure 3 3 Control Board Summary Table 3758440 Revision A October 2005 3 4 sue 2enod Pro Series 648PRO Electronic Control System CONTROL PANEL AND USER DISPLAYS LAYOUT FREEZER USER DISPLAY in Grille Assy Fw REPLACE Control Panel Fees F FILTER I A REFRIGERATOR USER DISPLAY in Grille Assy ICE MAKER POWER ALARM
34. every 2s Model ID Unit ID Main Software Version E2 Version Left Display Version Right Display Version Keyboard Version Tech Display Version Off Showroom Sabbath Sabbath mode Normal Scrolling Messages every 2s Scrolling Messages every 2s Model Name S N XXXXX Zone 1 Status Status Zone 2 Status Status Zone 3 Status Status Zone 4 Status Status Initiating Service Mode To initiate Service Mode press and hold any COLDER key then press the POWER key then release both keys See Figure 8 2 Service Mode 1 Diagnostics is the first sub mode to appear in the Technician s Display with a small arrow in the bottom right corner pointing right NOTES By following the basic directions on the Technicians Display cover and the prompts that appear in the 5 Display a Service Technician will be able to work through the Service Mode menu to the desired verification point configuration portion and troubleshooting section of the menu For sake of space the directions that follow will not explain or show what is seen in the display 4 after each key stroke Only the final and or desired result will be explained and illustrated There are three 3 ways to exit Service Mode 1 To exit the Service Mode at any time press the ICE MAKER key repeatedly until com c3 pletely out of Service Mode menu 2 Pressing the POWER key will switch the unit OFF and exit Service Mode 3 If no keys are
35. or similar tool cut heat exchanger in compartment as close as possible to wall or ceil ing where heat exchanger passes through 6 In upper compressor area use a tube cutter to cut drier from condenser 7 Extract nuts from stud bolts at each corner of com pressor base 8 Lift compressor up and pull forward to gain access to suction line 8 Using a tube cutter cut suction line approximately 1 from compressor 9 Pull remaining heat exchanger from unit NOTE It is not recommended to sweat tubing apart Doing so will induce moisture into the sealed system NOTE When replacing the heat exchanger it is recom mended to attach it at the evaporator end first then feed the heat exchanger through hole up to compres sor area 3758440 Revision A October 2005 7 24 Cut Here Figure 7 59 Heat Exchanger Pro Series 648PRO Drain Pan Heater Loop Removal The drain pan heater loop is located on the underside of the bottom panel of unit and above the drain pan NOTE When replacing a condensate heater loop the filter drier must also be replaced NOTE It is recommended that a suction line drier be added to the sealed system when replacing the con densate heater loop To remove the drain pan heater loop the drain pan must be removed first then after capturing the refriger ant from sealed system See Figure 7 60 1 Using a tube cutter cut condensate lo
36. 3758440 Revision A October 2005 Icemaker Information Pro Series 648PRO End of First Revolution See Figure 6 7 115 VOLTS 60 CYCLES The water valve solenoid switch is tripped by the timing cam back to normally open The timing cam trips the holding switch to normally close which ends the first revolution but the thermostat is still closed so the motor is again start ed The mold heater remains energized through the ther mostat NC NO WATER SOLENOID C SHUT OFF SWITCH THERMOSTAT MOLD HEATER SOLENOID SWITCH HOLDING SWITCH pre CD Ped I APPROXIMATE POSITION l OF ICE EJ ECTOR AND ICE LEVEL ARM DURING OPERATION Start of Second Revolution See Figure 6 8 115 VOLTS 60 CYCLES The water valve solenoid switch is tripped by the timing cam back to normally open The timing cam trips the holding switch to normally close which ends the first revolution but the thermostat is still closed so the motor is again start ed The mold heater remains energized through the ther mostat SHUT OFF SWITCH THERMOSTAT MOLD HEATER SOLENOID SWITCH NC NO WATER SOLENOID APPROXIMATE POSITION OF ICE EJ ECTOR AND ICE LEVEL ARM DURING OPERATION Figure 6 8 Start of Second Revolution 3758440 Revision A October 2005 6 6 Pro Series 648PRO Icemaker Information Second
37. Icemaker Information First Revolution Continued See Figure 6 5 115 VOLTS 60 CYCLES TCO The ice ejector reaches the ice in the mold The ice releases from the mold as the ejector blades SHUT OFF SWITCH THERMOSTAT begin to rotate the cubes out MOLD HEATER The drive motor remains energized through the hold ing switch The mold heater remains energized through the ther mostat SOLENOID SWITCH As the shut off arm rises the shut off switch is nC Ino tripped to normally closed and then the shut off arm begins to lower WATER SOLENOID HOLDING SWITCH i oy poamou NE S ICE LEVEL ARM I DURING OPERATION Figure 6 5 First Revolution Continued First Revolution Continued See Figure 6 6 115 VOLTS 60 CYCLES The ice has released from the mold The motor remains energized through the holding SHUT OFF SWITCH THERMOSTAT switch MOLD HEATER The shut off arm is lowered and the shut off switch is tripped to normally open The water valve solenoid switch is tripped by the tim ing cam but the solenoid is not energized because the thermostat is still closed and is energizing the mold heater Electric current follows the path of least resistance HOLDING SWITCH ji APPROXIMATE POSITION l OF ICE EJ ECTOR AND ICE LEVEL ARM DURING OPERATION ICE BUCKET Figure 6 6 First Revolution Continued 6 5
38. Mode must be initiated within the first 1 minute after switching the unit ON To convert Fahrenheit F temperature units of measure to Celsius C press and hold the ALARM key and the POWER key simultaneously for five 5 seconds then release the keys See Figure 3 10 A c will appear on the User Displays above the appliance icons indicating that temperatures will now be displayed in Celsius units of measure Please note that changing from Celsius temperature units of measure to Fahrenheit is the same proce dure See Figure 3 11 NOTES Temperature Units Selection Mode will end ten 10 seconds after the last key stroke Do not press and hold the POWER key first that will simply switch the unit OFF Press and hold for 5 seconds COLDER WARMER ICE MAKER POWER ALARM LIGHT COLDER WARMER COLDER armen Figure 3 10 Converting Temperature Units of Measure to C within first minute after switching unit ON Press and Hold ALARM Key and POWER Key for five 5 seconds JB 38 COLDER WARMER Press and hold for 5 seconds ICE MAKER POWER COLDER ALARM LIGHT COLDER WARMER
39. Press ALARM key two 2 times See Figure 3 50 and it is now possible to select change or verify model configuration reo JV COLDER WARMER ALARM COLDER WARMER ICE POWER LIGHT COLDER WARMER Press ALARM key 2 times Figure 3 50 Key Strokes and Tech Display Miodel Information 3758440 Revision A October 2005 3 34 Jreus zenog Pro Series 648PRO Electronic Control System Service Mode 4 Version Information Sub Mode Accessing Version Information allows the Service Technician to recall all the electronic control modules software ver sions and the E2 version of the main control board This page explains the steps for working through Version Information Mode For sake of space the directions that follow will not explain or show what is seen in the display after each key stroke Only the final and or desired result will be explained and illustrated As mentioned when Service mode is initiated WARMER 4 Service Mode 1 Diagnostics appears in the Technician s Display Follow the steps below to work to and through Service Mode 4 Version Information Sub Mode 1 After initiating Service Mode press the COLD A ER key three 3 times Service Mode 4 Version Info appears on display 2 Press ALARM key one 1 time See Figore 3
40. Remove light bulb from socket by turning the light bulb counterclockwise Extract screws from light socket mounting bracket Disconnect wire leads from light socket The light socket is held in place with retaining clips Depress the retaining clips and extract socket from mounting bracket 2 3 4 Drawer Closer Removal Drawer closer assemblies are located at the front right side wall of the drawer compartments Screws secure each drawer closer to the wall To removal a drawer closer assembly See Figure 7 28 1 2 Remove appropriate drawer assembly Extract screws that secure the drawer closer to side wall Drawer Slide Assembly Removal To remove a drawer slide assembly See Figure 7 29 1 Extract drawer slide assembly mounting screws 2 Pull assembly from side wall NOTE When removing drawer slides and their associ ated components it is important to keep track of their original location Failure to do so may lead to mis aligned drawers when reinstalled 3758440 Revision A October 2005 Figure 7 26 Crisper Lid Assembly Extract Screws Figure 7 27 Drawer Light Socket Removal Drawer Closer Extract Screws 7 12 Figure 7 29 Carriage Assembly Pro Series 648PRO Component Access Removal Lower R
41. Revolution Continued See Figure 6 9 The mold heater has warmed the thermostat so the thermostat opens and the mold heater is de ener gized If the shut off arm comes to rest top of the ice in the storage bin as illustrated the shut off switch will remain in the normally closed position The motor remains energized through the holding switch Second Revolution Continued See Figure 6 10 The water valve solenoid switch is tripped by the tim ing cam This time the solenoid is energized because the thermostat is open The water solenoid is open for approximately seven seconds filling the ice mold with water The mold heater is energized through the solenoid switch and holding switch 115 VOLTS 60 CYCLES SHUT OFF SWITCH THERMOSTAT MOLD HEATER SOLENOID SWITCH NC NO WATER SOLENOID inc HOLDING SWITCH r APPROXIMATE POSITION OF ICE EJ ECTOR AND ICE LEVEL ARM DURING OPERATION Figure 6 9 Second Revolution Continued 115 VOLTS 60 CYCLES SHUT OFF SWITCH THERMOSTAT MOLD HEATER NO RZ SOLENOID SWITCH WATER SOLENOID HOLDING SWITCH om APPROXIMATE POSITION l Ko OF ICE EJ ECTOR AND ICE LEVEL ARM DURING OPERATION ICE BUCKET fi Figure 6 10 Second Revolution Continued 3758440 Revision A October 2005 Icemaker Information End of Ice making Cycle See Figure 6 11
42. The water valve solenoid switch is tripped by the tim ing cam back to normally open ending the water fill The timing cam trips the holding switch to normally close which ends the second revolution The thermostat is still open so it does not start the drive motor Ifthe shut off arm has come to rest on top of the ice in storage bin as illustrated the shut off switch re mains in the normally closed position This interrupts power from reaching the thermostat until sufficient ice has been removed from the stor age bin allowing the shut off arm to lower NOTE To allow ice to freeze fully and reduce effects of low water pressure the electronic control system dis ables the icemaker system for 45 minutes after each ice harvest MANUALLY STOPPING ICE PRODUCTION Ice production can be manually stopped by pressing the ICE MAKER key on the control panel so that the ice making icon is not displayed on the left User Display NOTES If the ice level arm sticks in the up position ice pro duction will stop See Figure 6 12 Removing the ice bucket will NOT stop ice produc tion as there is no ice maker rocker switch used in this series 3758440 Revision A October 2005 Pro Series 648PRO 6 8 115 VOLTS 60 CYCLES THERMOSTAT SOLENOID SWITCH TCO SHUT OFF SWITCH MOLD HEATER NO NC NO MOTOR RIO HOLDING SWITCH po WATER SOLENOID C I APPROXIMATE P
43. This can be bypassed for service purposes by switching the ice maker system OFF then back ON with the ICE MAKER key lt ce Making system is activated F F COLDER WARMER COLDER WARMER gt ICE la POWER ALARM LIGHT COLDER WARMER Figure 3 7 Switching Icemaker System ON or OFF Press ICE MAKER Key Door Ajar Alarm Feature All units are equipped with a door ajar alarm feature To enable the door ajar alarm press the ALARM key on the control panel See Figure 3 8 The bell icon appears in both User Displays indicating the alarm is enabled With the alarm enabled the bell icon will flash and an audible alarm will beep whenever a door or drawer is left open for more then thirty 30 seconds To disable the door ajar alarm press the ALARM key again and the bell icon disap pears from the displays F e 30 1 2 Ta COLDER WARMER ICE MAKER POWER ALARM LIGHT COLDER WARMER WARMER gt COLDER Figure 3 8 Switching Door Ajar Alarm ON or OFF Press the ALARM Key Accent Lighting System ON OFF Model 648PROG Models produced with glass doors
44. be initiated NOTE When in Sabbath Mode the following holds true in accordance with Star K requirements Freezer defrosting functions will convert to a fixed time base sequence instead of adaptive defrosting which is usage based The zone thermistors will still detect high off set which is the determining factor to start the cooling process but there will be a random 15 to 25 second delay before cooling begins D FF COLDER ALARM WARMER SS LIGHT COLDER WARMER WARMER ICE MAKER POWER COLDER Figure 3 14 To Enter Sabbath Mode Switch Unit OFF First COLDER WARMER COLDER WARMER LIGHT COLDER WARMER ICE MAKER POWER ALARM Press and hold for 10 seconds Figure 3 15 Then Press and Hold POWER Key for ten 10 seconds 3758440 Revision A October 2005 3 10 Jreus zenog Pro Series 648PRO Electronic Control System Manual Zone Disable Mode Manual Zone Disable Mode allows a customer or Service Technician to switch one zone or compartment OFF for interior cleaning defrosting or diagnostic purposes while allowing the other zones to continue cooling To initiate Manual Zone Disable Mod
45. bins Crisper drawer Drawers with dividers found www star k org FEATURES The Sub Zero 648PRO side by side refrigerator freezer is available in classic stainless steel and with a glass door on Model 648PROG The 648PRO can be built in or with accessory kit used in a free standing application Dual refrigeration two compressors and three evaporators keep foods fresher longer and prevent odor transfer Exterior temperature display with easy to read digital readouts accurate within one degree of your preset temperatures Microprocessor and interior control panel with up front touch controls monitor pattern sensing defrost and automatic service alerts Holiday mode power down one or both sides for short or extended periods Slide out stainless steel bins two removable bins that fit neatly under any shelf Crisper drawer is a touch and glide crisper with a tight seal glass lid for high humidity Drawers have adjustable removable and interchangeable drawer dividers Automatic ice maker lets you retrieve filtered ice from a stainless steel bucket Shelves are cantilevered and spill proof with stainless steel trim refrigerator adjustable removable and 100 stainless steel freezer 3758440 Revision A October 2005 1 6 Auto close system with an advanced hinge design lets doors finish closing automatically Alarm with an audible beep lets yo
46. ciet sce tarte xe trc ends 7 20 Sealed 5 2 2 4 2 7 21 Freezer High Side Filter Drier 7 21 Refrigerator High Side Filter Drier Refrigerant Valve 7 21 c 7 22 Geld 7 22 EVADOFAIOMS e 7 23 Heat Exchangers a sioe at 7 24 Drain Pan Heater Loop 7 25 3758440 Revision A October 2005 Page Section 8 Troubleshooting Guides 8 1 Service Mode Troubleshooting Input Operations 8 2 Non Service Mode Display Information 8 3 Initiating Service Mode 8 3 Service Mode Men ree Ee ties 8 4 Error Code Table ui etin e 8 5 Sealed System Diagnostics 8 6 Normal Operating Pressures Evap Temp Sealed System Low Side Pressure Correlallon aea adverse ens 8 7 Pressure Indications iii 8 7 Section 9 Technical Data 9 1 Model G48PRO emet Re A ek 9 2 Section 10 Wiring Diagrams amp Schematics 10 1 Model 648PRO High Voltage Wire Diagram 10 2 Model 648PRO Low Voltage Wire Diagram 10 3 Model 648PRO Wire Schematic
47. d 21 32 45 D iagnostics 2 ErrorHistory gt rror 2 0 12345 d 10 29 01 Error 3 34 3 00 12345 d 8 15 45 Error 4 None Continue for 20 errors ErrorHistory C learHistory 2 ClearHistory gt No gt To initiate the Service Mode press and hold COLDER then POWER C learHistory Yes gt lt Diagnostics 3 Thermistors gt Ambient deg F 70 Condensers Lt143 Rt141 Zone 1 deg 51 18 Zone 2 deg F NotP To exit press ICE MAKER repeatedly until you are out Zone 3 deg F Evp51 Cab18 Zone 4 deg Evp51 Cab18 14 gt lt Diagnostics 4 Activ ate Zone gt lt Manual Zone Zone 1 start Manual Zone Z1 51 Cab 18 Manual Zone Z2 Evp51 Cab 18 Manual Zone Z3 Evp51 Cab 18 Manual Zone Zone 2 start Manual Zone Zone 3 start Manual Zone Zone 4 start ManualZone Z4 Evp51 Cab 18 D iagnostics 5 Statistics gt lt OpStatus 1 Zone Status gt Service Mode Z1 4C ooling 2 OpStatus gt Def Z2 NotPresent Z3 4C ooling Def Z4 C ooling Def lt OpStatus Ice MakerStatus 2 lce Maker gt Harvest Service Mode lt Model PRO48 lt SelectModel Accept New Model 3 ModelInfo gt Change Model gt PRO48 gt No gt Accept New Mode Yes gt er
48. energized SOLENOID HOLDING SWITCH p APPROXIMATE POSITION OF ICE EJ ECTOR AND ICE LEVEL ARM DURING OPERATION Figure 6 2 The Freeze Phase 6 3 3758440 Revision A October 2005 Icemaker Information Pro Series 648PRO Start of the First Revolution See Figure 6 3 115 VOLTS 60 CYCLES The water in the ice mold has turned to ice e At 15 F 3 F the thermostat closes Mold heater is energized through the thermostat The drive motor is started through the thermostat and normally closed terminal of the holding switch The ice ejector begins to turn and the shut off arm begins to rise SOLENOID SWITCH NC NO WATER SOLENOID C APPROXIMATE POSITION l OF ICE EJ ECTOR AND ICE LEVEL ARM DURING OPERATION SHUT OFF SWITCH THERMOSTAT MOLD HEATER Figure 6 3 Start of First Revolution First Revolution Continued See Figure 6 4 115 VOLTS 60 CYCLES The holding switch is tripped by the timing cam to normally open thus holding power to the motor The mold heater remains energized through the ther mostat The shut off arm begins to rise SHUT OFF SWITCH THERMOSTAT MOLD HEATER SOLENOID SWITCH NC NO WATER SOLENOID APPROXIMATE POSITION OF ICE EJ ECTOR AND ICE LEVEL ARM DURING OPERATION Figure 6 4 First Revolution Continued 3758440 Revision A October 2005 6 4 Pro Series 648PRO
49. ing properly Reverse osmosis systems can be used provided there is a constant water pressure of 20 psi 1 4 bar to 100 psi 6 9 bar supplied to the water valve at all times Installation Information 4712 1206 ROUGH OPENING WIDTH LOCATE WATER SUPPLY WITHIN SHADED AREA 3 76 I 17 117 4 718 ni FLOOR LEVEL Figure 2 6 Plumbing Front View TOP VIEW WATER LINE SPECIFICATIONS From wall 1 2 D 51 7 L 178 24 610 SHUT OFF VALVE 47 1 2 1206 TOP VIEW MINIMUM OF 48 1219 1 4 6 PLASTIC WATER LINE Figure 2 7 Plumbing Top View 2 5 3758440 Revision A October 2005 Installation Information Unpacking the Appliance Uncrate the unit preferably outside the home Inspect complete unit for any damages before proceeding Remove the wood base and discard the shipping bolts and brackets that hold the wood base to the bottom of the refrigerator except the anti tip bracket and hard ware Remove all packing material and tape as well NOTE Do not discard the kickplate Anti tip Kit and hardware or corner protectors as you will be reusing these items Make sure all the leveling jack assemblies are in the upmost position This will prevent damage to the floor or unit when moving Removing the Grille In order to prevent damage to the top grille assembly it is recommend the grille be removed prior to moving the unit Rotate t
50. locating pegs Upper Refrigerator Zone 3 Evaporator Fan Shroud Assembly Removal The evaporator fan shroud assembly is secured to the ceiling with screws To remove an evaporator fan shroud assembly the light diffuser and evaporator cover must be removed first then See Figure 7 24 1 Extract mounting screws along front flange and middle sides of shroud 2 Lower assembly and disconnect wire harness Upper Refrigerator Zone 3 Evaporator Fan Assembly Removal The fan assembly is secured to the shroud with screws To remove an evaporator fan assembly the light dif fuser evaporator cover and fan shroud must be removed first then extract the fan assembly mounting screws from the shroud and pull the fan assembly from the shroud See Figure 7 24 3758440 Revision A October 2005 CIE CES a Extract Screws at top then lean forward and lift up Figure 7 23 Zone 3 Evaporator Cover Removal _ Electrical Connection Middle Side Mounting Holes Mount Screws Figure 7 24 Zone 3 Fan Shroud Removal Pro Series 648PRO Component Access Removal Upper Refrigerator Zone 3 Compartment Thermistor Do DE DMI The upper refrigerator compartment thermistor is locat ed behind the evaporator cover and attached to the NN rear wall with a screw To remove the compartm
51. must first be removed then See Figure 7 38 Extract Screws 1 Remove light bulb from socket by turning the light 0 9 bulb counterclockwise 2 Extract screws from light socket mounting bracket 3 Disconnect wire leads from light socket 4 light socket is held place with retaining clips Depress the retaining clips and extract socket from mounting bracket Figure 7 38 Drawer Light Socket Removal Upper Freezer Evaporator Fan Shroud Removal The upper freezer evaporator fan shroud is located under the freezer bottom shelf and is mounted over the top of the evaporator fan assembly with screws To remove the upper freezer evaporator fan shroud the freezer bottom shelf must be removed first then See Figure 7 43 Upper Fan Shroud pos 1 Extract screws securing shroud to fan assembly 2 Liftfan shroud out of unit Lower Freezer Evaporator Fan Shroud Removal The lower freezer evaporator fan shroud is located under the freezer bottom shelf and is mounted in front of the evaporator fan assembly with screws To remove the lower freezer evaporator fan shroud the freezer bottom shelf must be removed first then See Figure 7 43 1 Extract screws securing shroud to fan assembly 2 Tilt top of shroud down then lift shroud out of unit Freezer Evaporator Fan Assembly Removal The
52. pressed for five 5 minutes after initiating Service Mode the electronic control will automatically exit the mode J COLDER WARMER ICE MAKER POWER COLDER WARMER ALARM LIGHT COLDER COLDER Figure 8 2 Key Strokes and Tech Display Initiate Service Mode 8 3 3758440 Revision A October 2005 Troubleshooting Pro Series 648PRO H Service Diagnostics Self Test Self Test Service Mode Menu 1 Diagnostics gt 1 Self Test gt Start gt Active Self Test Self TestData Results gt Board OK Diagnostics E rrorHistory Error 1 35 000 2 ErrorHistory gt 1 View History gt 12345 d 21 32 45 12345 d 10 29 01 To initiate the Service Mode press and hold COLDER then POWER Error 3 34300 12345 4 8 15 45 Error 4 None To exit press ICE MAKER repeatedly until you are out Continue for 20 errors lt ErrorHistory lt ClearHistory 2 C learHistory gt No gt To work through sub modes press ALARM ICE MAKER M WARMER or COLDER as Yes gt indicated by arrows in flowchart 3 Thermistors gt 70 Condensers Lt 143 Rt141 Zone 1 deg F 51 Cab18 Zone 2 deg F NotPresent 9 Evp 51 Cab 18 Zone 4 deg Evp51 Cab 18 v Diagnostics Manua
53. previous set point by one degree The set point will be displayed on the User Display for ten 10 seconds after the last key stroke then the zone temperature will be displayed As the zone temperature changes the temperature displayed will change by no more than one degree per minute F Upper refrigerator zone temper F F I atures being adjusted 0 ICE POWER COLDER WARMER ALARM WARMER gt COLDER LIGHT COLDER WARMER Figure 3 6 Adjusting Set Point Press Appropriate WARMER or COLDER Key In Multiple Key Strokes 3758440 Revision A October 2005 3 6 sue 2enod Pro Series 648PRO Electronic Control System Icemaker System ON OFF All units are shipped with the icemaker system is OFF By pressing the ICE MAKER key on the control panel power is allowed to the icemaker system and the ice making icon appears in the left User Display See Figure 3 7 To switch the ice maker system OFF press the ICE MAKER key again and the ice making icon disappears NOTES When in Sabbath Mode the icemaker system is deactivated Sabbath Mode will be explained later To allow ice to freeze fully and reduce effects of low water pressure power to the icemaker system is interrupted for forty five 45 minutes after each ice harvest
54. solenoid opening the valve during the fill cycle Holding Switch single pole double throw type switch that assures completion of a revolution once the icemaker has been energized Shut off Switch single pole double throw type switch that stops ice production when the ice bin is full TCO Thermal Cut Out The TCO is thermal protec tion device in the wire harness that would open in the event of mechanical failure thus protecting against over heating The TCO is not shown in diagram Pro Series 648PRO Icemaker Information Ice Ejector Location of Thermal Mastic Shut off S witch Bearing Inlet Support Thermostat Drive Motor Holding S witch Support Plate Ice Mold and Mold Heater Timing Gear Ice Level Arm Lever Arm Timing Cam Cover Water Valve Solenoid S witch Figure 6 1 Diagram of Icemaker Components NOTE For icemaker component part numbers see the Service Parts Manual ICEMAKER OPERATION 115 VOLTS 60 CYCLES I The following series of electrical schematics illustrate a typical icemaker cycle of operation Below each schematic is a diagram indicating the approximate loca tion of the ice ejector and ice level arm during the phase the schematic indicates SHUT OFF SWITCH THERMOSTAT MOLD HEATER Freeze Phase of Ice Making Cycle See Figure 6 2 The ice mold is filled with water The thermostat is open No icemaker components are
55. the Technician s Display when accessing Error Code History during Diagnostic Mode Error Codes are logged if the unit experienced specific problems related to electrical signals supplied by electrical components There are ninety nine possible Error Codes but only twenty can be stored at a time Temperature observed at the User and Technician Displays may be in Fahrenheit units of measure F or Celsius units of measure C A series of key strokes allows the temperature units of measure to be switched to display as either F or C The desired zone temperature established by pressing the COLDER or WARMER keys As the zone air temperature cycles up and down the high offset is the maximum zone temperature that the electronic control system will allow before calling for cooling As the zone air temperature cycles up and down the low offset is the minimum zone air temperature that the electronic control system will allow before interrupting cooling Also Referred to as a Temperature Sensor is a resistor with which resistance changes as the temperature around it changes For electronic control system purposes the microprocessor measures the resistance then displays it as a temperature reading A compressor that runs at varying speeds depending on the temperature detected in the corresponding zone s of the appliance 3758440 Revision A October 2005 3 2 Pro Series 648 ELECTRONIC CONTROL SYSTEM OVERVIEW This page c
56. to reference another component removal procedure earlier in this section NOTE Before continuing please take note of the WARNINGS and CAUTIONS below A WARNING IF IT IS NECESSARY TO REMOVE UNIT FROM ITS INSTALLATION REMEMBER THAT THE UNIT COULD TIP WHEN PULLED FORWARD BEYOND THE ANTI TIP COMPONENTS RESULTING IN SERIOUS INJURY OR DEATH PULLING A UNIT FROM ITS INSTALLATION SHOULD ONLY BE PERFORMED BY AN AUTHORIZED SERVICE TECHNICIAN OR INSTALLER TO AVOID ELECTRIC SHOCK POWER TO THE UNIT MUST BE DISCONNECTED WHENEVER ACCESS ING AND OR REMOVING COMPONENTS POWERED BY ELECTRICITY OR COMPONENTS NEAR OTHER ELECTRICAL COMPONENTS IF THE UNIT IS PLUGGED IN BUT HAS NOT BEEN SWITCHED ON BY PRESSING THE UNIT ON OFF KEY AC VOLTAGE IS STILL PRESENT AT THE CONTROL BOARD e IF REMOVING A DOOR OR DRAWER REMEMBER THAT DOORS AND DRAWERS ARE HEAVY IF THEY WERE TO FALL THEY COULD CAUSE SERIOUS PERSONAL INJURY A CAUTION f working in the compressor area remember that compressors and tubing may be hot f working on or around an evaporator or condenser remember that evaporator and condenser fins are sharp 3758440 Revision A October 2005 7 2 Pro Series 648PRO Component Access Removal Exterior Cosmetic and Mechanical Components Kickplate Removal The kickplate is located on the bottom of unit between the base assemblies To remove the kickplate extract screws from left and right corners of k
57. unit and use enough manpower to safely move unit Make sure the floor under the refrigerator is level with 9 y the surrounding finished floor Pushing the unit with front levelers down will cause damage to the floor Make sure the rear scissors jack is in the upmost posi tion prior to moving the product Protect a finished floor with masonite plywood 1 8 3 pressed fiberboard or some other suitable material before moving the refriger ator across it A CAUTION When using appliance dolly make sure the strapping is underneath the door handles and either underneath or over the top of drawer handles Use enclosed corner protectors to avoid damage to stainless steel Do not cut corner protectors when unpacking the product CAUTION Protect any finished flooring before moving the unit in place This Sub Zero product is equipped with rollers so it can be easily moved into place If for any reason the unit has been laid on its back side you must allow the unit to stand upright for a minimum of 24 hours before connecting power 2 7 3758440 Revision A October 2005 Installation Information Pro Series 648PRO INSTALLATION CONSIDERATIONS This section covers common installation issues seen by Service Technicians Improper installation though not a valid service issue has the potential to lead to a call for service NOTE If additional information is needed refer to the c
58. 0 ON Power to all lights is monitored by the microprocessor to control the door ajar alarm feature f in Sabbath Mode the lighting system is disabled Sabbath Mode will be covered later WHITE Ll 115 VOLTS p 60 CYCLES ORANGE WHITE GRAY WHITE Lighting power monitor lines ORANGE ORANGE RED 1 8 E 2 1 P2 AC YELLOW 5 il WHITE DOOR 2 LIGHT WHITE DRAWER 2 LIGHT DRAWER 2 SWITCH ORANGE RED WHITE 1 YELLOW m DRAWER 1 SWITCH DRAWER 1 LIGHT P5 vettow E 1 0 WHITE 16 Ip MAIN NE or Oa bis CONTROL nv BOARD 4 1 ORANGE WHITE QD ware pig DRAWER 4 SWITCH 19 P3 m 7 Power supplied through P16 to lighting u 1 system unless unit is switched OFF or rd is in Sabbath Mode WHITE DC POWER SUPPLY Figure 3 18 Signal Trace Schematic of Lighting System 3758440 Revision A October 2005 3 12 Jreus zenog Pro Series 648PRO Electronic Control System Monitor Display and Regulate Zone Temperatures Temperature signals from thermistors in each zone are monitored and displayed on the User Displays When zone temperature reaches high offset calling for coo
59. 19 _ RED ba BLUE BLACK ae YELLOW PURPLE M 7 YELLOW EXERNAL P14 BLUE ie n 1 E Fu TTT di NANNA YELLOW BROWN t 5de BLUEWHITE RIGHT WHITE 4 DISPLAY eo PART NUMBER 3758388 REVISION 3758440 Revision A October 2005 10 4 4 Pro Series 648PRO Wiring Diagrams Schematics MODEL 648PRO CONTROL BOARD LAYOUT EVAP 12 VDC POWER GROUND RETURN EVAP FAN POWER 12 VDC UNUSED ZONE 4 SPEED SIGNAL ZONE 3 SPEED SIGNAL ZONE 1 SPEED SIGNAL ZONE 4 TACHOMETER ZONE 3 TACHOMETER UNUSED ZONE 1 FAN TACHOMETER NETWORK LEFT DEFROST RIGHT DEFROST HTR LEFT COMPRESSOR RIGHT COMPRESSOR MAIN CONTROL BOARD ZONE 1 EVAP SENSOR ZONE 1 CABINET SENSOR ZONE 4 EVAP SENSOR ZONE 3 EVAP SENSOR MAIN LIGHTS ZONE 4 CABINET SENSOR L1 ZONE 3 CABINET SENSOR RIGHT CONDENSOR LEFT CONDENSOR AMBIENT GND NEUTRAL FRONT OF UNIT 20 P12 pepper epee I WATER VALVE INPUT ZONE 4 DRAWER INPUT ZONE 3 DOOR INPUT ZONE 1 DRAWER INPUT ZONE 1 DOOR INPUT ZONE 1 DEFROST BI METAL INPUT REFRIGERANT VALVE CONDENSER FAN ICEMAKER ICE ACCESSORIES WATER FILTER INPUT MODEL 648PRO CONTROL BOARD SUMMARY TABLE
60. 2 20 2 E A 7 MAIN 55 m CONTROL Aisi BOARD EREI PP E 5 Ho Figure 3 26 Signal Trace Schematic of Compressor Electrical System Bi Jo 3B Figure 3 27 SERVICE Flashing Several Excessive Compressor Run Periods 3758440 Revision A October 2005 3 20 Jreus zenog Pro Series 648PRO Electronic Control System Monitor Icemaker System and Display If Service is Needed The microprocessor observes the voltage supplied to the icemaker water valve solenoid If the solenoid is energized for more than fifteen 15 seconds power to the icemaker system is disabled for 12 hours See Figure 3 28 and an error code is logged If this happens five consecutive times ice making icons in both User Displays and the SER VICE icon in the right User Display will flash indicating the ice making system is now disabled See Figure 3 29 NOTES socveues NEUTRAL To clear this error indicator from the V User Displays and reactivate the ice making system the problem must be corrected the Error Code must be m 0000 WATER VALVE cleared from memory while in Service E IM Mode and the unit must be switched EIER TEES OFF then back ON ov CO n
61. Adjustment conii 2 10 Drawer Adjustment eerie nenne 2 11 Vertical Drawer Adjustment 2 11 Horizontal Drawer Adjustment 2 11 Section 3 Electronic Control System 3 1 E Control Terminology amp Component Descriptions 3 2 Electronic Control System OvervieW 3 3 Control Board Layout and Summary Table 3 4 Control Panel and User Displays Layout 3 5 Basic Electronic Control Input Operations 3 6 Unit riale 3 6 Adjusting Set Point Temp Adjustment 3 6 Icemaker System 3 7 Door Ajar Alarm Feature 3 7 Accent Lighting ON OFF Model 648PROG 3 7 Unique Electronic Control Input Operations 3 8 Temperature Units Selection Mode 3 8 Showroom Mode 3 9 Sabbath scsi iaia 3 10 Manual Zone Disable 202 3 11 Manual Freezer Evaporator Defrost 3 11 Functions of Electronic Control System 3 12 Supply Power to Lighting System 3 12 Monitor Display and Regulate Zone Temperatures Assist in Control of Variable Speed Compressors Control Refrigerator Dual Refriger
62. COLDER WARMER ICE MAKER POWER fA Figure 3 12 To Enter or Exit Showroom Mode Switch Unit OFF First 38 38 COLDER WARMER ALARM ICE MAKER POWER LIGHT COLDER WARMER COLDER WARMER Figure 3 13 Then Press and Hold Any Pair of WARMER and COLDER Keys Then the POWER Key 3 9 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO Jreus zerog Sabbath Mode Sabbath Mode was incorporated into the electronic control system for the observance of certain religious days Initiating Sabbath Mode disables the lighting systems ice making system alarm system and the User Displays and Sabbath Mode will appear on the Technician Display To initiate Sabbath Mode the unit must first be switched OFF using the POWER key See Figure 3 14 then press and hold the POWER key until the User Displays and lights switch OFF the alarm emits a quick series of beeps and Sabbath Mode appears on the Technician Display See Figure 3 15 This will take approximately ten 10 seconds To return to normal operation switch the unit OFF then back ON NOTE During Sabbath Mode set points cannot be changed and manual defrost cannot
63. DRIVE OUTPUT YELLOW P12 9 DEF BI METAL 1 SENSES WHEN HEATER 1 SHUTS OFF GRAY WHITE 8 8 EVAPORATOR FAN ZONE 4 PWM DRIVE OUTPUT YELLOW P URPLE P12 10 UNUSED UNUSED UNUSED P8 9 UNUSED UNUSED UNUSED 12 11 UNUSED UNUSED UNUSED P8 10 EVAPORATOR FAN 12 VDC POWER ZONE FAN POWER RED P 2 12 WATER FILTER INPUT SENSE WATER FILTER RED 8 11 EVAPORATOR FAN GROUND RETURN ZONE FAN RETURN WHITE 12 13 ICE ACCESSORIES POWERS FILL TUBE AND ACCESSORIES WHITE BLUE 12 14 ICE MAKER POWERS ICE MAKER UNUSED THERMISTER CIRCUITS P12 15 UNUSED UNUSED UNUSED P5 1 AMBIENT SENSES TEMPERATURE BROWN 12 16 UNUSED UNUSED UNUSED P5 2 AMBIENT SENSES TEMPERATURE BLUE P12 17 CONDENSER FAN CONDENSER FAN WHITE RED P5 3 CONDENSOR LT SYSTEM SENSES TEMPERATURE BROWN P12 18 TAWECO VALVE 2 POWERS AWECO VALVE 2 TAN WHITE P5 4 CONDENSOR LT SYSTEM SENSES TEMPERATURE BLUE P12 19 UNUSED UNUSED UNUSED P5 5 CONDENSOR RT SYSTEM SENSES TEMPERATURE BROWN P12 20 P5 6 CONDENSOR RT SYSTEM SENSES TEMPERATURE BLUE P5 7 REF UPPER CABINET ZONE 3 SENSES TEMPERATURE BROWN LOW VOLTAGE CIRCUITS P5 8 REF UPPER CABINET ZONE 3 SENSES TEMPERATURE BLUE 2 1 UNUSED UNUSED UNUSED 5 9 REF LOWER CABINET ZONE 4 SENSES TEMPERATURE BROWN P2 2 UNUSED UNUSED UNUSED P5 10 REF LOWER CABINET ZONE 4 SENSES TEMPERATURE BLUE P2 3 UNUSED UNUSED UNUSED P5 11 REF UPPER EVAP ZONE 3 SENSES TEMPERATURE BROWN P2 4 UNUSED UNUSED UNUSED P5 12 REF UPPER EVAP ZONE 3 SENSES TEMPERATURE BLUE P25 UNUSED UNUSED UNUSED
64. Device or Wiring 0 Ambient Thermistor Failure Device or Wiring x Check Zone X Defrost Bi metal for Proper Operation IX Check Zone X Defrost Bi metal for Proper Operation x Check Zone X Defrost Wiring x Check Zone X Defrost Wiring xX Check Zone X Defrost Heater Ohms Check for Stuck Icemaker or Water Valve Failure 35 X CheckZone X Fan Fan Speed Error gt O Zone X Excessive Run Check Zone X Compressor and Wiring 42 o Check Condenser Fan and or Wiring Check Condenser Fan and or Wiring Errors Detectable with Red Door Switches Disabled Now Check Overhead Lighting 46 0 Check Ice Accessory Wiring for Open Circuit Check Accent Lighting Wiring for Short Circuit X Check Power to Compressor Controller for Zone X Troubleshoot with Manual Activation Mode 83 Replace Zone X VS Compressor and Filter Drier Check Zone X VS Compressor Wiring Zone X VS Compressor Control Overheat Check Communication Wiring Replace Zone X VS Controller Check for Broken Wiring or Open Defrost Heater 89 X Check Icemaker Solenoid Valve and Wiring Change Main Control Board 92 Check Keypad Wiring 93 Replace Keypad 94 Check Wiring Replace User Display 1 94 Check Wiring Replace User Display 2 96 Datalogger Malfunction 97 Check Communications Cables Connectors 98 Brownout Check Input Power Supply gt
65. E A YELLOW BROWN 5 BLUEM HITE BOARD want E J Figure 3 1 Wiring Schematic 3 3 3758440 Revision A October 2005 Pro Series 648PRO CONTROL BOARD LAYOUT AND SUMMARY TABLE Electronic Control System The electrical connection points on the main control board are labeled alphanumerically These labels correspond with the alphanumeric control board summary table located on wiring diagrams By referencing the summary table it is possible to identify which components are connected at which connection points on the main control board Below is a layout diagram of the control board and a copy of a summary table See Figures 3 2 amp 3 3 NOTE All components on control board are non replaceable If problems with control board are identified the complete control board must be replaced EVAP 12 VDC POWER GROUND RETURN ZONE 1 SPEED SIGNAL ZONE 4 TACHOMETER ZONE 3 TACHOMETER EVAP FAN POWER 12 VDC UNUSED ZONE 4 SPEED SIGNAL UNUSED ZONE 1 FAN TACHOMETER ZONE 3 SPEED SIGNAL UNUSED NETWORK LEFT DEFROST HTR RIGHT DEFROST HTR LEFT COMPRESSOR RIGHT COMPRESSOR MAIN CONTROL BOARD ZONE 1 EVAP SENSOR ZONE 1 CABINET SENSOR ZONE 4 SENSOR ZONE 3 EVAP SENSOR MAIN LIGHTS ooo ooo
66. E R VALVE GRAY WHITE TAN 1 0000000 1600 ORANGE IM WHITE ORANGE RED miiniimiimim tn mins _ fq CONDENSER FAN MOTOR su 1 P12 20 2 NEI P2 A gl ware P13 3 1 ne YELLOW ORANGE RED D WHITE P15 DRAWER 1 SWITCH P5 Ne gl 4 0 rM P16 DOOR 1 SWITCH ne MAIN 24 4 YELLOW 1 D WHITE CO NTROL DRAWER 3 SWITCH DIARERS DIGHE FA BOARD y 1 ORANGE WHITE 0 WHITE IDRAWER 4 LIGHT 8 DRAWER SWITCH P18 3 EJ P19 3 230029000 FILL TUBE HEATER 4 7 1 P8 1 BLUE Wire n 1 4 1 Eb d d BI METAL 1 TROUGH HEATER 1 WHITE 4 TOFZ PURPLE COMPRESSOR VSPEED WHITE CONTROL BROWN 17 BLUE sux BOX FZ FOR NON GLASS LTS BEACK DOOR ONLY REFRIGERATOR COMPRESSOR STARTING RELAY VSPEED CONTROL BROWN BOX REF BLACK FOR GLASS DOOR ONLY WHITE 1 WHITE 4 DC POWER LOW VOLTAGE 1 RED pa ete 1 P12 20 2 1 THERMISTER 1 P13 P2 BROWN AMBIENT 5 BLUE THERMISTER 2 P1 BROWN FRE COND THERMISTER BLUE BROWN REF CABINET B m THERMISTER re BLUE BROWN REF COND pas pm BLUE P5 B m THERMISTER TERMER TE BROWN REBEVAR BROWN REF LWR CABINET P16 55 BLUE BLUE MAIN la E THERNISTER BROWN FZCABINET BROWN C REF LWR EVAP o CONTROL Iw E P P17 BOARD BLUE BLUE 8 5 THERMISTER BROWN FZ EVAP 5 g 2 1 m 2 2 8 30303 TECH DISPLAY _ _ P
67. FOR GLASS DOOR ONLY DC POWER LOW VOLTAGE ilo 1 Refrigerator compartment I 20 2 high offset temperature es observed via thermistors a m m tunt as in ea son e 7 MAIN ha parie n CONTROL e E BOARD i 1 Figure 3 21 Signal Trace Refrigerant Valve Activation 3 15 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO Peus zenod Control Condenser Fan Operation The microprocessor observes the condenser outlet temperatures of both systems If either compressor is running and a condenser outlet temperature is gt 90 F 32 C a signal is sent to the condenser fan relay on the control board to close supplying power to the condenser fan See Figure 3 22 If both compressors are off the condenser fan will be off
68. GE cT REF DOOR 2 SWITCH 2 ORANGE BLACK DRIVER WHITE TOP ACCENT LIGHT DEFROST HEATER FILL TUBE HEATER 3 gl fa E Si l3 E ii E 3 FEE d BES 1 BLACK z BROWN BLUE i WHITE 1 i BLACK gt DRAIN TROUGH zone 1 M EA ZONE 3 WHITE ORANGE WHITE BLUE 1 GRAY WHIT IO UPR DRAWER LIGHT TERMINATOR UPR DRAWER LIGHT YELLOW veto P ORANGERED ORANGE WHITE E WHITE WHITE DRAWER LIGH RANGER DRAWER LIGHT SWITCHES SWITCHES LWR DRAWER LIGHT LWR DRAWER LIGHT GREENIYELLOW ICEMAKER a oP EINE velo tog ORANGHRED ORANGE WRITE ZONE 1 ZONE 4 H 3758440 Revision October 2005 10 2 sue zeno d Pro Series 648PRO Wiring Diagrams Schematics This wiring information is provided for use by qualified service personnel only O D F R O 4 8 Disconnect appliance from electrical supply before beginning service Li Be sure all grounding devices are connected when service is complete Failure to observe the above warnings may result in severe electrical shock L O W V O L 1 G E PART NUMBER 3758388 REVISION C
69. Maximum defrost duration 30 minutes plus 5 minute dwell If the defrost sensing line is open defrost operation defaults to 30 minute defrost time 6 hour build time and an Error Code is logged If the evaporator thermistor detects an under heat or overheat situation at the same time another Error Codes is logged During defrost the displayed temper ature is locked 11 115 VOLTS 60 CYCLES up MAIN 24 CONTROL BOARD If the heater stays on for a longer time NEUTRAL Length of defrost time monitored by microprocessor via grey white defrost sense line 2300 2900 Q FILL TUBE HEATER DEF HEATER 1 TROUGH HEATER 1 BI METAL 1 LOW VOLTAGE CoO CoO ETET DC POWER SUPPLY TATE THERMISTER FZCABINET THERMISTER BROWN YELLOW 3 19 Figure 3 25 Signal Trace Schematic of Freezer Adaptive Defrost 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO Peus zenod Monitor Compressor Run Duration Displays If Service is Needed The microprocessor observes the changing sta
70. OSITION l OF ICE EJ ECTOR AND ICE LEVEL ARM DURING OPERATION Icemaker will Stop Arm DOWN Icemaker will Operate Figure 6 12 Stopping Icemaker Pro Series 648PRO MANUALLY STARTING THE ICEMAKER NOTE To allow ice to freeze fully and reduce effects of low water pressure the electronic control disables the icemaker system for 45 minutes after each ice harvest To bypass this 45 minute dwell for service purposes press the the ICE key at the control panel Manual Start Procedure 1 Pry the icemaker front cover from the support using a flat blade screwdriver or coin 2 With a flat blade screwdriver turn the drive gear counterclockwise until the holding switch is activat ed completing the circuit to the drive motor this will be about a 1 8 turn See Figure 6 13 The ice maker will then complete its cycle automatically NOTE If after 1 4 turn the icemaker is not running on its own it may be in the 45 minute dwell period or there is an electrical or mechanical problem ADJUSTING WATER FILL LEVEL Proper water fill level for a MidSouth icemaker is 100 110 3 5 3 75 oz If the fill level is checked and needs to be adjusted turn the water fill adjusting screw clockwise to reduce fill level or counterclockwise to increase fill level One full turn of the screw equals 15 ccs See Figure 6 14 NOTE Always check fill level before making any adjustments of the water fill adjusting scre
71. P5 13 REF LOWER EVAP ZONE 4 SENSES TEMPERATURE BROWN 5 14 REF LOWER EVAP ZONE 4 SENSES TEMPERATURE BLUE 5 15 FRE CABINET ZONE 1 SENSES TEMPERATURE BROWN P5 16 FRE CABINET ZONE 1 SENSES TEMPERATURE BLUE P5 17 FRE EVAP ZONE 1 SENSES TEMPERATURE BROWN P5 18 FRE EVAP ZONE 1 SENSES TEMPERATURE BLUE P5 19 UNUSED UNUSED UNUSED P5 20 UNUSED UNUSED UNUSED 648PRO CONTROL BOARD SUMMARY 5521 UNUSED UNUSED UNUSED P5 22 UNUSED UNUSED UNUSED P5 23 UNUSED UNUSED UNUSED 5 24 UNUSED UNUSED UNUSED 10 5 3758440 Revision A October 2005 Wiring Diagrams Schematics Pro Series 648PRO frsus zenod 3758440 Revision A October 2005 10 6
72. RDOUS OR UNSAFE PRAC TICES COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH CAUTION Indicates that hazardous or unsafe practices could result in minor personal injury and or product dam age and or property damage In addition please pay attention to the signal word NOTE which highlights information that is espe cially important for the topic being covered TECHNICAL ASSISTANCE If you should have any questions regarding the 600 2 Series and or this manual please contact Sub Zero Freezer Company Inc ATTN Service Department P O Box 44988 Madison WI 53744 4988 Customer Service amp Parts Warranty Claims Phone 800 222 7820 Technical Assistance Phone 800 919 8324 Customer Service amp Technical Assistance Facsimile 608 441 5887 Parts Warranty Claims Facsimile 608 441 5886 Service Department E Mail Address customerservice subzero com Office Hours 7 00 AM to 7 00 PM Central Time Monday through Friday This manual is designed to be used by Authorized Service Personnel only Sub Zero Freezer Co Inc assumes no responsibility for any repairs made on Sub Zero refrigeration units by anyone other than Authorized Service Technicians Information and images contained in this manual are the copyright property of Sub Zero Freezer Company Inc Neither this manual nor any information or images contained herein may be copied or used in whole or in part without
73. SENSES WATER VALVE ACTIVATION TAN P8 3 EVAPORATOR FAN ZONE 3 TACHOMETER INPUT BLUE P12 5 ZONE 4 DRAWER INPUT SENSES IF ZONE 4 DRAWERS ARE OPEN UNUSED P8 4 EVAPORATOR FAN ZONE 4 TACHOMETER INPUT BLUE BLACK 12 6 ZONE 3 DOOR INPUT SENSES IF ZONE 3 DOOR OPEN UNUSED P8 5 EVAPORATOR FAN ZONE 1 PWM DRIVE OUTPUT YELLOW BROWN 12 7 ZONE 1 DRAWER UNUSED UNUSED P8 6 UNUSED UNUSED UNUSED P12 8 ZONE 1 DOOR UNUSED UNUSED P8 7 EVAPORATOR FAN ZONE 3 PWM DRIVE OUTPUT YELLOW 12 9 BI METAL 1 SENSES WHEN HEATER 1 SHUTS OFF GRAY WHITE P8 8 EVAPORATOR FAN ZONE 4 PWM DRIVE OUTPUT YELLOW PURPLE 12 10 UNUSED UNUSED UNUSED P8 9 UNUSED UNUSED UNUSED P12 11 UNUSED UNUSED UNUSED 8 10 EVAPORATOR FAN 12 VDC POWER ZONE FAN POWER RED 12 12 WATER FILTER INPUT SENSE WATER FILTER RED P8 11 EVAPORATOR FAN GROUND RETURN ZONE FAN RETURN WHITE P12 13 ICE ACCESSORIES POWERS FILL TUBE AND ACCESSORIES WHITE BLUE 12 14 MAKER POWERS ICE MAKER UNUSED THERMISTER CIRCUITS P12 15 UNUSED UNUSED UNUSED P5 1 AMBIENT SENSES TEMPERATURE BROWN P12 16 UNUSED UNUSED UNUSED 5 2 AMBIENT SENSES TEMPERATURE BLUE 12 17 CONDENSER FAN CONDENSER FAN WHITE RED 5 3 CONDENSOR LT SYSTEM SENSES TEMPERATURE BROWN P12 18 VALVE 2 POWERS AWECO VALVE 2 TAN WHITE P5 4 CONDENSOR LT SYSTEM SENSES TEMPERATURE BLUE P12 19 UNUSED UNUSED UNUSED P5 5 CONDENSOR RT SYSTEM SENSES TEMPERATURE BROWN P12 20 P5 6 CONDENSOR RT SYSTEM SENSES TEMPERATURE BLUE P5 7
74. Service Mode 4 Version Information 3 35 Section 4 Sealed System Information 4 1 HFC 134a Refrigerant Information General 134a RUles 1 reete tete tentes Sealed System Repair Procedures Freezer Sealed System Operation Refrigerator Sealed System Operation 4 6 Refrigerant Flow Diagrams 4 8 Section 5 Airflow amp Fan Blade Spacing 5 1 Model 648PRO ba iaia hand dva d 5 2 Section 6 Icemaker Information 6 1 Icemaker System 6 2 Icemaker Components 2 2 0 2 2 0 400 000000060000 6 2 Icemaker 1 2 1 0 2 000000000000090 6 3 Manually Stopping 6 8 Manually Starting 6 9 Adjust Water Fill 6 9 Section 7 Component Access and Removal 1 1 Table of Contents Warnings and Cautions 7 2 Exterior Cosmetic and Mechanical 7 3 Kickplale 7 3 Drain ez 1 P illa 7 3 Door Drawer Handles 7 3 7 3 Drawer Assembly ot aa t
75. Service Mode menu can be found on the Technician s For Service Mode Press and hold then press Display cover See Figure 3 40 These basic instructions the Key Pro48 Zones Symbol and Arrows correspond with keys on the control panel thus directing the technician as to what keys need be pressed in order to move in the direction indicated by the arrow closest to each key symbol For complete Service Mode menu see back NOTES bile f d A complete Service Mode inp SERITUR SEMEN O H Menu can be found on the back of the wiring diagram and on the next page of this manual WARMER 4 Since it is possible to initiate bypass an or step back through the four different sub modes while in Service Mode initiating Service Mode will always be the first step when explaining how to work through the Service Mode menu for the sub modes CAUTION The grille is connected with a AL low voltage display cable behind this cover It MUST be disconnected before grille is removed JV 2 3758484 B Figure 3 40 Technician s Display with Service Mode Menu 3 25 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO I Serv ice Mode lt Diagnostics Self Test Self Test Service Mode Menu 1 Diagnostics gt 1 Self Test gt Active Self Test Results gt lt rrorH istory 1 View History gt Self TestData Board OK Error 1 35 0 00 12345
76. Sizes T 10 T 15 T 20 T 25 3758440 Revision A October 2005 Pro Series 648PRO 2 2 Pro Series 648PRO UNIT DIMENSIONAL INFORMATION Installation Information 48 B 1219 ES E lt lt 25 13 16 B I 27 7 8 4 2134 C 30 5 32 1 C c 30 5 32 tal h Figure 2 1 Front View Figure 2 2 Side View 23 13 16 23 13 16 656mm 656mm BEHIND BEHIND FACE FRAME 2 51 FACE FACE FRAME FRAME DEPTH Figure 2 3 Top View Side and Top View Dimensions Breakdown A 25 13 16 656 mm Depth to Face Frame 27 7 8 708 mm Depth to Door Front C 30 5 32 766 mm Depth to Handles Minimum Door Clearance at 90 D 23 7 8 606 mm Depth Behind Face Frame E 28 3 4 730 mm Refrigerator Door F 20 1 2 521 mm Freezer Door 2 3 3758440 Revision October 2005 Installation Information Pro Series 648 PRE INSTALLATION SPECIFICATIONS Preparing the Space NOTE Make sure the floor under the refrigerator is level with the surrounding finished floor Pro
77. TECHNICAL SERVICE MANUAL Pro Series model 648PRO PR048 SUB ZERO FREEZER COMPANY INC 2005 ALL RIGHTS RESERVED JOB AID 3758440 Revision A December 2005 Pro Series 648PRO General Information SECTION 1 GENERAL INFORMATION 1 1 3758440 Revision A October 2005 General Information INTRODUCTION Pro Series 648 This Technical Service Manual has been compiled to provide the most recent service information on the Sub Zero Pro Series Currently only the model 648PRO This information will enable the service technician to troubleshoot and diagnose malfunctions perform necessary repairs and return a unit to proper operational condition The service technician should read the complete instructions contained in this manual before initiating any repairs on a Pro Series Unit IMPORTANT SAFETY INFORMATION Below are Product Safety Labels used in this manual The Signal Words used are WARNING or CAUTION When reviewing this manual please note these differ ent Product Safety Labels placed at the beginning of certain sections of this manual You must follow the instructions given in the boxes of the Product Safety Labels in order to avoid personal injury and or product damage The sample Product Safety Labels below illustrate the precautions that should be taken when the signal word is observed A WARNING INDICATES THAT HAZA
78. To remove the freezer thermistor the light diffuser and upper duct cover must be removed then See Figure 7 36 1 Extract screw and clamp holding thermistor to back wall 2 Cut thermistor s wire leads six 6 to twelve 12 inches from the back wall then pull thermistor from compartment Ice Bucket Removal The ice bucket sits in the bottom freezer drawer To remove the ice bucket open bottom freezer drawer and lift bucket out of drawer See Figure 7 37 NOTE When reinstalling the ice bucket make sure its rear flange is not sitting up on the back edge of the drawer If this happens the ice level arm will be held in the up position stopping ice production 3758440 Revision A October 2005 Pro Series 648 Locating Pegs Tx 3 M Figure 7 35 Freezer Bottom Shelf Removal a 7 Freezer Compartment Thermistor a SS Figure 7 36 Freezer Compartment Thermistor 7 16 Figure 7 37 Bucket Removal Pro Series 648PRO Component Access Removal Drawer Light and Socket Removal The drawer lights are located at the top front of each drawer compartment iu To remove the drawer light or replace the light socket the drawer assembly
79. V 280 1070 1070 DEFROST METHOD DEFROST TERMINATOR DEFROST HEATER DRAIN TROUGH HEATER FILL TUBE HEATER WATER VALVE THERMISTORS Evap amp Compartment GLASS REFRIGERATOR DOOR HEATER 3758440 Revision A October 2005 Fan Assisted Off Adaptive Defrost Cycle Defrost Intervals and duration Evap gt 38 F before varies Followed by 5 Compressor ON min compressor delay 30 F 1 C 55 F 13 C Cut In Temp Cut Out Temp 450 3 75 32 la cor Watts P Amps Ohms Inductive Ohms at 32 F 0 C 30000 33000 30000 33000 5 12VDC A 29 80 66 180 Jreus zenog Pro Series 648PRO Wiring Diagrams Schematics SECTION 10 WIRING DIAGRAMS AND SCHEMATICS Wiring Diagrams Schematics Pro Series 648PRO sus zero WIRING DIAGRAM rCAWARNING This wiring information is provided for use by qualified service personnel only Disconnect appliance from electrical supply before beginning service Be sure all grounding devices are connected when service is complete Failure to observe the above warnings may result in severe electrical shock IG VO L 1 PART NUMBER 3758388 REVISION C
80. ant Valve Control Condenser Fan Operation Minimize Condensation on Ref Door Glass Monitor and Control Refrigerator Fan Assisted Off Cycle Defrost Monitor and Control Adaptive Defrost of Freezer Evaporator Monitor Compressor Run Duration Display if Service is Needed Page Monitor Ice Making System and Display if Service is Needed eed 3 21 Monitor Water Filter Time in Use and Display when it s Time to Replace 3 22 Self Diagnostics of Electronic Control System 3 23 Possible Error Indicators eee 3 24 Service Mode Troubleshooting Input Operations 3 25 Service Mode Menu rt mrt 3 26 Non Service Mode Display Information 3 27 Initiating Service 3 27 Service Mode 1 Diagnostics ssss 3 28 Diagnostics 1 Self Test 3 28 Diagnostics 2 Error History 3 29 Error Code Table 3 30 Diagnostics 3 Thermistors 3 31 Diagnostics 4 Activate Zone 3 31 Diagnostics 5 Statistics 3 32 Service Mode 2 Operational Status 3 33 Op Status 1 Zone Status 3 33 Op Status 2 3 34 Service Mode 3 Model Information 3 34
81. appliance ON or OFF An electrical component on the control board which switches other components in the appliance ON or OFF when instructed to do so by the microprocessor Similar in function to the relay the triac is a three terminal semiconductor for controlling current in either direction Also referred to as the Control Keypad Interface is that part of the electronic control system where all input operations are performed Part of the control panel assembly which consists of the function keys The buttons the Membrane Switch used for input operations POWER ALARM ICE MAKER LIGHTS and 3 sets of WARMER amp COLDER Those parts of the electronic control system one at each bottom corner of the grille assembly which display zone temperatures mode and some error indicators That part of the electronic control system behind the grille assembly which displays temperatures along with mode error and service text information semi liquid substance sandwiched between glass in the User Technician s Display Modules The molecules of this semi liquid substance have no specific orientation However when electricity is applied to them they react predictably aligning and straightening in such a way as to control light passage The words numbers and icons that appear at the User Displays and the Technician s Display through the use of LCD s The code numbers that may appear on
82. cessing the sealed system After all mechanical and electrical components have been ruled out sealed system pressures can be checked by applying solder on process valves and ref erencing the preceding page Do NOT use bolt on process valves as they are prone to leak This table should only be used as a last quick check before entering the sealed system 21912242 SRSA EASE SRE ERE If low side pressure is amp high side pressure is possible problem is NORMAL NORMAL MECHANICAL see General Troubleshooting Guide LOW LOW LEAK LOW HIGH RESTRICTION HIGH LOW INEFFICIENT COMPRESSOR HIGH HIGH OVER CHARGE 8 7 3758440 Revision A October 2005 Troubleshooting Pro Series 648PRO Jreus zenog 3758440 Revision A October 2005 8 8 Pro Series 648PRO Technical Data SECTION 9 TECHNICAL DATA 9 1 3758440 Revision A October 2005 Technical Data Pro Series 648 Model 648PRO CHARGE R 134a Refrigerant REFRIGERATOR NOTE Always check serial tag for exact charge NORMAL OPERATING PRESSURES COMPRESSOR Low Side High Side NOTE Always check current parts price list for possible substitutions Service Part No 4201880 4204741 Manufacturer Embraco Embraco Mfg Part No EMI30HER VEGY Original Compressor Service Compressor Amps 2 1 V 0 8 non V 1 1 2 6 2 6 Original Compressor Service Compressor BTU s 864 V 345 non
83. control board to the rest of the unit indicated by the appliance running through a self test in which the lights and all the LCD s in the User Displays energize then the User Displays show temperatures NOTE If the unit is switched OFF using the POWER key the word OFF will be visible on the right User Display A WARNING WHEN IN OFF MODE AC LINE VOLTAGE IS STILL PRESENT AT THE MAIN CONTROL BOARD AND DC POWER SUPPLY AND LOW DC VOLTAGE IS PRESENT IN THE LOW VOLTAGE ELECTRICAL SYSTEM ICE MAKER POWER COLDER WARMER ALARM LIGHT COLDER WARMER COLDER WARMER Figure 3 5 Switching Unit ON or OFF Press POWER Key Adjusting Set Point Temperature Adjustment To adjust set points press the appropriate WARMER or COLDER key on control panel in multiple key strokes until desired set point is achieved See Figure 3 6 One key stroke equals one degree change NOTES To the right of each temperature reading is an icon representing the appliance The darkened portion of the appli ance icon indicates which zone is associated with the temperatures to its left The temperature range in a freezer zone is 5 F 20 C to 5 F 15 C The temperature range in a refrigerator zone is 34 F 1 C to 45 F 7 C The initial stroke of the WARMER or COLDER key will change the
84. display after each key stroke Only the final and or desired result will be explained and illustrated Op Status 1 Zone Status As mentioned when Service mode is initiated Service Mode 1 Diagnostics appears in the Technician s Display Follow the steps below to work to and through Op Status Mode 1 Zone Status 1 After initiating Service Mode press COLDER key one 1 time Service Mode 2 Op Status appears on display 2 Press ALARM key two 2 times See Figure 3 48 and it is now possible to work through the following four 4 levels 1 Z1 Cooliing Def Zone 1 is cooling or defrosting 2 Z2 Not Present Zone 2 is currently not present in this appliance 3 73 Cooliing Def Zone is cooling or defrosting 4 74 Cooliing Def Zone 4 is cooling or defrosting corr COLDER WARMER ICE MAKER POWER ALARM LIGHT COLDER WARMER COLDER WARMER SS Press ALARM key 2 times Figure 3 48 Key Strokes and Tech Display Operational Status Zone Status 3 33 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO cc Op Status 2 Ice Maker As mentioned when Service mode is initiated Service Mode 1 Diagnostics appears in the Technician s Display Follow the steps belo
85. e the unit must be ON With the unit ON press and hold the WARMER key for the zone being disabled then press the POWER key then release both keys See Figure 3 16 When a zone is disabled double dashes will appear on the User Display in place of zone temperatures indicating all cooling functions for that zone are disabled There are two ways to exit Manual Zone Disable Mode and return the unit to normal operation Repeating the WARMER and POWER key strokes is one way The other way is to switch the unit OFF then back ON NOTE Always check set points after returning unit to normal operation 4 a 36 ALARM LIGHT COLDER WARMER for that zone are disabled Indicating that all cooling functions COLDER WARMER ICE MAKER POWER WARMER COLDER gt Figure 3 16 To Enter or Exit Manual Zone Disable Mode Press and Hold WARMER Key for Zone Being Disabled Then Press POWER Key Manual Freezer Evaporator Defrost Manual Freezer Evaporator Defrost was incorporated into the electronic control to assist in servicing and diagnos tics To initiate manual freezer evaporator defrost press and hold the ICE MAKER key for five 5 seconds See Figure 3 17 NOTE Manual Freezer Evaporator Defrost will not operate if uni
86. e Schematic of Condenser Fan Operation 3758440 Revision A October 2005 3 16 Pro Series 648PRO Electronic Control System Minimize Condensation on Refrigerator Door Glass On units produced with glass doors the microprocessor detects when the refrigerator door is opened via the light switch so when the door closes the evaporator fan is energized for five 5 minutes regardless of compressor oper ational status This draws any warmer moist air aw minimizing condensation on the glass the door is e NOTES ay from the door glass See Figure 3 23 To further assist in quipped with a braided wire heater around the glass perimeter Refrigerator evaporator fans also cycle with the refrigerant valve This door heater on glass door models is powered off of the condenser fan circuit relay L1 115 VOLTS a eocveLes NEUTRAL 0000000 AWECO REF VALVE 2 wa 2950 Wives CONDENSER FAN MOTOR sola ET 1 P12 20 2 1 P2 Men al 1 P15 m P5 pe d ORANGE Dr mune P16 Um 1 If Ref door is opened then Ue BOARD closed microprocessor Jos 1 sen
87. ed LOW VOLTAGE E gH I 1 17 EY UNE nnunnannanun n Figure 3 30 Signal Trace Schematic of Icemaker Electrical System 28 3B Ln Figure 3 31 REPLACE FILTER Icon Appears after approximately one 1 Year of Filter Use 3758440 Revision A October 2005 3 22 Pro Series 648 Electronic Control System Self Diagnostics of the Electronic Control System The electronic control system automatically runs through self diagnostics at predetermined time intervals and in the event of an excessive run condition During this self test the control cycles the loads and checks the inputs for fail ures The following components are energized for a few seconds during the self diagnostic program Thermistors Glass Door Heater Evaporator Fans RS485 Transceiver Aweco Refrigerant Valve Condenser Fan Accent Lights Power Relays and Triacs Digital AC Inputs If there is a problem with the electronic control system or an electrical compo nent the appropriate Error Code will be logged If the problem causes the inability of the appliance to maintain temperature SERVICE will flash on the right User Display See Figure 3 33
88. eep charge system NOTE If evacuating refrigerator sealed system unit must be evacuated from the low amp high sides due to refrigerant valve If sweep charging refrigerator sealed system refrigerant valve must be energized during procedure See Diagnostics 4 Activate Zone in Section 3 e Recharge system with Virgin 134a refrigerant Low Side Leak Capture refrigerant Repair leak if at solder joint or replace part Back flush high side of sealed system If all refrigerant has escaped and system is a vacuum replace compressor 1 Replace filter drier Evacuate or sweep charge system NOTE If evacuating refrigerator sealed system unit must be evacuated from the low amp high sides due to refrigerant valve If sweep charging refrigerator sealed system refrigerant valve must be energized during procedure See Diagnostics 4 Activate Zone in Section 3 g Recharge system with Virgin 134a refrigerant Contaminated Sealed Capture refrigerant System Repair leak if at solder joint or replace part Back flush high side of sealed system Replace compressor Replace filter drier Replace heat exchanger if cap tube is clogged leak in condensate loop or Install a low side drier on suction tube in low side Evacuate or sweep charge sealed system Plugged capillary tube NOTE If evacuating refrigerator sealed system unit must be evacuated from the low amp high sides due to refrigerant valve If sweep charging refrigerator sealed system ref
89. efrigerator Zone 4 Evaporator Fan Shroud The lower refrigerator evaporator fan shroud is secured to the evaporator cover assembly with screws To remove the lower evaporator fan shroud extract its mounting screws and pull it from the compartment See Figure 7 30 31 Fan Assembly Lower Refrigerator Zone 4 Evaporator Cover Assembly Switch The lower refrigerator evaporator cover assembly Enclosure includes the evaporator fan assembly and is attached to the back wall with screws Evaporator Qum remove the evaporator cover assembly the left Cover NI drawer slide assemblies and fan shroud must be E m removed first then See Figure 7 30 1 Extract evaporator cover mounting screws 2 Work the compartment thermistor wires through the key hole slot in the left side of the evaporator cover Figure 7 30 3 Lean evaporator cover assembly forward and dis Zone 4 Fan Shroud Evaporator Cover Assembly and connect evaporator fan wire leads then pull assem Light Switch Assembly bly from the compartment Lower Refrigerator Zone 4 Evaporator Fan Assembly The lower refrigerator evaporator fan assembly is attached to the evaporator cover with screws To remove the evaporator fan assembly the left drawer slide assemblies fan shroud and evaporator cover assembly must be removed first then extract evapora tor fan assembly mounting screws and
90. el Figure 2 4 Pre install Specifications TOP VIEW SHOWING FINISHED ROUGH IN DEPTH AND WIDTH 24 610 1219 TOP VIEW Figure 2 5 Rough in Specifications Pro Series 648 Plumbing Requirements This unit comes with an automatic ice maker First rough in water supply line Route water line through floor or within 1 2 13 from wall and no higher than 3 76 from floor If water supply is brought in from behind unit route water line through the wall no more than 3 76 from floor Make connection to home sup ply using enclosed 6 1829 1 4 6 plastic tubing and associated hardware See Figure 2 6 Use an easily accessible shut off valve between water supply and refrigerator The ice maker operates on water pressure of 20 psi 1 4 bar to 100psi 6 9bar If local water supply has high levels of sediment con sider adding an in line filter Do not use self piercing valves as they have the tendency to clog up in time See your Sub Zero dealer for a saddle valve kit ask for part number 4200880 Good water is important for good ice quality It is not recommended that the ice maker be connected to a softened water supply Water softener chemicals such as salt from a malfunctioning softener can damage the ice maker mold and lead to poor ice quality If a soft ened water supply cannot be avoided it is important that the water softener be well maintained and operat
91. ent Access Removal Water Filter Removal The water filter is located behind the grille assembly To remove the water filter 1 Lift Louvered section of grille assembly up See Figure 7 9 2 Rotate filter counterclockwise to remove it See Figure 7 10 clockwise to install it NOTE The water filter timer will reset to a one year countdown when the filter is replaced If the water filter was removed only to service other components press the filter switch five times within five seconds to allow the filter timer to continue the original countdown A Figure 7 9 Lift Grille Louvers beep will be emitted indicating the original countdown has been resumed Water Valve Removal The water valve is attached to the back side of the water valve bracket located behind the grille assembly NOTE Before continuing disconnect or switch off water supply To remove the water valve See Figure 7 11 Lift Louvered section of grille assembly up Rotate water filter counterclockwise to remove it Extract mounting screws from mounting bracket Disconnect wire leads from valve Disconnect water lines from valve Figure 7 10 Water Filter Removal Extract mounting screws from valve mounting bracket Water Valve Electrical Pa Connection Q Screws fl gt Wi Water E Water Connec
92. ent thermistor the light diffuser Compartment and evaporator cover must be removed first then See Thermistor Figure 7 25 1 Extract thermistor mounting screw 2 Cut thermistor s wire leads six 6 to twelve 12 Evaporator inches from the back wall then pull thermistor from Thermistor compartment Upper Refrigerator Zone 3 Evaporator Thermistor The upper refrigerator evaporator thermistor is inserted into the third opening from the top in the evaporator fins left side and extending approximately to the center of the evaporator Figure 7 25 Zone 3 Thermistors To remove the evaporator thermistor the light diffuser and evaporator cover must be removed first then See Figure 7 25 1 Pull thermistor from evaporator fins 2 Cutthermistor s wire leads six 6 to twelve 12 inches from the back wall then pull thermistor from compartment 3758440 Revision A October 2005 Component Access Removal Pro Series 648 Refrigerator Crisper Lid Assembly Removal To remove the crisper lid assembly See Figure 7 26 1 Open top drawer until the slides are fully extended 2 Pull glass crisper lid forward 3 Lift front of crisper lid up and out Drawer Light and Socket Removal The drawer lights are located at the top front of each drawer compartment To remove the drawer light or replace the light socket the drawer assembly must first be removed then See Figure 7 27 1
93. epending on model If not present Zone X F Not Present will appear in display ceo JV WARMER COLDER ICE MAKER POWER LIGHT COLDER WARMER COLDER gt WARMER Figure 3 45 Key Strokes and Tech Display Thermistor Read Diagnostics 4 Activate Zone As mentioned when Service mode is initiated Service Mode 1 Diagnostics appears in the Technician s Display with a small arrow in the bottom right corner pointing right That is the prompt to enter Diagnostics Mode Follow the steps below to work through Diagnostics Mode 4 Activate Zone 1 After initiating Service Mode press ALARM Press COLDER three 3 times 2 3 Press ALARM now and Manual Zone Zone 1 Start gt appears on the display See Figure 3 46 4 If Zone 1 is the desired zone to activate press ALARM If Zone 1 is NOT the desired zone to activate press COLDER until desired zone appears then press ALARM When a zone is activated the compressor will run ICE MAKER at high speed and the compartment s evaporator fan will energize for five minutes During this five lt minute run the activated zone s evaporator and cabinet real time temperatures will be displayed on the Technician s Display Note Zones 2 and 4 may or may not be present depending on model If
94. er Evaporator Electronic Control System Initially the freezer compressor cycle runs 12 hours The control board defrost relay is then closed supplying power to the defrost and drain trough heaters The compressor and evaporator fan are switched OFF With Adaptive Defrost the length of time the defrost heater stays on to open the defrost terminator bimetal 55 F 13 C is observed by the microprocessor via the grey w white stripe wire to P12 9 This length of time is used to calculate the number of hours before the next defrost defrost interval If the heater then stays on for a shorter time period the microprocessor increases the next defrost interval period the microprocessor decreases the defrost interval See Figure 3 25 This is an ongoing process whereby the defrost time and the defrost interval will vary by unit use NOTES A five 5 minute time delay dwell fol lows all defrosts during which the drain trough and fill tube heaters remain energized At the end of the dwell the compressor and evaporator fan are energized and the drain trough heater switches OFF If the freezer is at high offset calling for cooling after the five 5 minute time delay dwell the compressor will switch ON but the evaporator fan will remain OFF until the evaporator has fallen below 20 F 7 C Minimum defrost interval 6 hours of compressor run time Maximum defrost interval 80 hours of com pressor run time
95. er system for 45 minutes after each ice harvest ICEMAKER COMPONENTS Following are descriptions that explain the function of each icemaker component The components are dia gramed in Figure 6 1 on the next page Support The support is the housing around the elec trical components and wire connections The support is attached to the ice mold Mounting Plate The drive motor holding switch water valve solenoid switch timing gear timing cam and water fill adjusting screw are attached to the metal mounting plate The mounting plate is then attached to the support Drive Motor AC power supplied to the drive motor causes the motor to operate The motor has a single output shaft with a small gear The motor gear drives spins the timing gear Timing Gear The timing gear is driven spun by the drive motor gear and is attached to the timing cam Timing Cam The timing cam is attached to the tim ing gear and the ice ejector is inserted into the center of the timing cam As the timing cam rotates high and low spots on the cam operate the water valve solenoid switch and the holding switch The timing cam also moves the lever arm side to side and rotates the ice ejector 3758440 Revision A October 2005 Ice Mold mold is where the eight crescent shaped ice cubes are formed Mold Heater The mold heater uses 175 watts to thaw the ice free from the mold Ice Ejector The drive end of the ice ejector is
96. evaporator thermistor the left drawer slide assemblies fan shroud and evaporator cover assembly must be removed first then See Figure 7 31 1 Pull thermistor from evaporator fins 2 Cut thermistor s wire leads six 6 to twelve 12 inches from the back wall then pull thermistor from compartment 3758440 Revision A October 2005 Pro Series 648 Evaporator Compartment Thermistor Thermistor 7 14 Figure 7 31 Zone 4 Thermistors Pro Series 648PRO Component Access Removal Freezer Interior Cosmetic and Mechanical Components Freezer Shelf Adjustment and or Removal To adjust and or remove a freezer shelf lift up at front slightly then lift back up and out of shelf ladders See Figure 7 32 Light Diffuser Removal The freezer light diffuser is located at the top of the compartment The light diffuser is held in place by C shaped clamps fitting over pegs protruding from the side walls See Figure 7 33 To remove the light diffuser push diffuser toward rear of unit to disengage C shaped clamps from the pegs in the side wall then lower the diffuser down and pull from the compartment Figure 7 32 Freezer Shelf Upper Freezer Light Assembly Removal To remove the upper freezer light assembly Not Illustrated Pegs in Side Wall Extract the screws at each end of the assembly
97. freezer evaporator fan assembly is located behind the freezer evaporator fan shrouds To remove the freezer evaporator fan assembly the freezer bottom shelf and both fan shrouds must be removed first then See Figure 7 44 1 Disconnect wire leads from fan assembly 2 Extract fan assembly mounting screws 3 Lift assembly from the compartment Figure 7 44 Freezer Evaporator Fan Assembly 3758440 Revision A October 2005 Component Access Removal Pro Series 648PRO Icemaker Assembly Removal Screws The icemaker is located behind the bottom freezer drawer mounted on a plate that is attached to the back wall To remove ice maker the freezer drawers must be removed first then See Figure 7 45 1 Extract icemaker mounting screws from below and above ice maker 2 Pull ice maker forward and disconnect icemaker electrical leads 3 Pull icemaker forward out of the compartment Freezer Evaporator Cover Removal The freezer evaporator cover is located behind the top freezer drawer compartment To remove the freezer evaporator cover the freezer bottom shelf needs to be removed first then See Figure 7 46 1 Extract evaporator cover mounting screws 2 Pull cover forward and out of compartment E EJ Freezer Evaporator Cover Freezer Evaporator Thermisto
98. front leveler legs clockwise to raise counterclockwise to lower See Figure 2 12 3 Rear adjustment can be completed from the front of unit through unit base To raise unit rear use 3 8 10 mm socket wrench with an extension to turn 3 8 10 mm rear leveling bolt clockwise to raise counterclockwise to lower See Figure 2 12 NOTE Level is best checked at top amp side of main frame 2 9 Kickplate Figure 2 11 Kickplate Removal Front Leveling Leg Figure 2 12 Unit Leveling 3758440 Revision A October 2005 Installation Information Door Adjustment NOTE Unit must be level before adjusting doors A CAUTION When adjusting hinges it is important to keep hinges parallel to the face of the door and side of the cabinet Excessive misalignment will result in door switch malfunction If switch is not activated the fan will not operate and lights will remain on This will result in elevated cabinet temperatures After hinge adjustments are made check for prop er functioning of door switch If unit is properly installed blocked and leveled it may still be necessary to adjust door s left to right and or in and out Adjustments are performed at top and or bot tom door hinge s 1 2 Open door to about 45 degrees and lift door off the cabinet hinge assembly See Figure 2 13 Open the vent portion of the top grille CAUTION Doors are very heavy Use care and caut
99. ghten all screws reinstall drawer assembly then check door seal for proper gasket seating NOTE Assure the drawer is fully engaged onto the tracks Check alignment of the drawer closer If the closer catch does not align with closer pin adjust the location of drawer closer Horizontal Drawer Adjustment NOTE Before attempting drawer adjustment remove drawer assembly Pull drawer assembly out then lift at front and pull forward until drawer is free from unit See Figure 2 17 1 Loosen screws on the front two slide assemblies See Figure 2 19 2 Move adjust blocks to desired location and tighten screws See Figure 2 19 3 Release rear adjust block by disengaging snaps 4 Move the block forward to shift drawer to the right and back to move to the left Each position will move the drawer 030 8 mm See Figure 2 19 NOTE Both sides should be moved in the same direc tion 5 Snap the block over the pins located on the rear adjuster See Figure 2 19 6 After adjustment tighten all screws reinstall drawer assembly then check door seal for proper gasket seating NOTE Assure the drawer is fully engaged onto the tracks Check alignment of the drawer closer If the closer catch does not align with the closer pin adjust the location of the closer Installation Information Figure 2 17 Drawer Assembly Removal
100. he lower portion of the grille up See Figure 2 8 Disconnect low voltage display cable con necting the grille assembly to the technician s display module Extract the 7 16 11 bolts from grille base Remove the phillips screw from the upper grille Remove the grille in order to access the power cord and to move the unit through doorways To access power cord release the cord from the retainer clips 3758440 Revision A October 2005 Pro Series 648PRO 2 6 UPPER GRILLE SCREW 0 LOW VOLTAGE DISPLAY CABLE LOWER 7 16 11 GRILLE BOLTS Figure 2 8 Grille Removal Pro Series 648PRO Installation Information Moving the Unit After uncrating the unit do not discard the kickplate that is taped to the side of the refrigerator Do not discard the Anti Tip Kit or hardware you will need them to block your installation Carefully move the unit from the crate base onto an appliance dolly Tip to one side removing styrene pads under unit Tip back onto appliance dolly Retract all scissors jacks to their upmost position for easy movement of the unit while installing Remember this unit is very heavy 900Ibs 408kg and enough man power should be used when attempting to move this USE PROTECTIVE CORNERS TO PROTECT DOOR DRAWERS FROM STRAPPING equipment A WARNING Product is very heavy 900 Ibs 408kg keep door s Protect the Flooring and drawer s closed while moving
101. ickplate then pull kickplate forward See Figure 7 1 Drain Pan Removal The drain pan slides in from the front of unit on two side brackets coming to rest on a rear bracket A locking feature was formed into the drain pan that drops into notches at the front of the side brackets To remove the drain pan See Figure 7 2 1 Remove kickplate 2 Push front of drain pan up slightly and pull forward Door Drawer Handle Assembly Removal screw through the handle standoff into the handle secures the handle to the standoff The standoff then slides over a threaded stud that is attached to the door shell A socket head set screw inserted through the standoff secures the standoff to the stud To remove a handle assembly See Figure 7 3 1 Use a 3 32 Allen wrench to loosen the set screw in each handle standoff 2 Pull handle assembly off of the threaded studs Door Removal To remove a door See Figure 7 4 NOTE See WARNING at beginning of this section 1 Open door to ninety 90 degrees 3 Lift door up off off hinge pins NOTE Hinge pins sit loosely in hinge assemblies Take care to not drop the hinge pins during this pro cedure 7 3 Kickplate Figure 7 1 Kickplate Removal Figure 7 2 Drain Pan Removal Handle Mount Screw Threaded Stud Set Screw Handle Handle Standoff Figure 7 3 Handle and Standoff Cut Away View Hinge Pi
102. illary tube which is attached to the suc tion tube these two tubes soldered together create the heat exchanger As the high pressure warm liquid refriger ant travels through the capillary tube it gives up heat to the cool refrigerant gas traveling through the suction tube and the pressure drops so it is a low pressure cool liquid before it enters the evaporator 5 Evaporator s Figure 4 11 As the low pressure cool liquid refrigerant enters the evapo rator it vaporizes This is caused by a dramatic pressure change which occurs when the refrigerant enters the larger diameter evaporator tubing from the smaller diameter capil lary tubing This vapor travels through the evaporator absorbing heat from the compartment gradually converting the vapor to a cool gas This cool gas then enters the suc tion tube 6 Suction Tube s amp Heat Exchanger s Figure 4 12 The cool gas travels through the suction tube which is sol dered to the capillary tube as mentioned earlier these two tubes soldered together create the heat exchanger As this cool refrigerant gas travels through the suction tube it absorbs heat from the warm liquid refrigerant traveling through the capillary tube making it a luke warm gas There is a suction tube T connection that diverts the two separate suction tubes from the evaporators to one suction tube that enters the compressor The lukewarm refrigerant gas is pulled back to the compressor via vacuum force
103. instructions for working through the Service Mode menu can be found on the Technician s For Service Mode Press and hold then press Display cover See Figure 8 1 These basic instructions the Key o 48 7 5 Symbol and Arrows correspond d p with keys on the control panel thus directing the technician as to what keys need be pressed in order to move in the direction indicated by the arrow closest to each key symbol i z For complete Service NOTES Mode menu see back A complete Service Mode O 1 Menu can be found on the back of the wiring diagram and on the next page of this manual WARMER 4 Since it is possible to initiate bypass an or step back through the four different sub modes while in Service Mode initiating Service Mode will always be the first step when explaining how to work through the Service Mode menu for the sub modes CAUTION The grille is connected with a low voltage display cable behind this cover It MUST be disconnected before grille is removed 3758484 B Figure 8 1 Technician s Display with Service Mode Menu 3758440 Revision A October 2005 8 2 Pro Series 648 Troubleshooting Non Service Mode Display Information Prior to initiating Service Mode the following information will appear on the Technician s Display depending on oper ational mode Operational Mode LCD Line 1 LCD Line 2 Power Up Scrolling Messages every 2s Scrolling Messages
104. ion when removing them 3 Remove hinge pins See Figure 2 14 4 Loosen the two cabinet hinge screws 1 4 to 1 2 turn See Figure 2 15 5 Reinstall hinge pin and door With door open use the Allen wrench provided and turn adjustment screw to adjust cabinet hinge See Figure 2 16 6 Close the door and check alignment NOTE If addition adjustment is required loosen the two door hinge screws and adjust as necessary Tighten the two door hinge screws 7 Repeat prior steps until proper alignment is obtained 8 Open door to approximately 45 degrees and lift door off the hinges Remove hinge pins and tighten cabinet hinge screws 9 Reinstall hinge pins and doors 10 Close vent portion of the top grille 3758440 Revision A October 2005 Pro Series 648 Hinge Pin Cabinet Hinge Assembly Hinge Pin Figure 2 16 Cabinet Hinge Adjustment 2 10 Pro Series 648PRO Drawer Adjustments Vertical Drawer Adjustment NOTE Before attempting drawer adjustment remove drawer assembly Pull drawer assembly out then lift at front and pull forward until drawer is free from unit See Figure 2 17 1 Loosen drawer slide mounting screws See Figure 2 18 2 Using a 7 16 11 mm open end wrench turn adjustment screw until proper alignment is obtained See Figure 2 18 3 After adjustment ti
105. l Zone 4 Activ ate Zone gt Zone 1 start lt Manual Zone Zone 2 start Manual Zone 21 51 Cab18 Manual Zone 22 Evp51 Cab 18 Manual Zone Z3 Evp51 Cab 18 lt Manual Zone Zone 3 start anualZone Manual Zone Z4 Zone 4 start 51 Cab18 Diagnostics 5 Statistics gt ServiceMode lt OpStatus Z1 4C ooling 2 OpStatus gt 1 Zone Status gt Def lt OpStatus IceMakerStatus 2 1 Maker gt Harvest Service Mode lt Model PRO48 lt SelectModel Accept New Model 3 Modelinfo gt Change Model gt PRO48 gt No gt c uc Yes gt lt SelectModel Accept New Model PRO48G gt No gt ii Accept New Model gt emiceMode eron into Continuefornumber 4 Version Info gt of models defined Control 01 3 3 lt Version info Hv Micro 02 2 0 Version info EEConf 01 1 1 Version info LtLCD 01 2 0 Version info RtLCD 01 2 0 ersion info Logger 02 2 4 Version info Key pad unknown Version info S N M0000000 3758440 Revision A October 2005 8 4 Pro Series 648PRO Troubleshooting Error Code Table CODE zone SERVIGEINSTRUCTION _ SS Zone X Cabinet Thermistor Failure Device or Wiring Zone X Evaporator Thermistor Failure Device or Wiring X 2 X Condenser Thermistor Failure
106. ling the compressor and evaporator fan are switched ON and if a refrigerator zone the refrigerant valve is switched to the appropriate side See Figure 3 19 When a zone reaches low offset cut out temperature the compressor and evaporator fan are switched OFF Though zone air temperature fluctuates from off and on cycles the average temperature is displayed NOTES Freezer zone temperature range is 5 F 21 C to 5 F 15 C Refrigerator zone temperature range is 34 F 1 C to 45 F 7 C If average zone temperature changes the display will change by only one degree per minute If a freezer zone thermistor is faulty the compressor defaults to 20 minutes on 20 minutes OFF cycling the evap orator fan will cycle with the compres sor at medium fan speed EE LI 115 VOLTS 60 CYCLES appears in appropriate User Display V SERVICE flashes and the Error Code islogged 0000000 meco ner vau f a freezer evaporator thermistor is faulty the freezer compressor and 5 Refrigerator refrigerant evaporator fan will not energize until iu bl solenoid valve opens to zone air temperature exceeds high m appropriate side offset by 5 F 3 C SERVICE flash n If a refrigerator zone thermistor is faulty the compressor defaults to 10 minutes ON 10 minutes OFF cycling cont the evaporator fan will cycle with the BOARD com
107. moval To remove the freezer high side filter drier first captur ing the refrigerant from sealed system then See Figure 7 53 1 With a file score a line around capillary tube 1 or less from drier outlet then fatigue capillary tube at this line until it separates 2 With a tube cutter cut inlet tube 1 or less from drier inlet NOTE It is not recommended to sweat tubing apart Doing so will induce moisture into the sealed system NOTE After capillary tube separates check tubing for internal burrs If burrs exist repeat step 1 above NOTE When installing replacement filter drier insert capillary tube until it touches screen inside drier then pull capillary tube away from screen approximately 3 8 before brazing See Figure 7 54 NOTE Filter drier outlet must be facing downward in order to function properly Refrigerator High Side Filter Drier Refrigerant Valve Assembly Removal To remove the refrigerator drier valve assembly first capturing the refrigerant from sealed system then See Figure 7 55 1 With a file score a line around capillary tubes 1 or less from drier valve outlet tubes then fatigue capil lary tubes at these lines until they separate 2 With a tube cutter cut inlet tube 1 or less from drier inlet NOTE It is not recommended to sweat tubing apart Doing so will induce moisture into the sealed system NOTE After capillary tube separates check tubing for internal burrs If bu
108. n L Cabinet Hinge Assembly Figure 7 4 Door Removal 3758440 Revision A October 2005 Component Access Removal Drawer Assembly Removal To remove a drawer assembly See Figure 7 5 1 Open drawer until the slides are fully extended 2 Lift front of drawer up then continue pulling drawer forward off of slides Door and Drawer Gasket Removal A dart at the back of the door and drawer gaskets fit into channels built into the door and drawer liners NOTE To remove a drawer gasket the drawer must be removed from the unit To remove a door or drawer gasket pull the gasket dart from the channel in the door or drawer See Figure 7 6 NOTE On older models silicone may have been used at the corners of the gasket to help hold it in place Cabinet Hinge Assembly Removal Cabinet hinge assemblies are mounted to the exterior of the appliance The upper hinge assemblies house the door light switches To remove a cabinet hinge assembly 1 Remove door 2 Extract hinge mounting screws See Figure 7 7 3 Disconnect wire leads from unit See Figure 7 8 3758440 Revision A October 2005 Pro Series 648PRO Y Figure 7 6 Door Drawer Gasket Removal Hinge Mounting Screws 55 Figure 7 8 Disconnect Wire Leads Pro Series 648PRO Compon
109. ng Water Valve Powered 15 Sec Icemaker System Disabled Ui 4 4 111 11 SERVICE lt an aum ees Figure 3 38 SERVICE alone Flashing Multiple Possibilities See Error Code History Figure 3 39 3758440 Revision A October 2005 Double Dashes Displayed Zone Manually Disabled Jreus zerog Pro Series 648PRO Electronic Control System SERVICE MODE Troubleshooting Input Operations The service features in this electronic control system allow the technician to perform a series of key strokes at the control panel in order to verify configure query and troubleshoot the appliance and its electronic control system These service features are activated while in the four sub modes of the Service Mode The four sub modes of the Service Mode are 1 Diagnostics Mode 2 Operational Status Mode 3 Model Information Mode 4 Version Information Mode The technicians display located behind the top grille assembly utilizes a two 2 line X sixteen 16 character LCD While in Service Mode this display will indicate which sub mode is active the data being searched for and what other data can be accessed When not in the Service mode the Technician s display will indicate system informa tion as defined for each particular operational mode Basic instructions for working through the
110. not present Manual Zone Not Present will appear in display 9 cower JV WARMER COLDER ALARM LIGHT COLDER WARMER COLDER fe WARMER Figure 3 46 Key Strokes and Tech Display Thermistor Read 3 31 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO cc Diagnostics 5 Statistics As mentioned when Service mode is initiated Service Mode 1 Diagnostics appears in the Technician s Display with a small arrow in the bottom right corner pointing right That is the prompt to enter Diagnostics Mode Follow the steps below to work through Diagnostics Mode 5 Statistics 1 After initiating Service Mode press ALARM 2 Press COLDER four 4 times 3 Press ALARM now See Figure 3 47 and it is possible to work through the following ten 10 levels Ice Maker gt Number of ice harvests 14 days Number of minutes ON in 14 days Self Test gt Amount of time since last self test was implemented 1 Running Time gt Total days hours and minutes unit has been operating 2 Power Cycles gt Total number of power cycles unit has performed 3 Run Btwn Def gt of freezer compressor run time between freezer defrosts four possible zones 4 Run 50 Cycles
111. ointing right NOTES By following the basic directions on the Technicians Display cover and the prompts that appear in the 5 Display a Service Technician will be able to work through the Service Mode menu to the desired verification point configuration portion and troubleshooting section of the menu For sake of space the directions that follow will not explain or show what is seen in the display 4 after each key stroke Only the final and or desired result will be explained and illustrated There are three 3 ways to exit Service Mode 1 To exit the Service Mode at any time press the ICE MAKER key repeatedly until com c3 pletely out of Service Mode menu 2 Pressing the POWER key will switch the unit OFF and exit Service Mode 3 If no keys are pressed for five 5 minutes after initiating Service Mode the electronic control will automatically exit the mode J COLDER COLDER WARMER ICE MAKER POWER COLDER WARMER ALARM LIGHT COLDER WARMER Figure 3 41 Key Strokes and Tech Display Initiate Service Mode 3 27 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO cc Service Mode 1 Diagnostics Sub Mode There are five levels under Diagnostics Mode they are 1 Self Test 2 Error Code History 3 Thermisto
112. omplete Installation Guide A WARNING IF UNIT IS UNDER A SOLID SOFFIT AND CLEARANCE BETWEEN TOP OF UNIT AND SOFFIT IS GREATER THEN 1 25 4 mm OR IF SOFFIT IS NOT SOLID UNIT COULD TIP FORWARD UNDER CERTAIN LOAD CONDITIONS FAILURE TO INSTALL ANTI TIP COMPONENTS AND EXTEND LEVELERS TO FLOOR ACCORDING TO INSTALLATION MANUAL COULD RESULT IN SERIOUS INJURY OR DEATH MAKE SURE THERE ARE NO ELECTRICAL WIRES OR PLUMBING THAT THE SCREWS CAN COME INTO CONTACT WITH A CAUTION Always wear safety glasses and other necessary protective devices or apparel when installing or working with anchors Not recommended for use in light weight masonry material such as block or brick Use of core drills not recommended to drill holes for this anchor Not recommended for use in new concrete which has not had sufficient time to cure Anti Tip Components Installation All Models NOTE The anti tip bracket is included and fastened to crate base at the front of the unit NOTE Use the center line reference point on the anti tip bracket to assure proper alignment and engagement of the product to the anti tip bracket See Figure 2 9 1 Install anti tip bracket exactly 26 660 mm from front face frame centered in the rough opening See Figure 2 10 NOTE The 26 660 mm measurement is from the front face frame to the back of the anti tip bracket 2 Drill 6 pilot holes 3 16 5 mm diameter maximum for mounting an
113. ontains the wiring schematic of the model 648PRO See Figure 3 1 Input operations for the electronic control system are performed at the membrane switch part of the the control panel assembly with monitoring reg ulating and controlling functions taking place at the main control board Temperatures mode activation icons and possibly error indicators are displayed on the two user displays The entire electronic control system is described in greater detail on the following pages Electronic Control System NOTE For more detailed electrical diagrams refer to the wiring diagram and schematic supplied with the unit
114. op inlet and outlet NOTE It is not recommended to sweat tubing apart Doing so will induce moisture into the sealed system 2 Extract tubing from heater loop brackets Component Access Removal 7 25 Figure 7 59 Drain Pan Heater Loop Removal 3758440 Revision A October 2005 Component Access Removal Pro Series 648PRO 3758440 Revision A October 2005 7 26 Pro Series 648PRO Troubleshooting SECTION 8 TROUBLESHOOTING GUIDES Troubleshooting Pro Series 648PRO Jrevs zenog SERVICE MODE Troubleshooting Input Operations The service features in this electronic control system allow the technician to perform a series of key strokes at the control panel in order to verify configure query and troubleshoot the appliance and its electronic control system These service features are activated while in the four sub modes of the Service Mode The four sub modes of the Service Mode are 1 Diagnostics Mode 2 Operational Status Mode 3 Model Information Mode 4 Version Information Mode The technicians display located behind the top grille assembly utilizes a two 2 line X sixteen 16 character LCD While in Service Mode this display will indicate which sub mode is active the data being searched for and what other data can be accessed When not in the Service mode the Technician s display will indicate system informa tion as defined for each particular operational mode Basic
115. or compartment To remove the control panel 1 Remove the top light diffuser 2 Disconnect the communication cables from the left Light Strip P rear side of the control panel See Figure 7 22 3 Extract screws from the top rear of the control panel olo and pull the assembly down and out Figure 7 21 LED Light Strip Removal Upper Refrigerator Zone 3 Light Assembly Removal a remove the upper refrigerator light assembly the gt 0 Ll control panel must first be removed then Not Illustrated e A 1 Extract the screws at each end of the assembly T 2 Lower the light assembly down and disconnect the Ja sy wire leads behind the right side c x 3 Now push the communication cable grommet from lt lt the hole at the left end and remove the Communication Cables tion cables from the hole Figure 7 22 Control Panel Removal 7 9 3758440 Revision A October 2005 Component Access Removal Pro Series 648 Upper Refrigerator Zone 3 Evaporator Cover Removal The bottom of the evaporator cover is secured by slots in the side flanges that fit over pegs at the bottom of each shelf ladder The top is secured by screws hold ing it to the evaporator fan shroud To remove an evaporator cover the light diffuser must be removed first then See Figure 7 23 1 Extract screws from top of evaporator cover 2 Tilt cover forward and lift off of
116. own through the Self Test Data If there are no problems the display will read Self Test Data Board OK corr Lb COLDER WARMER ALARM COLDER WARMER COLDER WARMER Press ALARM key 3 times Figure 3 42 Key Strokes and Tech Display Self Test ICE POWER 3758440 Revision A October 2005 3 28 Pro Series 648PRO Diagnostics 2 Error History As mentioned when Service mode is initiated Service Mode 1 Diagnostics appears in the Technician s Display with a small arrow in the bottom right corner pointing right That is the prompt to enter Diagnostics Mode Follow the steps below to work through Diagnostics Mode 2 Error History 1 After initiating Service Mode press ALARM key once 2 Press the COLDER key once 3 Press the ALARM key two 2 times Now if error codes are present the most recent will be displayed See Figure 3 43 Below the Error Code will be the number of days hours and minutes since the error was logged NOTE Though there are ninety nine possible Error Codes twenty is the most that can be stored If over twenty occur the newest error code over writes the oldest 4 To see if multiple error codes are logged press the COLDER key to toggle down through the Error History NOTE See following page for Error Code Table
117. place User Display 1 94 Check Wiring Replace User Display 2 96 Datalogger Malfunction 97 Check Communications Cables Connectors 98 Brownout Check Input Power Supply Explanation of zone error codes G ZONES If X 0 Failure was with a common component If X 1 Failure occurred in Zone 1 or left system If X 2 Failure occurred in Zone 2 If X 3 Failure occurred in Zone 3 or right system If X 4 Failure occurred in Zone 4 Note Zone 2 and zone 4 may or may not be present depending on model 3758440 Revision A October 2005 3 30 Pro Series 648PRO Diagnostics 3 Thermistors As mentioned when Service mode is initiated Service Mode 1 Diagnostics appears in the Technician s Display with a small arrow in the bottom right corner pointing right That is the prompt to enter Diagnostics Mode Follow the steps below to work through Diagnostics Mode 3 Thermistor Read WARMER 4 1 After initiating Service Mode press ALARM 2 Press COLDER two 2 times 3 Press ALARM now and the ambient thermistor is the first to be read See Figure 3 45 Electronic Control System 4 Press the COLDER key to toggle down through the other thermistor readings These readings are real time temperatures with den no temperature averaging as seen on the User Displays Note Zones 2 and 4 may or may not be present d
118. possess an accent lighting system which allows the lights on each side of the upper refrigerator zone to stay ON when the door is closed To make this happen press the LIGHT key See Figure 3 9 To switch back to normal operation so that the lights on each side of the upper refrigerator zone switch ON and OFF with light switch activation press the LIGHT key again ICE MAKER POWER ALARM LIGHT COLDER WARMER COLDER COLDER WARMER WARMER Figure 3 9 648PROG Accent Lighting System ON or OFF Press the LIGHT Key 3 7 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO cc UNIQUE ELECTRONIC CONTROL INPUT OPERATIONS The following pages illustrate unique customer input operations performed at the control panel The input operations described are Temperature Unit Selection Mode Sabbath Mode Showroom Mode Manual Zone Disable Mode and Manual Freezer Evaporator Defrost Temperature Units Selection Mode Selecting Degrees Fahrenheit or Degrees Celsius Display The appliance is initially set to display temperatures in Fahrenheit temperature units of measure indicated by the F on the User Displays above the appliance icons This can be changed so Celsius units of measure are displayed by initiating Temperature Units Selection Mode NOTE Temperature Units Selection
119. pressor and or the refrigerant valve at medium fan speed EE appears in appropriate area of User x Display SERVICE flashes and the MA 122 4 Compressor s energized Error Code is logged su WSEEED BROWN LT BLUE If a refrigerator evaporator thermistor _ CONTROL NON GLASS es and the Error Code is logged Lt se DOOR ONLY is faulty the refrigerator compressor REFRIGERATOR gt gt comPRESSOR and evaporator fan will not energize SED arme TT vree CONTROL BROWN and or the refrigerant valve will not switch sides until zone air tempera POOR ONE ture exceeds high offset by 5 F 3 C SERVICE flashes and the Error Code is logged LOW VOLTAGE EA If in Sabbath Mode the zone thermis tors still control compressor opera tion except that when high offset is reached there is a random 15 to 25 second delay before a compressors is energized LT BLUE 2 Zone s calling for cooling m Temp above high offset REF CABINET Lc Lc
120. pull fan assem bly from evaporator cover See Figure 7 30 Lower Refrigerator Zone 4 Light Switch Removal The light switches for the lower refrigerator zone are located in the right rear switch enclosure The enclo sure is held to the back wall with screws To remove a light switch the right drawer slide assem blies fan shroud and evaporator cover assembly must be removed first Then See Figure 7 30 1 Extract switch enclosure mounting screw 2 Pull enclosure forward and disconnect switch elec trical leads 3 Depress tabs at back side of switch and push switch from switch enclosure 7 13 3758440 Revision A October 2005 Component Access Removal Lower Refrigerator Zone 4 Compartment Thermistor The lower refrigerator compartment thermistor is attached to the left side wall with screws and tube clamps To remove the compartment thermistor the left drawer slide assemblies fan shroud and evaporator cover assembly must be removed first then See Figure 7 31 1 Extract screws and clamps holding thermistor to left side wall 2 Cut thermistor s wire leads six 6 to twelve 12 inches from the back wall then pull thermistor from compartment Lower Refrigerator Zone 4 Evaporator Thermistor The lower refrigerator evaporator thermistor is inserted into the third opening from the top in the evaporator fins left side and extending approximately to the center of the evaporator To remove a
121. r Drier Figure 4 8 The high pressure warm liquid travels through the high side filter drier which removes moisture from the refrigerant before it enters the dual refrigerant valve 3 Dual Refrigerant Valve Figure 4 9 A Tubing T connection that is part of the dual refrigerant valve has a bead inside This bead is forced to one side or the other of the T connection depending on the electrical signal from the control board to the valve solenoid When the bead is to one side of the T connection that side is closed the other side is open The open side allows the high pressure warm liquid to the appropriate capillary tube Compressor Door Gasket Seat Heater Loop in Mullion Sag NS 4 Figure 4 7 Compressor Condenser High Side Y Filter Drier V 2 Dual rd Refrigerant Valve gt NS 4 Figure 4 8 Condenser amp Filter Drier 3758440 Revision A October 2005 4 6 Figure 4 9 Dual Refrigerant Valve Pro Series 648PRO Sealed System Information 4 Capillary Tube s Figure 4 10 The high pressure warm liquid refrigerant travels through the long skinny cap
122. r Read 4 Activate Zone 5 Statistics The next few pages explain the steps for working through the five levels of Diagnostics Mode For sake of space the directions that follow will not explain or show what is seen in the display after each key stroke Only the final and or desired result will be explained and illustrated Diagnostics 1 Self Test As mentioned when Service mode is initiated Service Mode 1 Diagnostics appears in the Technician s Display with a small arrow in the bottom right corner pointing right That is the prompt to enter Diagnostics Mode Follow the steps below to work through Diagnostics Mode 1 Self Test 1 After initiating Service Mode press ALARM key three 3 consecutive times Self Test Active appears on display See Figure 3 42 During Self Test which lasts approximately ninety 90 seconds the main controller board cycles through all relays and triacs switching components ON and OFF and checking for correct feedback information from various electrical components For example each evaporator fan will be energized for a few sec onds regardless of the door being opened or closed Then if a relay or triac fails to function properly or incorrect feedback is received a ICE MAKER message will appear on the Technician s Display headed by the words Self Test Data c with words indicating where the problem exists 2 To see if multiple problems were detected press the COLDER key to toggle d
123. r Removal The freezer evaporator thermistor is inserted into the third opening from the top in the evaporator fins left side and extending approximately to the center of the evaporator To remove the evaporator thermistor See Figure 7 47 1 Pull thermistor from evaporator fins 2 Cutthermistor s wire leads six 6 to twelve 12 inches from the back wall then pull thermistor from compartment o Freezer Defrost Terminator Removal Defrost Terminator The freezer defrost terminator sits on the tubing at the upper left hand side of the evaporator gt To remove the defrost terminator See Figure 7 47 1 Disconnect the terminator clip from the evaporator tubing 2 cable ties at the back wall 3 Disconnect terminator electrical leads then pull the terminator from the freezer compartment Evaporator Thermistor Figure 7 47 Freezer Evaporator Thermistor amp Defrost Terminator 3758440 Revision A October 2005 7 18 Pro Series 648PRO Freezer Defrost Heater Removal The freezer defrost heater is located under the freezer evaporator and is held in place by a heater bracket that is screwed to the back wall To remove the freezer defrost heater See Figure 7 48 1 Cut heater electrical leads at wiring junction points 2 Extract heater bracket mounting screws 3 Lift defrost heater from freezer compartment Freezer Drain Trough Hea
124. r filter When the filter is installed the switch behind the fil ter is depressed closed telling the microprocessor to start the filter timer countdown see Figure 30 After approxi mately one 1 year of use the REPLACE FILTER icon on the left User Display will appear See Figure 3 31 Removing the filter will will open the switch and replacing the filter with a new one the switch When this is done the REPLACE FILTER Ll 115 VOLTS Em socycies NEUTRAL icon will disappear and the countdown Le V will start over E i NOTES If removing the filter for service pur poses it is possible to avoid restart ing the filter timer by depressing the ET filter switch five 5 times within five 5 seconds before replacing the filter a al If this is done the timer will resume Filter switch monitored by microprocessor When switch is closed 1 year countdown begins counting from when the filter was removed One unique operation that is possible di when in Showroom Mode is to force n BOARD the REPLACE FILTER icon to appear Do this by pressing and holding the ICE MAKER key for five so seconds but only if the filter is in m place to deactivate the REPLACE FILTER icon the filter must be removed then replac
125. r line Water Supply 35 psi 2 4 bar to 120 psi 8 3 bar Annual Energy Usage 689 kWh 58 based on 8 29 cents per kilowatt hour Shipping Weight 648PRO 860 Ibs 390 kg 648PROG 875 lbs 397 kg Specifications are subject to change without notice 1 7 3758440 Revision A October 2005 General Information Pro Series 648PRO 3758440 Revision A October 2005 1 8 Pro Series 648PRO Installation Information SECTION 2 INSTALLATION INFORMATION Installation Information RECOMMENDED TOOLS AND MATERIALS Below is a list of tools and materials that should be used during the installation of a Pro Series Unit Phillips screwdriver set Slotted screwdriver set Copper tubing cutter 4 1219 mm of 1 4 6 mm copper tubing and water line saddle valve Saddle valve for the water line Part 4200880 Level 2 610 mm and 4 1219 mm are recom mended Appliance Dolly able to support 1 000 Ibs 454kg with proper manpower to handle weight Various sized pliers Wrench set Allen wrench set e 1 2 13 mm drive socket set with 10 254 mm socket extension Crescent wrenches Cordless drill and assorted drill bits Masonite plywood 1 8 pressed fiberboard or card board or some other suitable material for floor pro tection Moving blankets for protection of product and home 6 Lobe Torx drive bits or 6 Lobe screwdrivers
126. rain Pan Heater Tubing Figure 4 2 Condenser Figure 4 3 High Side Filter Drier 3758440 Revision A October 2005 4 4 Pro Series 648PRO Sealed System Information 4 Capillary Tube Part of Heat Exchanger Fig 4 4 The high pressure warm liquid refrigerant travels through the long skinny capillary tube which is attached to the suc tion tube these two tubes soldered together create the heat exchanger As the high pressure warm liquid refrig erant travels through the capillary tube it gives up heat to the cool refrigerant gas traveling through the suction tube and the pressure drops so it is a low pressure cool liquid before it enters the evaporator 5 Evaporator Figure 4 5 As the low pressure cool liquid refrigerant enters the evap orator it vaporizes This is caused by a dramatic pressure change which occurs when the refrigerant enters the larger diameter evaporator tubing from the smaller diameter capil lary tubing This vapor travels through the evaporator absorbing heat from the compartment gradually converting the vapor to a cool gas This cool gas then enters the suc tion tube 6 Suction Tube amp Heat Exchanger Figure 4 6 The cool gas travels through the suction tube which is attached to the capillary tube as mentioned earlier these two tubes soldered together create the heat exchanger As this cool refrigerant gas travels through the suction tube it absorbs heat from the warm liquid
127. re Date LISTED HOUSEHOLD REFRIGERATOR OR FREEZER R CO MADISON e 200 SERIAL NO TOTAL AMPS 4 0 REFRIGERANT VERIFIED R134a PERFORMANCE NEASETIQUE n Refrigerant Charge 115V 6062 1 PHASE 890 222 7820 Total Amps Refrigerant Type Figure 1 1 Serial Tag Layout 1 5 3758440 Revision A October 2005 General Information Pro Series 648 648PRO Side by Side Refrigerator Freezer Model Features Stainless steel construction Dual refrigeration system Easy access grille Exterior temperature display Water filter Alarm Advanced lighting Microprocessor and interior control panel Auto close hinge system Adjustable stainless Model 648PROG with Glass Door This appliance is certified by steel shelves Automatic ice maker Star K to meet strict religious regulations in conjunction with specific instructions Model 648PROG shown Holiday mode Triple pane UV resist ant glass 648PROG Adjustable spill proof glass shelves Slide out stainless steel
128. refrigerant traveling through the capillary tube making it a luke warm gas The lukewarm refrigerant gas returns to the compressor where Figure 4 4 Capillary Tube Part of Heat Exchanger Capillary Tube the process begins again Accumulator Evaporator Suction Tube Heat Exchanger Figure 4 5 Evaporator 4 5 Figure 4 6 Suction Tube Part of Heat Exchanger 3758440 Revision A October 2005 Sealed System Information Pro Series 648 REFRIGERATOR SEALED SYSTEM OPERATION The following six diagrams illustrate a 648PRO refrigerator sealed system The components are listed in order of refrigerant flow with an explanation of their fundamental role as part of a sealed system 1 Compressor Figure 4 7 The compressor creates a high and low side pressure dif ference in the sealed system by compressing the refrigerant gas raising its pressure and temperature The compressor pushes the high pressure high heat gas through the heater loop in the mullion to prevent sweat then to the condenser 2A Condenser Figure 4 8 The high pressure high heat gas travels through the con denser where the heat is dissipated by cooler air being drawn over the condenser tubing by the condenser fan This changes the gas into a high pressure warm liquid that then enters the high side filter drier 2B Filte
129. reus zerog Pr o Series 648PRO Airflow amp Fan Blade Spacing SECTION 5 AIRFLOW AND FAN BLADE SPACING Airflow amp Fan Blade Spacing Pro Series 648 AIRFLOW DIAGRAMS UPPER REFRIGERATOR FAN BRACKET TO FAN BLADE HUB SPACING 1 3 8 1 16 34 93 mm 1 59 mm Clamp Down FREEZER FAN BRACKET TO FAN BLADE HUB SPACING LOWER REFRIGERATOR FAN BRACKET TO FAN BLADE HUB SPACING 1 3 16 1 16 30 16 mm 1 59 mm 1 1 8 x 1 16 28 58 mm 1 59 mm Clamp Up Clamp Front Figure 5 1 Air Flow and Fan Blade Spacing Model 648PRO 3758440 Revision A October 2005 5 2 Pro Series 648PRO Information SECTION 6 ICEMAKER INFORMATION 6 1 3758440 Revision A October 2005 Icemaker Information Pro Series 648 ICEMAKER SYSTEM INFORMATION All 648PRO series units utilize a MidSouth icemaker Icemaker operation is not complex but icemaker com ponents and operation cycles should be understood by a Service Technician in order to make proper diagnosis A WARNING TO AVOID ELECTRIC SHOCK ALWAYS DISCON NECT ELECTRICAL POWER TO UNIT WHEN SER VICING ICEMAKER NOTE The ICE MAKER key at the control panel acti vates the icemaker system If the ice making icon is not displayed on the LCD the icemaker system is OFF NOTE To allow ice to freeze fully and reduce effects of low water pressure the electronic control disables the icemak
130. riate area of User Display ni SERVICE flashes and the Error Code Jn Hi is logged Des If a refrigerator evaporator thermistor is faulty the refrigerator compressor will not energize and or the refriger ant valve will not switch sides until zone air temperature exceeds high offset by 5 F 3 C SERVICE flash es and the Error Code is logged Er ES MAIN CONTROL zx BOARD ui n 3 Compressor will not switch REFRIGERATOR COMPRESSOR LT BLUE VSPEED STARTING RELAY CONTROL BROWN BOX REF FOR GLASS DOOR ONLY Co Co C3 BLACK DC POWER LOW VOLTAGE ae 1 RED mo 1 Refrigerator compartment es thermistor s at high offset AY 5 i 15 E LJ ps ci BROWN P16 DI p MAIN 2 a4 r1 CONTROL A BOARD 1_ 2 Refrigerator evaporator ii Des thermistor s below 38 F Qua 7 3 C PB a 5 fan s will not switch on Figure 3 24 Signal Trace Schematic of Refrigerator Off Cycle Defrost 3758440 Revision A October 2005 3 18 Pro Series 648 Monitor and Control Adaptive Defrost of Freez
131. rigerant valve must be energized during procedure See Diagnostics 4 Activate Zone in Section 3 i Recharge with Virgin 134a refrigerant Examples gt Burned out compressor gt Excessive moisture from 2o79oo0com Restriction Capture refrigerant Locate and remove restriction locate and replace part NOTE If restriction is due to Back flush high side of sealed system sealed system being contami Replace filter drier nated see Contaminated Evacuate or sweep charge system Sealed System above NOTE If evacuating refrigerator sealed system unit must be evacuated from the low amp high sides due to refrigerant valve If sweep charging refrigerator sealed system refrigerant valve must be energized during procedure See Diagnostics 4 Activate Zone in Section 3 f Recharge system with Virgin 134a refrigerant Overcharge a Capture refrigerant b Replace filter drier e Evacuate or sweep charge system NOTE If evacuating refrigerator sealed system unit must be evacuated from the low amp high sides due to refrigerant valve If sweep charging refrigerator sealed system refrigerant valve must be energized during procedure See Diagnostics 4 Activate Zone in Section 3 d Recharge system with Virgin 134a refrigerant 4 3 3758440 Revision A October 2005 Sealed System Information Pro Series 648PRO Jreus zerog FREEZER SEALED SYSTEM OPERATION The following six diagrams illustrate
132. ritt a ntes 7 4 Door Drawer Gaskets 7 4 Gabine t HINGES i4 irr 7 4 cuiii 7 5 Water E 7 5 Grille Assembly Aelia 7 6 Grill SpFihg aetate unten 7 6 User DISplays ere risit esi cain anioni 7 6 Main Controller Board 7 7 Unit Shro d erbe derit 7 7 3758440 Revision A October 2005 General Information Pro Series 648 Page Refrigerator Interior Cosmetic Mechanical 7 8 EI ES 7 8 Shelf Assembly iii 7 8 Upper Light DIfIUSer c ca nigi 7 8 LED Accent Lights iade totes 7 9 Control Panel ie alia 7 9 Upper Light Assembly eee 7 9 Upper Evaporator Cover 7 10 Upper Evaporator Fan Shroud Assembly 7 10 Upper Evaporator Fan 7 10 Upper Compartment Thermistor 7 11 Upper Evaporator Thermistor 7 11 Crisper Lid Assembly etnies 7 12 Drawer Light Socket eiue em 7 12 Drawer Closer edo ed 7 12 Drawer Slide Assembly 7 12 Lower Evaporator Fan 7 13 Lower Evapora
133. rrs exist repeat step 1 above 7 21 Figure 7 53 Freezer Filter Drier Removal Cut Here High Side Filter Drier n 7 220 Cut Here D E TE Cut Here Cut Here Cut Here High Side Filter Drier Figure 7 55 Refrigerator Drier Valve Assembly 3758440 Revision A October 2005 Component Access Removal Compressor Removal Compressors are secured to the top of the unit with nuts over stud bolts The left compressor is the freezer compressor the right compressor is the refrigerator compressor NOTE When replacing a compressor the high side fil ter drier must also be replaced After capturing the refrigerant from sealed system See Figure 7 56 1 Disconnect electricals from compressor 2 Extract nuts from stud bolts at each corner of com pressor base 3 Lift compressor up and pull forward to gain access to suction and discharge lines 4 Using a tube cutter cut suction and discharge lines approximately 1 from compressor NOTE It is not recommended to sweat tubing apart Doing so will induce moisture into the sealed system Condenser Removal NOTE When replacing the condenser both high side filter driers must also be replaced To remove the condenser the unit shroud will need to be removed first then after capturing the refrigerant from sealed system See Figure 7 57
134. ses light switch opera tion Li P8 e D 5 DC POWER LOW VOLTAGE 1 I P4 05 1 P12 20 2 r1 1 P13 I A 2 Evaporator fan HE switched on for 5 MAIN ha minutes even if m CONTROL Lm BOARD compressor IS 2 Door heater not energized Ur on with con Ig 7 denser fan E 5 Ue BEY YY 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO cc Monitor and Control Refrigerator Fan Assisted Off Cycle Defrost Temperature signals from refrigerator evaporator s thermistor s are observed by the microprocessor During off cycle defrost if a refrigerator zone temperature reaches high offset calling for cooling before evaporator temperature rises to 38 F 3 C no power will be supplied the the compressor and or no or pulse signal will be supplied to the refrigerant valve But the the zone evaporator fan will switch ON at low speed Once the evaporator temperatur reaches 38 F 3 C normal cooling functions begin See Figure 3 24 11 115VOLTS NOTES refrigerator zone thermistor is GOCYCLES faulty the refrigerator compressor defaults to 10 minutes 10 min utes OFF cycling the evaporator fan will cycle with the compressor at medium fan speed EE appears in approp
135. t Thermistor Failure Device or Wiring 702 X 2 7 Evaporator Thermistor Failure Device or Wiring 7 Zone X Condenser Thermistor Failure Device or Wiring 04 o Ambient Thermistor Failure Device or Wiring 20 X Check Zone X Defrost Bi metal for Proper Operation Check Zone X Defrost Bi metal for Proper Operation Check Zone X Defrost Wiring Check Zone X Defrost Wiring 24 X Check Zone X Defrost Heater Ohms 30 o Check for Stuck Icemaker or Water Valve Failure Check Zone X Fan Fan Speed Error 40 X X Excessive Run gt gt Check Zone X Compressor and Wiring 42 0 Check Condenser Fan and or Wiring 44 X Check Zone X Glass Door Heater and Wiring Errors Detectable with Red Door Switches Disabled Now Check Overhead Lighting 46 0 Check Ice Accessory Wiring for Open Circuit Check Accent Lighting Wiring for Short Circuit X Check Power to Compressor Controller for Zone X Troubleshoot with Manual Activation Mode Replace Zone X VS Compressor and Filter Drier 84 X Check Zone X VS Compressor Wiring 35 x Zone X VS Compressor Control Overheat 86 X Check Communication Wiring Replace Zone X VS Controller Check for Broken Wiring or Open Defrost Heater 89 X Check Icemaker Solenoid Valve and Wiring 90 x Change Main Control Board 92 0 Check Keypad Wiring 93 o Replace Keypad 94 Check Wiring Re
136. t is in Sabbath Mode NOTE The defrost terminator opens at fifty five 55 F 13 C degrees and closes at thirty 30 F 1 C degrees so it will not allow power to the defrost heater if the evaporator is above thirty degrees JB 3B ICE MAKER POWER ALARM LIGHT COLDER WARMER COLDER WARMER COLDER armen Press and hold for 5 seconds Figure 3 17 Initiate Manual Freezer Evaporator Defrost Press and Hold ICE MAKER Key for 5 Seconds 3758440 Revision A October 2005 Electronic Control System Pro Series 648PRO cc FUNCTIONS OF THE ELECTRONIC CONTROL SYSTEM The following pages explain monitoring regulating and controlling functions of the electronic control system Signal traces on a model 648PRO wiring schematic are used to show current flow for functions being explained Supply Power to the Lighting System Power is supplied to the lighting system through the control board when the unit is switched ON by pressing the POWER key With a door or drawer open light switches allows power to the lights See Figure 3 18 NOTES Power to the upper refrigerator lights is monitored by the microprocessor to control switching ON and OFF of the accent lights This information is ignored if the accent lighting system has been switched to 10
137. te of the compressor relays to determine the length of compressor run time See Figure 3 26 If a compressor runs 100 Fre 6 hours Ref 4 hours an error code is logged and defrost is initiated but SERVICE will not flash If several 10096 run periods occur and the compartment temperature does not ce NEUTRAL fall to at least the set point low off set V temperature average and the door is not opened during the last run period then SERVICE alone will flash See Figure 3 27 1 NOTE To clear a flashing SERVICE D P120 fe the problem must be corrected the Dr all Error Code must be cleared from mem ory while in Service Mode and the unit _ must be switched OFF then back ON n MAIN 24 m CONTROL 1 e BOARD Length of compressor run time is ps nia monitored by microprocessor s PURPLE VSPEED Fener CONTROL BROWN IT BLUE soc BOXFZ FRN DOOR ONLY REFRIGERATOR COMPRESSOR LT BLUE STARTING RELAY CONTROL BROWN 1 BOX REF BLACK FOR GLASS DOOR ONLY DC POWER LOW VOLTAGE 1 I 7 05 1 P1
138. tect a fin ished floor with masonite plywood 1 8 3 mm pressed fiberboard or some other suitable material before moving the refrigerator across it Make sure the opening where the unit is to be installed is properly prepared Refer to the Pre Installation Specifications illustration chart to be sure of the rough in dimensions electrical service and plumbing are cor rect for the model you are about to install Electrical Requirements To prepare the electrical system rough in the electrical outlet following the Pre Installation Specifications You will need a 115 Volt 60 Hertz electrical supply Dedicate a separate 15 Amp fuse or circuit breaker to the Sub Zero unit and follow any local codes that apply The Sub Zero unit comes with a power supply cord with a three prong grounded plug The refrigerator must be plugged into a mating three prong wall receptacle grounded in accordance with the National Electrical Code and local codes 3758440 Revision A October 2005 2 4 TOP VIEW EXTEND WATER LINE APPROX 37 940 FROM BACK WALL SHUT OFF VALVE Top View NOTE Dimensions in parentheses are in millimeter LOCATE ELECTRICAL WITHIN SHADED AREA 471 2 1206 ROUGH OPENING WIDTH 831 8 751 2 2111 1918 MINIMUM HEIGHT OPENING REQUIRED HEIGHT LEVELERS IN LOCATE WATER SUPPLY WITHIN SHADED AREA 3 76 4 5 8 gt 117 Y Floor Lev
139. ter Removal The drain trough heater is located at the bottom rear of the freezer compartment behind the lower freezer evaporator cover assembly To remove the drain trough heater access the drain trough heater the freezer drawers and the icemaker assembly must be removed first then See Figure 7 49 1 Cut heater wire leads at their junction points 2 Extract heater bracket mounting screws 3 Lift drain trough heater from the freezer compart ment o Component Access Removal Condenser Defrost Heater 3 Figure 7 48 Freezer Defrost Heater Removal
140. the express written consent of Sub Zero Freezer Company Inc Sub Zero Freezer Company Inc all rights reserved 3758440 Revision A October 2005 General Information Pro Series 648PRO TABLE OF CONTENTS Page Section 1 General Information 1 1 Introduction ite aioe 1 2 Important Safety 1 2 Technical Assistance enean nnn 1 2 Table OF Contents carina ita 1 3 Warranty Information causer it Rv ene 1 5 Model Features eie a 1 6 Model Specifications sss 1 7 Section 2 Installation Information 2 1 Recommended Tools and Materials 2 2 Unit DIMENSIONS i ntt etes reo he bn TER n 2 3 Pre Installation Specifications 2 4 Preparing the Space 2 4 Electrical Requirements 2 4 Plumbing Requirements sse 2 5 Unpacking the Appliance 2 6 Removing the 2 6 Moving the Unit iretur pte ta pe EUR ERAS 2 7 Protecting iuste 2 7 Installation Considerations see 2 8 Anti tip Components Installation 2 2 8 Unit Leveling me c tete e en vr Rae 2 9 Door
141. the upper evaporator is supplied with refrigerant If the pulse signal is negative the lower evaporator is supplied with refrigerant See Figure 3 21 NOTES On initial pull down the refrigerant valve will receive a pulse signal then switch back and forth between and on thirty 30 minute inter vals until a zone achieves set point If neither compartment is calling for cooling the compressor and evapora tor fans are switched off Refrigerator evaporator fans cycle with the refrigerant valve L1 115VOLTS socyces NEUTRAL raworack 0000000 AWECO REF VALVE 2 ware 2950 3 Refrigerator refrigerant valve receives or pulse signal to E m 2b force bead in valve T connector to un one side the other depending i pulse polarity to supply refrigerant 1 H to appropriate evaporator E MAIN 24 n1 CONTROL 97 BOARD mo 7 1 2 Refrigerator compressor energized REFRIGERATOR COMPRESSOR LT BLUE STARTING RELAY CONTROL BROWN BOX REF BLACK
142. ti tip bracket to the floor See Figure 2 9 3 Drill 6 pilot holes 3 16 5 mm diameter maximum for mounting anti tip bracket to wall a minimum of 3 A 19 mm into the wall plate 4 Install twelve 12 x 2 1 2 64 mm wood screws and twelve 1 4 6 mm flat washers See Figure 2 8 NOTE If screws do not hit a wall stud in any of the upper holes of anti tip bracket use the provided 8 x 1 1 4 32 mm wood screw 1 4 6 1 mm flat washer and a nylon zip it wall anchor MIN ene di NOTE For concrete floors use three 3 8 X 3 3 4 10 Mi cus pests mm x 95 mm concrete wedge anchors to secure anti aj m mr tip bracket to floor Use six 12 x 2 1 2 64 mm wood i sail bids screws and six 1 4 6 mm flat washers to secure anti i Sub Flooring tip bracket to wall See Figure 2 9 Figure 2 10 Anti Tip Mounting 3758440 Revision A October 2005 2 8 Pro Series 648PRO Installation Information Unit Leveling All Models NOTE The rear levelers must be in their lowest posi tion before unit is installed Unit must be installed before final leveling If unit is anchored to cabinets remove anchor screws before leveling reinstall after leveling 1 To level unit first remove kickplate See Figure 2 11 2 To raise unit front turn
143. tion Connection _ Figure 7 11 Water Valve Removal Rear View 7 5 3758440 Revision October 2005 Component Access Removal Grille Assembly Removal The grille assembly is located at top front of the unit The grille Louvers can be lifted up to provide access to the technician display and sealed system components To remove the grille assembly See Figure 7 12 1 Lift Louvered section of grille assembly up 2 Disconnect communication cable from behind the Technician display cover and remove any cable tie downs 3 Extract the bolts holding the grille assembly to the top of the refrigerator 4 Extract the mounting screw to right of center then lift the assembly from the top of the appliance Gas Grille Spring Cylinder Valve Removal To remove a gas grille spring cylinder valve See Figure 7 13 1 With small flat bladed screwdriver expand the retaining clips at each end of the gas grille spring away from the stud mounts 2 Then pull each end from the mounts User Display Removal The two User Displays are mounted in the grille assem bly The left User Display is for the freezer zone and the right User Display is for the two refrigerator zones To remove a User Display See Figure 7 14 1 Remove the grille assembly 2 Disconnect the communication cables from display being removed 3 Extract mounting screws securing the displays to the grille assembly
144. tor 2 7 13 Lower Evaporator Fan 7 13 Lower Light SwitcheS 7 13 Lower Compartment Thermistor 7 14 Lower Evaporator Thermistor 7 14 Freezer Interior Cosmetic Mechanical 7 15 Shelf Assembly 7 15 Light DiffUSer 7 15 Shelf Assembly suc 7 15 Upper Freezer Light Assembly 7 15 Upper Freezer Ducl Cover in 7 15 Freezer Bottom Shelf Assembly 7 16 Freezer Compartment Thermistor 7 16 eie p eie ede 7 16 Drawer Light Socket rti ons 7 17 Upper Evaporator Fan 7 17 Lower Evaporator Fan 7 17 Evaporator Fan Assembly 7 17 Icemaker 7 18 Evaporator COVer oia etre eb oen 7 18 Evaporator Thermistor 7 18 Defrost Terminator eir tite rto De frost Heater irte e Drain Trough Heater Compressor Area Mechanical 7 20 Walter Ere cre tee erret 7 20 CIC m 7 20 Condenser
145. tube cutter cut evaporator outlet 1 or less from accumulator if applicable or 1 or less from suction line connection point NOTE It is not recommended to sweat tubing apart Doing so will induce moisture into the sealed system NOTE After capillary tube is fatigue until it separates check tubing for internal burrs If burrs exist repeat step 3 above 7 23 Component Access Removal Figure 7 58 Refrigerator Evaporator NOTE Freezer evaporator removal not illustrated 3758440 Revision A October 2005 Component Access Removal Pro Series 648 Heat Exchanger NOTE When replacing a heat exchanger the high side filter drier must also be replaced To remove the heat exchanger the top cover and evap orator cover must be removed then after capturing the refrigerant from the sealed system See Figures 7 59 1 Extract screws which hold evaporator 2 Remove insulation from heat exchanger 3 With a file score a line around capillary tube 1 or less from evaporator inlet then fatigue capillary tube at this line until it separates 4 With a tube cutter cut evaporator outlet 1 or less from accumulator if applicable or 1 or less from suction line connection point 5 With a tin snips
146. u know when doors or drawers are left ajar Water filter is easy to replace and just behind the pop up grille for ice as pure as it is fresh Easy access grille pops up to reveal the water filter and condenser for cleaning Stainless steel construction and classic finish inside and out for professional strength and beauty LED lights bathe upper compartments a soft glow on the refrigerator side chan neled sidewall LEDs can even serve as door area night lights night light option available on Model 648PROG only gt Triple pane UV resistant glass offers conven ient visibility while filtering harmful rays and saving energy Model 648PROG UL approved for US and Canada gt Two five and twelve year residential warranty exclusions apply see warranty General Information Pro Series 648PRO SPECIFICATIONS Model 648PRO Side by Side Refrigerator Freezer Model 648PROG Side by Side Refrigerator Freezer with Glass Door Overall Width 48 1219 Overall Height 84 2134 Depth from behind face frame Depth to front of face fram 23 7 8 606 25 718 657 Refrigerator Capacity 18 4 cu ft 521 L Freezer Capacity 17 cu ft 331 L Minimum Height levelers in 83 1 2 2121 Door Swing Clearance 28 3 4 730 Electrical Requirements 115 V 60 Hz 15 amp dedicated circuit Plumbing Requirements 14 coppe
147. v ice Mode Version info 4 Version Info gt Control 01 3 3 Hv Micro 02 2 0 lt Version info Continue f ornumber EEConf 01 1 1 of models defined Accept New Model Yes gt lt SelectModel Accept New Model PRO48G gt No gt lt Version info LtLC D 01 2 0 lt Version info RtLCD 01 2 0 Version into Logger 02 2 4 lt Version info Key pad unknown lt Version info S N M0000000 3758440 Revision A October 2005 3 26 Jreus zenog Pro Series 648PRO Electronic Control System Non Service Mode Display Information Prior to initiating Service Mode the following information will appear on the Technician s Display depending on oper ational mode Operational Mode LCD Line 1 LCD Line 2 Power Up Scrolling Messages every 2s Scrolling Messages every 2s Model ID Unit ID Main Software Version E2 Version Left Display Version Right Display Version Keyboard Version Tech Display Version Off Showroom Sabbath Sabbath mode Normal Scrolling Messages every 2s Scrolling Messages every 2s Model Name S N XXXXX Zone 1 Status Status Zone 2 Status Status Zone 3 Status Status Zone 4 Status Status Initiating Service Mode To initiate Service Mode press and hold any COLDER key then press the POWER key then release both keys See Figure 3 41 Service Mode 1 Diagnostics is the first sub mode to appear in the Technician s Display with a small arrow in the bottom right corner p
148. vice only e Use only 134a refrigerant for back flushing and sweep charging Always replace the filter drier when servicing the sealed system e filter drier must be cut from the sealed system Never un braze the drier as the heat will drive moisture back into the sealed system e Do not leave sealed system nor replacement compressor open to the atmosphere for more than 10 minutes e When the rubber plugs are pulled from the service compressor a release of pressure should be heard If no release of pressure is heard do not use the compressor e Use ONLY virgin 134a refrigerant when recharging the sealed system 3758440 Revision A October 2005 4 2 Pro Series 648PRO Sealed System Information PRO SERIES SEALED SYSTEM REPAIR PROCEDURES Problem Service Procedures Non Operating Inefficient a Capture refrigerant Noisy Compressor b Replace Compressor Replace filter drier NOTE To check for a non d Evacuate or sweep charge system operating compressor a hard NOTE If evacuating refrigerator sealed system unit must be evacuated from the low amp high start kit can be used sides due to refrigerant valve If sweep charging refrigerator sealed system refrigerant valve must be energized during procedure See Diagnostics 4 Activate Zone in Section 3 Recharge system with Virgin 134 refrigerant High Side leak Capture refrigerant Replace filter drier Evacuate or sw
149. w Icemaker Information Turn Drive Gear Counterclockwise Figure 6 13 Manually Start Icemaker Water Fill Adjusting Screw 1 Full Turn Equals 15 CC s Turn Clockwise to Reduce Fill Figure 6 14 Adjust Water Fill Level 3758440 Revision A October 2005 Icemaker Information Pro Series 648PRO 3758440 Revision A October 2005 6 10 Pro Series 648PRO Component Access Removal SECTION 7 COMPONENT ACCESS AND REMOVAL Component Access Removal Pro Series 648PRO COMPONENT ACCESS AND REMOVAL This section explains how to adjust access and or remove components This section is arranged as follows Page Exterior Cosmetic Mechanical Components 7 3 Refrigerator Interior Cosmetic Mechanical Components 7 8 Freezer Interior Cosmetic Mechanical Components 7 15 e Compressor Area Mechanical Components _ 7 20 Sealed System Combponehls 7 21 An attempt has been made to arrange these procedures in such a way as to simulate which components would need to be removed first in order to gain access to other components When following a component removal proce dure it may be necessary
150. w gt WHITE us BEN ST 1 reuow ORANGERED eis a P5 YELI WHITE P16 ELLOW Ln WHITE MAIN 24 pue 60 CONTROL x BOARD venon ORANGE MITE D m op TUGHT Li P18 1 219 2300 2900 Q FILL TUBE HEATER wis 7 DEF HEATER 1 PB 1 BLUE WHITE P 5 BI METAL 1 TROUGH HEATER 1 PS torz PURPLE COMPRESSOR VSPEED CONTROL BROWN IT BLUE na xi Ez FOR NON GLASS 1 BLACK DOOR ONLY REFRIGERATOR COMPRESSOR LT BLUE STARTING RELAY VSPEED CONTROL BROWN BOX REF TACK FOR GLASS DOOR ONLY wure wane 1 DC POWER LOW VOLTAGE n 1 I depi 20 2 se 07 5 THERMISTER 2 P1 rown FRE COND A n T8 wi 2 mom Cond 15 BLUE MZ L P5 TE THERMISTER THERMISTER _ B n gt REF chemer P16 BLUE NI BLUE wy 5 88 MAIN muc Gp FEE UNR ever g BROWN FZ CABINET BROWN AND i M wd 2 2 2 dE THERMISTER BROWN 8 5 P18 1 awe WT 3 i J Po P a gt TIUEBIACK ze x E GLASS DOOR 6 a 2 veLLowenown 5 SLUEATHITE I went Figure 3 32 Signal Trace Schematic E Control System Components Ui Figure 3 33 3 23 JB lily SERVICE
151. w to work to Op Status Mode 2 Ice Maker 1 After initiating Service Mode press the COLD ER key one 1 time Op Status 1 Zone 4 Status appears on display Press COLDER key one 1 time Press the ALARM key one 1 time See Figure 3 49 Ice Maker Status Harvest or Production appears on display corr COLDER WARMER COLDER WARMER ICE MAKER POWER ALARM LIGHT COLDER WARMER gt Press ALARM key 1 time Figure 3 49 Key Strokes and Tech Display Operational Status Ice Maker Service Mode 3 Model Information Sub Mode Accessing Model Information allows the Service Technician to verify or change model configuration This page explains the steps for working through Model Information Mode For sake of space the directions that fol low will not explain or show what is seen in the display after each key stroke Only the final and or desired result will be explained and illustrated As mentioned when Service mode is initiated Service Mode 1 Diagnostics appears in the 4 Technician s Display Follow the steps below to work to and through Service Mode 3 Model Information Sub Mode 1 After initiating Service Mode press the COLD 2 ER key two 2 times Service Mode 3 Model Info appears on display 2

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