Reach-In Refrigerators Service Manual
Contents
1. co 13 COR ZABRRIMT xau ope aere AE CR QE 14 Troubleshooting y Rog AUREIS MES S ES 15 Possible causes and solutions 15 2004 IMI Cornelius Inc 1 Publication Number 630460272SER Reach In Refrigerator Service Manual lt lt Publication Number 630460272SER ii 2004 IMI Cornelius Inc Reach In Refrigerator Service Manual FEATURES OF THE UNIT Heavy duty condensing unit located on top for easy access maintenance COR48RRTMD 2004 IMI Cornelius Inc PN FIGURE 1 Control panel with temperature display door ajar light power indicator condensate switch U L compliant electrical components Heavy duty hinges with self closing mechanism Strong body with 2 1 2 thick walls injected with CFC free polyurethane Stainless steel front and exterior sides Heavy duty shelves Recessed handles with cylinder lock Solid doors save energy by preventing warm air from reaching your products Forced air evaporator for quick temperature pull down 6 swivel casters Publication Number 630460272SER Reach In Refrigerator Service Manual CLEANING AND PREVENTIVE MAINTENANCE Weekly or sooner as required 1 2 Publication Number 630460272SER 2 Disconnect the power source before cleaning Remove all products and place in a proper cooler Clean the interior and exte2. Compare these pressures to the specifications to determine the cause and solution If there is an electrical problem the service person should use a volt amp meter a watt meter and a continuity tester An ohm meter can be used as a continuity tester common refrigeration failure is a leak of some or all of the refrigerant Because the leak can be very small it can be very difficult to find It usually develops on the high side of the system and only leaks when the compressor is running The condenser fan carries the refrigerant away making the leak difficult to detect If a leak detector does not find the leak put a block of wood or a wad of rags against the fan blade to keep it from turning while the compressor is running This will cause the pressure to build up and make the leak easier to find This will not harm the fan motor or system if the fan blade is only stopped for a few minutes The pick up hose of the torch should be passed back and forth over all tubing joints and over the entire condenser very carefully After the leak is found repair it if possible If it cannot be repaired replace the leaking part Whenever a leak has been located and repaired the entire charge should be removed and a triple evacuation procedure must be followed to be sure that all contaminants are removed A good dryer of proper size should be installed in the liquid line and a new charge of refrigerant put back in allowing extra to compensate for the dry
3. Stoves walls that are exposed to the sun or places that lack sufficient air flow If there is air in the system purge and recharge Check temperature control refrigerant charge and defrost mechanism Remove all ice manually and start over Locate exact point of restriction and correct The shelves must never be covered with any type of plastic or other material that will block the circulation of cold air within the refrigerator Advise user to decrease if possible Advise user not to put in products that are too hot Check to see if condensation or ice crystals have formed on the suction line If so charge with the correct amount of gas Find the location where the gas is leaking in order to seal it or replace the defective component Change the drier Perform a good vacuum and recharge the unit Check the electrical connections and make sure that the fan blade isn t stuck Replace the fan motor if it doesn t work Use a voltage regulator if the voltage is lower than 103 volts Check for appropriate insulation on the connections of each electrical component 2004 IMI Cornelius Inc PROBLEM NOISE EXTREME CONDENSATION INSIDE THE REFRIGERATOR NO ILLUMINATION 2004 IMI Cornelius Inc POSSIBLE CAUSE The refrigerator is not properly leveled The condenser is not fastened correctly Copper tubings are in contact with metal The evaporator and or condenser fans are loose
4. 1 Remove the two mounting screws 2004 IMI Cornelius Inc 5 Publication Number 630460272SER Reach In Refrigerator Service Manual 2 Pullthe feeler bulb from the well which is usually located on the coil or header and pull the lead wires off the control terminals TEMPERATURE CONTROL MOUNTED IN RACEWAY SIDE RACEWAY TEMPERATUR CONTROL BAC LIP TIM an C BULB TEMPERATURE CONTROL MOUNTED IN BAFFLE FIGURE 7 If the temperature control is within the first year warranty and is to be returned for credit be sure to coil the tubing neatly and do not kink it or damage the control in any way No credit can be issued for any parts that arrive in a damaged condition 3 Replace the control with an exact factory replacement or one equal to the original specifications Be sure the feeler bulb is in the proper well and tight Do not allow the tubing connecting the feeler bulb to the body of the control to touch the coil U bends Time clocks In the cabinets which have bottom mounted condensing units the time clock will be located along the side of the unit It will be readily visible when the motor cover is removed The timer is set at the factory for two defrost periods with a fail safe of 40 minutes for both single and multiple door cabinets For SAV models the timer is set at the factory for four 4 defrost periods of 30 minutes Tests have shown that the factory setting is
5. Compressor has an internal noise Thermostat knob is set at a very cold position The outside environment s relative humidity is very high over 75 The refrigerator door won t shut completely The refrigerator has been placed at an inadequate location The light switch is in off position False contact on the light switch the fluorescent tube or the ballast Light switch ballast and or fluorescent tube are damaged 17 Reach In Refrigerator Service Manual SOLUTION Check if the noise goes away after you level the refrigerator While the compressor is working check to see if metal parts are in contact with one another and or if the screws that fasten the condenser are tightened Check if the fans are securely fastened Also check if the fan blades are loose broken or crooked If so change the faulty blade If the noise persists after all other measures have been taken it may be originating from the compressor Set the thermostat knob to a warmer position and check if the compressor stops according to the thermostat s operating range This type of occurrence is caused by local climatic conditions and not by the refrigerated unit Check the door and or the magnetic gasket Adjust the door hinges if needed replace the gasket if broken The unit must not be near sources that produce too much heat Press the light switch to the on position Inspect all connecti
6. FIGURE 15 Publication Number 630460272SER 14 2004 IMI Cornelius Inc Reach In Refrigerator Service Manual TROUBLESHOOTING Possible causes and solutions PROBLEM COMPRESSOR WILL NOT START THE TEMPERATURE IS TOO COLD 2004 IMI Cornelius Inc POSSIBLE CAUSE No voltage in the electrical socket The electrical conductor or wires may be cut Defective electrical components such as thermostat relay thermal protector etc Thermostat in off position Compressor motor has a winding open or shorted Dirty condenser lack of air flow Low voltage Compressor is stuck Temperature control contacts are open Time clock circuits are open Incorrect wiring Thermostat knob is set at a very cold position Thermostat does not disconnect the condensing unit Thermostat capillary bulb is loose or installed improperly Control contacts are stuck closed Defective or incorrect temperature control 15 SOLUTION Use a voltmeter to check the voltage Use an ohmmeter to check for continuity Replace defective components Turn the thermostat s knob to its maximum position and wait to see if the compressor starts Measure the ohmic resistance of the main and auxiliary windings using an ohmmeter Compare them with the correct values Clean condenser and allow for air circulation Use a voltage regulator if the voltage is lower than 103 volts Change the co
7. satisfactory for most applications However changes can be made after a sufficient trial period if necessary The fail safe is controlled by the small copper pointer on the inner dial To reset the timer grasp the knurled knob and turn it counterclockwise until the pointer is at the correct time As soon as the power is turned on if the temperature control is in the on position the time clock and condensing unit will start Publication Number 630460272SER 6 2004 IMI Cornelius Inc Gino D Reach In Refrigerator Service Manual CLOCH RMT EYELE Gih Tula n FIGURE 8 When the coil temperature reaches the proper temperature the fan s will automatically start and continue to run until it comes to the defrost cycle The fan s may turn off if the doors are left open too long during a loading period and the coil becomes warm Do not call for service until the freezer is given enough time to come down to the proper temperature After the unit is put into operation the fan s will continue to operate until the storage area reaches a proper temperature recommended average 38 F The red pilot on the front of the top grill should turn off after about an hour of operation or whenever the sensing element reaches the prescribed temperature Under some conditions the red warning light may go on at the end of the defrost cycle However after the defrost cycle is ended the temperature should recover in a reasonable length o
8. 027226644 REACH IN REFRIGERATORS COR20RRTM COR22RRTM COR40RRTMD COR48RRTMD COR74RRTMT Service Manual Release Date June 16 2004 Publication Number 630460252SER Revision Date NA Revision A Visit the IMI Cornelius web site at www cornelius com for all your Literature needs SERVICE MANUAL The products technical information and instructions contained in this manual are subject to change without notice These instructions are not intended to cover all details or varia tions of the equipment nor to provide for every possible contingency in the installation operation or maintenance of this equipment This manual assumes that the person s working on the equipment have been trained and are skilled in working with electrical plumbing pneumatic and mechanical equipment It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met in addition to the information contained in this manual To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact www cornelius com 800 238 3600 Trademarks and copyrights Aurora Cornelius Decade Hydro Boost Sitco Spirit UF 1 Vanguard Venture Olympus and Vista are registered trademarks of IMI Cornelius Inc Optifill trademark is pending This document contains proprietary information and it may not be reproduced in any way without pe
9. GREEN 1 1 N 35 To T 4 el CONDES i RED UNIT Br WHITE AANA e eie 652 1 ee CONTROL Ra WHITE L 4 S 2 1 1 1 3 2 125 d Black BLACK L BAFFLE CONNECTION 2004 IMI Cornelius Inc stis Publication Number 630460272SER Reach In Refrigerator Service Manual CORAORRTMD SPEARLINE CN 2 5 P COND UNIT Nu P d N WHITE NDS N BLACK I x z w JUNCTION i S E 6 1 WHITE WHITE 7 RED BLACK gt gt Sa l 8 up Er 22 5 3 PERIMETER HEATER 1 3 l 3 AS e TEMP CONTROL Lj HE c BLACK 5 9 RED I E XY PUSH PUSH BUTTOM LIGHT BUTTOM BULB FIGURE 13 Publication Number 630460272SER 12 2004 IMI Cornelius Inc Reach In Refrigerator Service Manual COR48RRTMD MULLION CANOPY CONNECTION BLACK GREY GREY 4 WHITE RED RED BLACK BLACK BLACK lgzl POWER 1 WHITE WHITE Hand poor 1 LAN 2 BLACK WHITE B GREEN BLACK Q B w Q2 2 WHITE PUSH 1 1 PU
10. SH 9 8 BUTTOM j 5 R kt a cope a ar 1 3 LIGHT ear g BULB 1 i ELECT BOX NS WHITE fF FEED URAK 1 4X4 JL M GREEN HEATERS FASCIA i c LIPS en jJ 4 switch e e 1 1 EP AIT AE 1 WHITE 2 1 BLACK F GREEN O 1 1 1 7 5 p 1 dec p COND RED UNIT Lp 1 WHITE 1 1 1 ees ese BE EITI MOTOR CONTROL EISE doch WHITE RED MEM S au M I BLACK BLACK we el BAFFLE CONNECTION 2004 IMI Cornelius Inc FIGURE 14 18 Publication Number 630460272SER Reach In Refrigerator Service Manual COR74RRTMT MULLION CANOPY CONNECTION BLACK GREY GREY ory BLACK HACK SACK les zi POWER E WHITE 5 WHITE WHITE H El DOOR 1 LAW BLACK T WHITE GREEN BLACK WHITE 8 2 2 4 5 5 5 BE ul A Nigh T 2 E 2 ij ELECT BOX Sy 4X4 Dae HEATERS FASCIA d ou 1 1 1 1 1 RETO P APAE ETETEA PENERE A 1 52 MOTOR Ee CONTROL 12 WHITE RED RENS IE lt E gre 2 1 Y BLACK BLACK RUE NM BAFFLE CONNECTION
11. enter rear This must make good contact with the drain pan or baffle at the drain opening in order to work properly If it does not make good contact the drain line will freeze up and the defrost water will overflow into the food compartment during the defrost cycle Condensing unit The condensing unit consists of the following parts e Compressor Condenser fan motor assembly Condenser e Relay e Starting capacitor running capacitor on some models Service valves Most units have high and low side service valves but in some instances there may be only a low side service valve Some compressors have the mechanism mounted on springs inside the housing referred to as internal mounts and others have the entire compressor body mounted on springs and rubber bushings referred to as external mounts to absorb the vibration In the latter case bolts run up through the springs and are secured with a retainer nut During shipping the nuts on these bolts are tightened to prevent the compressor from moving and damaging itself or other parts Before the cabinet is placed in operation these nuts must be loosened enough to allow the compressor to float freely on the springs so that vibration will be absorbed by the springs Problems with the refrigeration system are usually due to failure of one of the components in the condensing unit area The service person should install a set of gages on the service valves to determine the operating pressures
12. er After the cabinet has run for several hours it should be rechecked to be sure the gas charge is correct and the system is balanced 2004 IMI Cornelius Inc 9 Publication Number 630460272SER Reach In Refrigerator Service Manual WIRING DIAGRAMS COR20RRTM WHITE BLACK COND UNIT T I Let get WHITE RED FAN MOTOR wie LZTS I TEMP CONTROL 1 5 3 RED BLACK WHITE BLACK RED Publication Number 630460272SER FIGURE 11 10 BLACK WHITE WHITE BLACK LIGHT BULB PERIMETER HEATER BLACK BLACK PUSH BUTTOM SPEARLINE 2004 IMI Cornelius Inc Reach In Refrigerator Service Manual COR22RRTM MULLION CANOPY CONNECTION BLACK GREY GREY Urra WHITE RED RED BLACK BLACK BLACK PE POWER WHITE WHITE WHITE S 3 LAM us GREEN PUSH L BUTTOM ji 11 Noe LIGHT 4 tmm m A RAN 4 BULB ped 1 1 1 i ELECT BOX WHITE TRAC 1 gt FEED BLACK 4X4 k GREEN HEATERS FASCIA A Uz d pra E SWITCH WHITE 7 m T BLACK
13. f time and the red light will go out The defrost periods are set at the factory for 6 a m and 6 p m and may be changed if needed When the pin on the outer dial of the time clock is opposite the pointer the defrost cycle will start The condensing unit and the blower fan shut off and the defrost heaters turn on The heaters are located on the coil As soon as the coil has reached approximately 50 F and the coil is clear the combination defrost limit and fan delay switch will trip the timer solenoid and end the defrost cycle to put the system back into the refrigeration cycle The blower fan will remain off until the coil cools down to 20 F If the limit switch or solenoid should fail to terminate the defrost cycle the inner fail safe dial will take over and terminate the defrost cycle when the prescribed time is up The length of the defrost cycle will vary depending on the type of product stored in the cabinet the number of door openings and the atmospheric conditions The defrost cycle will usually take longer in the summer than in the winter Before you make changes to the length of the fail safe or the number of defrost periods a competent service engineer should make a complete study of all the contributing factors 2004 IMI Cornelius Inc 7 Publication Number 630460272SER Reach In Refrigerator Service Manual Blower fan assembly To change the fan blade remove the speed nut from the threaded shaft If the fa
14. mpressor Repair or replace the contacts Determine the reason and repair or replace Check the wiring diagram and correct Set the thermostat knob to a warmer position and check if the compressor stops according to the thermostat s operating range Check the insulation of the thermostat If the problem persists change the thermostat Correctly fasten the thermostat capillary bulb File contacts Change the control Check amperage load Determine correct control and replace Publication Number 630460272SER Reach In Refrigerator Service Manual PROBLEM THE TEMPERATURE IS NOT COLD ENOUGH ELECTRICAL SHOCKS Publication Number 630460272SER POSSIBLE CAUSE Thermostat knob is set at a very warm position Condenser is dirty The refrigerator has been placed at an inadequate location Compressor is inefficient or there is a high head pressure due to air in the system Iced up evaporator coil Restriction in system The refrigerator has been used improperly Too many door openings Excessive heat load placed in cabinet The refrigerator has been overcharged with the refrigerant gas The refrigerant gas is leaking The evaporator and or condenser fans aren t working Low voltage Wires or electrical components are in direct contact with metallic parts 16 SOLUTION Set the thermostat knob to a colder position Clean the condenser The unit must not be near
15. n motor must be changed 1 Remove the fan blade and lay it carefully aside Be careful not to bend or damage the blade or it will become out of balance FIGURE 9 Remove the four machine screws around the perimeter of the hole in the baffle These hold the motor mounting bracket in place The small rubber washers that eliminate vibration should be saved for reassembly 3 Drop the motor and bracket through the hold 4 Remove the three machine screws holding the motor to the mounting bracket and disconnect the wire leads 5 Install the new fan motor and reinstall the fan blade Defrost heater To change the defrost heater element 1 Remove the baffle from under the coil This is the part that catches the condensate water and funnels it down the drain It also directs the flow of air through the coil and down the air ducts To remove the baffle take out the screws and let it down far enough to get to the defrost element Use a pair of side cutters or diagonal pliers to snip off all of the copper wires holding the heater element to the coil 3 Disconnect the element from the cabinet leads DISCONNECT WIRES FIGURE 10 Publication Number 630460272SER 8 2004 IMI Cornelius Inc Reach In Refrigerator Service Manual 4 Install a new heater element Be sure to use similar copper wire to install the new element tightly against the coil Note that there is a bend in the heater element along the c
16. ock which will automatically shut the condensing unit off for an hour or two each night to be sure the coil is completely cleared of frost It should be connected so the blower fan is left on to speed up the defrosting process A qualified service person should be consulted before attempting to make these additions SERVICE PROCEDURES A CAUTION Make sure the power supply is turned off before making any electrical repairs If any electrical problems arise a wiring diagram is included with each cabinet to aid in tracing the source of trouble and making the necessary repairs Light switches Each hinged solid door has a switch which will turn on the interior light whenever the door is opened In most cases the switch may be examined or exchanged without removing the mounting bracket Place a knife blade or similar tool behind the switch flange and pry it out To replace the switch disconnect the Publication Number 630460272SER 4 2004 IMI Cornelius Inc Reach In Refrigerator Service Manual leads from the terminals and attach them to the new switch and snap it back in place Make sure there are no breaks or bare wires to cause a short before putting the switch back FIGURE 6 Lights The incandescent light bulb can be replaced by any 40 watt appliance bulb Temperature controls A CAUTION Make sure the power supply is turned off before making any electrical repairs To replace the temperature control
17. of warm product is put in at one time CONDENSATE GREEN ELIMINATOR SWITCH ipower FIGURE 4 2004 IMI Cornelius Inc 3 Publication Number 630460272SER Reach In Refrigerator Service Manual Temperature control If the condensing unit does not run after the power cord is plugged in check that the temperature control is in the on position This can be done with an ordinary screwdriver After the system has operated for several hours the temperature control may be adjusted to suit your needs Turn it clockwise to make it colder and counterclockwise to make it warmer Do not make more than 1 4 turn at one time then allow it to operate for several hours before making any further adjustment Once it is set there should be no need to change it FIGURE 5 After the cabinet has been used for a while if you should notice any great change in termperature do not attempt to compensate for it by turning the control It is much more likely that there is some other problem and a qualified refrigeration service person should be called Automatic defrosting Normally when the cabinet storage area temperature is kept at a range of 36 F to 42 F all refrigerators will defrost the coil during the off cycle when the compressor is not running Under some conditions such as heavy product load or a lot of door openings in a high ambient temperature or excessive relative humidity it may be advisable to install a time cl
18. onditions however under some conditions where practical and convenient a drain line to a floor drain may be preferable to the vaporizer On base mounted condensing units the defrost water flows into the unit compartment and is vaporized by the heat from the hot gas line FIGURE 3 Warning light and thermometer A fan circulates the cold air from the coil throughout the storage area This provides uniform termperatures and more rapid recovery after door openings The number of door openings and the length of time the door is left open should be kept to a minimum to reduce the operating cost and maintain the most efficient operation The temperature in the cabinet will rise very rapidly whenever the doors are opened however the product temperature is not greatly affected Some top mounted cabinets have a thermometer and two small lights located at the right end of the front motor cover grill directly over the door One light is green and is always lit when there is power to the cabinet One light is red and should only be lit when the temperature is above the safe zone It is controlled by a bi metallic disk type switch The red light will be on at start up until the temperature comes down to normal When warm product is put in or the doors are held open for a time the red light may come on but it will go out again as soon as the temperature has recovered When the doors are closed again the recovery is very rapid unless a large quantity
19. ons Replace the damaged component Publication Number 630460272SER IMI Cornelius Inc www cornelius com
20. rior with a mild soap or detergent solution and then rinse with a warm baking soda solution one cup of baking soda to one gallon of warm water Dry the interior completely before replacing products Clean the condenser unit periodically by vacuuming the unit compartment especially the condenser unit coil it looks like a small auto radiator If the condenser coil has accumulated dirt and grease possible in heavy traffic areas or a kitchen use a strong cleaning solution If you find any oil in the condensing unit compartment call a qualified service person immediately WITH FIGURE 2 Empty out and clean drain pan located next to the condensing unit as required Check regularly for excessive water accumulation Plug in the cabinet and wait until the proper temperature is achieved before reloading the cabinet with product 2004 IMI Cornelius Inc Reach In Refrigerator Service Manual How YouR CABINET OPERATES A CAUTION Make sure the power supply is turned off before making any electrical repairs Defrost water flow Your new cabinet is completely self defrosting The frost that collects on the concealed coils is automatically removed at predetermined intervals The defrost water on top mounted condensing units flows into a thermostatically controlled electric vaporizer where it is dissipated into the atmosphere All defrost evaporator systems are designed for normal c
21. rmission from Cornelius Printed in U S A Copyright 2004 All Rights Reserved IMI Cornelius Inc Reach In Refrigerator Service Manual TABLE OF CONTENTS Features of the 1 Cleaning and Preventive Maintenance 2 How Your Cabinet Operates 3 Defrost water flow 3 Warning light and 1 1 3 Temperature control 4 Automatic defrosting sock oie Paws e a aa ees S 4 Service 4 Light switches 2o he ee Fare a a 4 n ot HL Na ea Sat Bat SEM og 5 Temperature controls 5 Time ClOCKS 22 ee ace AGA os 6 Blower fan assembly 8 Ra REUS Pel s gene att tios 8 Condensing UNT educar EE SES BEEN LEUR EE 9 Wiring Diagrams iw hacen ia Daa oa 10 COR20RRTM a dans ier qni CC Y RIP EUR a et tw 10 COR22RRTM 45 Ree Re ed Ae uA Ue ERE AUR RC e ar RR Re aoe 11 CORSORAUMD Late Het m Ue L De e a dod 12
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