Fisher & Paykel 790 Active Smart Service Manual
790 ACTIVE SMART
REFRIGERATOR FREEZER
517800
2
3
MANUAL 517800 - DATE OF ISSUE MAY 2004
The specifications and servicing procedures outlined in this manual are subject to change without notice.
The latest version is indicated by the reprint date and replaces any earlier editions.
Fisher & Paykel Appliances Inc
27 Hubble, Irvine
California, CA92618
USA
Telephone: 949 790 8900
Facsimile: 949 790 8911
Fisher & Paykel Appliances Ltd
Technical Publications
PO Box 58-732, Greenmount, Auckland
78 Springs Road, East Tamaki
New Zealand
Telephone: 09 273 0600
Facsimile: 09 273 0656
COPYRIGHT FISHER & PAYKEL LTD 2004
4
C O N T E N T S
1 TERMINOLOGY ..........................................................................................................6
2 SPECIFICATIONS.......................................................................................................7
2.1 Cabinet Specifications.........................................................................................................................7
2.2 Model Number Identification................................................................................................................8
2.3 Serial Number Identification ................................................................................................................8
3 SERVICING REQUIREMENTS ...................................................................................9
3.1 Interface Pen Mk 2 ..............................................................................................................................9
3.2 Health & Safety....................................................................................................................................9
3.2.1 Good Work Practices ...........................................................................................................9
3.2.2 Environmental Health And Safety........................................................................................9
3.2.3 Good Practice And Safety....................................................................................................9
4 INSTALLATION INSTRUCTIONS .............................................................................10
4.1 Levelling ........................................................................................................................................... 10
4.2 Air Space Requirements .................................................................................................................. 11
4.3 Temperature Adjustment.................................................................................................................. 11
5 THEORY OF OPERATION........................................................................................12
5.1 Internal Air Flow ............................................................................................................................... 12
5.2 Defrost Cycle .................................................................................................................................... 13
5.3 The Refrigeration Circuit .................................................................................................................. 14
5.4 Servicing Features ........................................................................................................................... 15
5.4.1 Condensate Disposal........................................................................................................15
5.4.2 Internal Condenser ........................................................................................................... 16
5.4.3 Cross Rail.......................................................................................................................... 19
5.4.4 Divider Partition................................................................................................................. 19
6 ELECTRONICS SECTION ........................................................................................20
6.1 Overview Function Description......................................................................................................... 20
6.1.1 Control & Peripheral Functions ......................................................................................... 20
6.1.2 Power/Control Module ...................................................................................................... 20
6.1.3 Display Module ................................................................................................................. 21
6.1.4 Door Switches................................................................................................................... 21
6.1.5 Compressor....................................................................................................................... 22
6.1.5.1 Variable Capacity Compressor Control Overview ....................................................... 22
6.1.5.2 Built-in Electronic Protections (Within the Module/Inverter) ........................................ 23
6.1.5.2.1 Compressor Start-up............................................................................................ 23
6.1.5.2.2 Overload Detection and Protection ...................................................................... 23
6.1.5.2.3 Power Limitation (Temperature Protection) ......................................................... 23
6.1.5.2.4 Short Circuit Protection ........................................................................................ 23
6.1.5.3 VCC Module/Inverter Identification.............................................................................. 23
6.1.5.4 Fault Finding ................................................................................................................ 23
6.1.5.4.1 High Voltage Power Supply Circuit ...................................................................... 23
6.1.5.4.2 Signal Circuit ........................................................................................................ 23
6.1.6 Defrost Heater................................................................................................................... 24
6.1.7 Thermal Fuses .................................................................................................................. 25
6.1.8 Low Ambient Heater .........................................................................................................25
6.1.9 PC / FC Fans .................................................................................................................... 26
6.1.10 Light .................................................................................................................................. 26
6.1.11 Thermistor Temperature Sensors ..................................................................................... 27
5
6.2 Fault Finding Procedure....................................................................................................................28
6.2.1 Fault Code Display Status .................................................................................................28
6.2.2 Diagnostic Mode ................................................................................................................ 31
6.2.3 Sensor Temperature Conversion ......................................................................................31
6.2.4 Input/Output Status............................................................................................................ 32
6.2.5 Data Download ..................................................................................................................33
6.2.6 Manual Defrost ..................................................................................................................33
6.2.7 Show Room Mode .............................................................................................................33
6.2.8 Special Option Mode (Israel) .............................................................................................34
6.3 Door Gasket - (Integral) ....................................................................................................................34
7 REMOVING AND REFITTING OF COMPONENTS.................................................. 35
7.1 Removal Of Power/Control Module ..................................................................................................35
7.2 PC Sensor Replacement...................................................................................................................35
7.3 FC Sensor Replacement................................................................................................................... 35
7.4 PC Fan Motor - “T” Model .................................................................................................................36
7.5 PC Fan Motor - “B” Models ...............................................................................................................36
7.6 Cross / Base Rail Door Reed Switches ............................................................................................36
7.7 Defrost Heating Element...................................................................................................................36
7.8 Removal Of Display Module .............................................................................................................37
7.9 Thermal Fuse ....................................................................................................................................37
7.10 Replacement Of Interior Lamp..........................................................................................................37
7.11 Replacement Of Low Ambient Heater - “T” Model..........................................................................37
7.12 Replacement Of Low Ambient Heater - “B” Model .........................................................................38
7.13 Replacement Of Low Ambient Heater - “B” Model (In Return Air Grill) ..........................................38
7.14 Evaporator Replacement ..................................................................................................................38
7.15 Removal Of The FC Evaporator Cover.............................................................................................39
7.16 Pressure Testing Of The Refrigeration System ................................................................................40
7.17 Transporting Of Refrigerators ...........................................................................................................41
8 WIRING DIAGRAM ................................................................................................... 42
9 SERVICE REFERENCE ........................................................................................... 43
9.1 “B” Models.........................................................................................................................................43
9.2 “T” Models .........................................................................................................................................46
10 FLOW DIAGRAMS.................................................................................................... 48
10.1 Refrigerator Not Operating................................................................................................................48
10.2 No Power To Power/Control Module And/Or Display Module ..........................................................49
10.3 PC/FC Warm.....................................................................................................................................50
10.4 FC Too Cold – PC Too Warm...........................................................................................................51
10.5 PC Too Cold......................................................................................................................................52
10.6 Ice/Condensation Forming................................................................................................................53
10.7 No Light.............................................................................................................................................54
10.8 Door Switch Not Operating ...............................................................................................................55
10.9 Defrost Heater Faults ........................................................................................................................56
10.10 Compressor Faults.......................................................................................................................57
10.11 Compressor Runs Continuously ..................................................................................................57
10.12 Compressor Will Not Run And Is Hot To Touch ..........................................................................58
10.13 Compressor Electrical Tests ........................................................................................................ 58
10.14 Refrigeration System Faults.........................................................................................................59
6
1 TERMINOLOGY
The following are terms used in this manual:
“B” MODELS
Dual temperature refrigerator/freezers in which the freezer compartment is below the refrigerator
compartment.
“T” MODELS
Dual temperature refrigerator/freezers in which the freezer compartment is above the refrigerator
compartment.
FC COMPARTMENT
Freezer compartment. The compartment in a dual temperature refrigerator used for keeping frozen food,
where the temperature is maintained at approximately –16
o
C (3oF).
PC COMPARTMENT
Provision compartment. The compartment in a dual temperature refrigerator used for keeping fresh food,
where the temperature is maintained at approximately 4
o
C (39oF).
CABINET WRAPPER
Pre-painted steel.
LINER
A one-piece vacuum formed ABS liner with a plug-in divider.
DIVIDER PARTITION
Injected moulding of HIPS, with two outer injected moulded housings, and an insulated ducted moulded
polystyrene inner core.
FAN MOTORS
DC 12 volt brushless variable speed fan motors for air circulation in both the FC and PC compartments.
EVAPORATOR
Aluminium corrugated type mounted vertically on the back wall of the FC.
SUCTION & CAPILLARY LINE
Foamed into the back of the cabinet with all joints of the evaporator in the FC.
POWER/CONTROL MODULE
Contains the microprocessor that controls all functions of the refrigerator and gathers data from the sensors.
This module also contains support circuitry to switch the various outputs.
DISPLAY MODULE
Using signals from the Power Module, this module generates the L.E.D. display. The lamp is also switched
via this module.
REED SENSORS
A reed switch encapsulated within a plastic housing, mounted on the cross and base rails behind a plastic
cover. A magnet housed just under the lower end cap of each door activates this sensor when the door is
closed.
LOW AMBIENT HEATER
Two types are used. A PCB type is used in the air duct of “T” models. A blanket wire type is used in the
divider of “B” models.
7
2 SPECIFICATIONS
2.1 Cabinet Specifications
DIMENSIONS E521T E522B
Height 1695mm (67.8 inches) 1695mm (67.8 inches)
Depth 703mm (28.7 inches) 703mm (28.7 inches)
Width 790mm (31.1 inches) 790mm (31.1 inches)
CAPACITY GROSS VOLUME IN LITRES (AS 1430)
Provision Compartment 400 litres (14.1 cu.ft.) 360 litres (12.7 cu.ft.)
Freezer Compartment 117 litres (4.13 cu.ft.) 160 litres (5.65 cu.ft.)
TOTAL 517 litres (18.25 cu.ft.) 520 litres (18.36 cu.ft.)
ELECTRONICS 110 volt
Display Module Part No. 881218 Part No. 881218
Power/Control Module Part No. 884252 Part No. 884252
Module/Inverter Part No. 884260 Part No. 884260
SUCTION LINE ASSEMBLY
Part Number 875113 874810
DEFROST ELEMENT
Part Number 881414 881414
COMPRESSOR SPECIFICATIONS
Make Embraco Embraco
Model VEG Y6H VEG Y6H
Part Number 884259 884259
Volts 110 110
Hertz 53 - 150 53 - 150
Phase 3 3
Input Watts 55.7 - 205 55.7 - 205
Output Watts 97 - 468 97 - 468
Nominal BTU 330 - 1596 330 - 1596
Start Resistance (Ohms) 6.40 6.40
Run Resistance (Ohms) 6.40 6.40
Starting Device Type Inverter Inverter
Oil Charge (cm3) 430 430
Refrigerant Type R134a R134a
Gas Charge 140 Grams of R134a 135 Grams of R134a
8
2.2 Model Number Identification
The following is an example of the model number identification for Fisher & Paykel Appliances:
E 522 B R E D FP SM
Cabinet/Door Colour (1)
Brand (Fisher & Paykel)
Series (2)
Style (3)
Door Hinging Side (4)
Freezer Location (5)
Approximate Capacity in Litres (6)
Type of System (7)
(1) Colour of Cabinet/Door WW = White Cabinet/White Doors
SM = Silver Wrapper/Matt Stainless Steel Doors
SX = Silver Wrapper/Brushed Stainless Steel Doors
(2) Series The series of the cabinet is located on the serial plate as Series A, B, etc.
(3) Style E = Elegence
I = Inox
M = Iridium
(4) Door Hinging L = Left Hand
R = Right Hand
(5) Freezer Location B = Bottom
T=Top
(6) Litreage of Cabinet Approximate total capacity.
(7) Type of System E = Electronic
N=No Frost
C=Cyclic
2.3 Serial Number Identification
The serial number consists of three letters and six digits and contains the following information:
Example:
B I Q 123456
Sequential Serial Number
Manufacturing Plant Code
FISHERPAYKUL Code indicates month of manufacture
CUMBERLAND Code indicates year of manufacture
Cumberland Code
Letter C U M B E R L A N D
Year 1234567890
Fisherpaykul Code
Letter F I S H E R P A Y K U L
Month 1 2 3 4 5 6 7 8 9 10 11 12
Manufacturing Plant Code
A Laundry – Australia
F Refrigeration – New Zealand
M Range & Dishwasher
N Laundry – New Zealand
Q Refrigeration - Australia
In the example above, the appliance was manufactured in the second month of the fourth year (2004) at the
New Zealand Refrigeration plant.
9
3 SERVICING REQUIREMENTS
3.1 Interface Pen Mk 2
Used to retrieve and download data from the electronic control module when used in conjunction with the
Fisher & Paykel Smart Tool diagnostic program on a laptop computer. The part number of the interface pen
is 425930.
3.2 Health & Safety
3.2.1 Good Work Practices
1. Take care while removing all plastic components especially when cold.
2. Leave the product clean and tidy when service work is completed.
3. Extreme heat in cabinets will cause plastic deterioration or distortion and thermal fuses in the defrost
heater to go open circuit (be careful with heat guns).
3.2.2 Environmental Health And Safety
When servicing products, consider safety and health issues and requirements which must be adhered to at
all times. Specific safety issues are:
1. Electrical safety.
2. Electrostatic discharge.
3. Mixing of foam insulation.
4. Vapours while brazing.
5. Reclaiming of refrigerant.
3.2.3 Good Practice And Safety
1. Take care when removing or servicing any electrical components to avoid electrical shock or short circuit
conditions.
2. Take care when removing plastic components at low temperatures as breakages can occur with these
components.
3. Extreme heating of plastic components can cause distortion of those parts being heated.
4. Avoid overheating temperature sensitive devices such as the element thermal fuses and cabinet sensors.
5. Avoid using solvents, citrus-based cleaners on all plastic parts. We advise only warm soapy water be
used.
10
4 INSTALLATION INSTRUCTIONS
4.1 Levelling
The word 'level' is somewhat of a misnomer as a 'spirit level' need not be used to set the appliance level. It
is preferable to have the appliance level in appearance where both doors will close with the aid of the door
closing components. It is also important that the appliance sits solidly on the floor.
• Front and rear rollers are fitted ex factory.
• Cabinet levelling can be done by adjustment of the front roller levelling wheel fitted ex factory. See
diagram 4.1B.
• Weight should be lifted off the cabinet for ease of adjustment.
• The product should be levelled with the majority of the weight on the hinge side front foot. The opposite
side front foot should then be adjusted to stabilise the product.
REAR ROLLERS
Diagram 4.1A
FRONT ROLLER/LEVELLING WHEEL
Diagram 4.1B
11
4.2 Air Space Requirements
On all refrigerators and freezers it is important that an air gap is left around the product:
• 2 inches clearance at top
• 1 inch clearance each side
4.3 Temperature Adjustment
Refer DISPLAY MODULE in Section 6.1.3.
12
5 THEORY OF OPERATION
5.1 Internal Air Flow
The freezer fan draws air through the evaporator and into a duct in the rear wall of the freezer compartment.
This air exits through the fan grill at the top of the freezer compartment. The air behind the freezer coil cover
is also diverted through the divider partition to another fan which supplies the cold air into the provision
compartment. The amount of air is controlled electronically by two sensors which in turn regulate the speed
of both PC and FC fans to maintain selected temperatures in each compartment.
Air from the PC returns to the FC evaporator by way of the return air duct which is built into the divider
partition. This air is drawn across the evaporator by the evaporator FC fan motor to be recirculated again
throughout the PC / FC compartments.
“B” Model
Active Smart
Diagram 5.1A
“T” Model
Active Smart
PC Fan
PC Sensor
FC Fan
Diagram 5.1B
13
5.2 Defrost Cycle
A heating element is used to defrost the ice accumulated on the evaporator. The defrosts are adaptive to
the usage and environment and are controlled by the power/control module. During a defrost, the
temperature above the evaporator is sensed by the defrost sensor located on the evaporator chassis. This
sensor must register +8
o
C (46oF) before terminating the defrost heater element. If the sensor does not
register a temperature of +8
o
C (46oF) within 30 minutes of the commencement of the defrost cycle, the
defrost will be terminated. If two successive defrost attempts fail to reach this temperature, a fault code is
displayed (refer Section 6.2.1). Previous defrost history, the number of door openings, and the compressor
run time are used to determine the interval between defrosting. The typical time interval for defrosts is
between 12 and 24 hours. However, it can be as short as 5 hours or as long as 96 hours depending on the
usage and environment.
NOTE: The defrost cycle will not start if the defrost sensor is above +8°C (46
o
F).
The defrost cycle follows a predefined sequence:
There is a delay of 2 minutes before the element starts to heat (commonly known as evaporator
warm up time).
The defrost element will remain on until the defrost sensor has reached +8
o
C (46oF).
The compressor will remain off for a further 4 minutes (commonly known as drip time).
The compressor will restart, and a further 30 seconds later both fans will restart.
The following table outlines the defrost cycle of an Active Smart refrigerator.
Diagram 5.2
14
5.3 The Refrigeration Circuit
The compressor discharges high pressure, high temperature gas into the back panel condenser circuit first,
and then into the right hand side condenser in the cabinet by way of the base tube. This tube runs from the
compressor compartment forward to the front bottom edge of the cabinet, returning down the left hand side
to be connected to the left hand side condenser coil.
A loop from this condenser coil forms the cross rail mullion on dual temperature cabinets. The condenser
then continues across the top front edge of the cabinet to form the right hand side condenser before entering
the filter drier which is mounted vertically in the unit compartment.
Now the high pressure gas has been condensed, the liquid refrigerant flows through the capillary tube,
entering the evaporator mounted in the freezer compartment. The liquid refrigerant then boils off due to the
low suction pressure applied to within the evaporator from the compressor. The heat laden vapour is drawn
back to the compressor by way of the suction line to start the cycle all over again.
The above information relates to the cabinet, not the drawing below.
F.F.C.
Diagram 5.3
15
5.4 Servicing Features
5.4.1 Condensate Disposal
During the defrost cycle, which is electronically timed and controlled, live frost is melted off the evaporator by
means of heat from the defrost element. Condensate from the evaporator defrosting drops into a collection
trough, which has an outlet hole in the centre of the liner. A tube then allows the condensate to flow into a
water evaporation tray above the compressor.
FILTER DRIER
Diagram 5.4.1
The filter drier or molecular sieve, as the name suggests, is both a filter and a drier. Whenever a system is
opened, it is essential that the filter drier is replaced. ALWAYS ensure that replacement filter driers are kept
well sealed and airtight prior to being fitted to a system.
PLEASE NOTE: When filter driers are replaced on systems being serviced, it is important that the filter
drier is either cut from the system or the desiccant is removed before heat is applied to the old filter
drier. Failure to do so will drive any moisture held in the desiccant back into the system.
ALWAYS mount vertically or as near to vertical as possible and use the correct desiccant to suit the
refrigerant being used.
XH7 or XH9 suits R134a.
16
5.4.2 Internal Condenser
The internal condenser is made in three sections (see circuit diagram below). One third of the condenser is
attached to the back panel, and the other parts are attached to the inside of the right and left sides of the
cabinet wrapper (as viewed from the back) all being foamed into place. It is very important, if pressure
testing the high side circuit, to split the condenser into its 3 sections to locate which section is at fault.
Always ease the back panel away from the cabinet slightly before pressure testing the internal pipework.
This will prevent a pressure build-up within the cabinet should any leak be found internally in the foam
insulation. Such a leak could pressurise and damage the cabinet liner.
The back panel condenser comes as part of the back panel and should always be replaced as a complete
assembly if the back panel is ever removed.
F.F.C.
Diagram 5.4.2A
17
CONDENSER LAY OUT 680 / 790
"T" MODELS
CONDENSER WITH TUBE CROSS RAIL
FROM BACK PANEL
CONDENSER
BACK PANEL CIRCUIT REMOVED FOR CLARITY
ALL BRAZED CONDENSER JOINTS ARE EXTERNAL IN UNIT COMPARTMENT
Diagram 5.4.2B
18
CONDENSER LAY OUT 680 / 790
"B" MODELS
CONDENSER WITH TUBE CROSS RAIL
FROM BACK PANEL
CONDENSER
ALL BRAZED CONDENSER JOINTS ARE EXTERNAL IN UNIT COMPARTMENT
Diagram 5.4.2C
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