How it Works
Fisher & Paykel
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R134a
Service Manual
145 pgs8.99 Mb0
Table of contents
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Fisher & Paykel 635 Active Smart, 680 Active Smart, 790 Active Smart, R600a, 900 Active Smart Service Manual

...
Service Manual
635 / 680 / 790 / 900 Active Smart®
Refrigerator/Freezer
R134a & R600a Systems
321144
2
321144 - JULY 2012 REPRINT - AUGUST 2012
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 Ltd
78 Springs Road, East Tamaki Auckland 2013 PO Box 58-732, Botany, Auckland 2163, New Zealand
Fisher & Paykel Australia Pty Ltd
A.C.N. 003 335 171 19 Enterprise Street P O Box 798 Cleveland, Queensland 4163 Telephone: 07 3826 9100
Facsimile: 07 3826 9164 Telephone: 09 273 0600 Facsimile: 09 273 0656
Fisher & Paykel Appliances
5800 Skylab Road Huntington Beach CA 92647 Telephone: 888 936 7872
Fisher & Paykel Appliances Ltd U.K
Maidstone Road,
Kingston, Milton Keynes
Buckinghamshire, MK10 0BD
England
Telephone: 0845 066 2200
Facsimile: 0845 331 2360
COPYRIGHT © FISHER & PAYKEL LTD 2012 - ALL RIGHTS RESERVED
3
Fisher & Paykel Singapore Pte Ltd
150 Ubi Avenue 4 Sunlight Building #02-00 Singapore 408825 Telephone: 65 65470100 Facsimile: 65 65470123
CONTENTS
SPECIFICATIONS ...................................................................................................................................8
1
1.1 Cabinet Specifications – 230 - 240 Volt....................................................................................8
1.2 Cabinet Specifications – 110 - 115 Volt..................................................................................10
1.3 Compressor Specifications – R134a – 220 - 240 Volt............................................................11
1.4 Compressor Specifications – R600a – 220 - 240 Volt............................................................12
1.5 Compressor Specifications – R134a – 110 - 115 Volt............................................................13
1.6 Model Number Identification – 635 / 680 / 790 .......................................................................14
1.7 Model Number Identification – 900 .........................................................................................15
2 SERVICING REQUIREMENTS..............................................................................................................16
2.1 Specialised Service Tools.......................................................................................................16
2.1.1 Static Strap .........................................................................................................................16
2.1.2 Interface Light Pen Mk 2 ....................................................................................................16
2.2 Health & Safety .......................................................................................................................16
2.2.1 Good Work Practices.........................................................................................................16
2.2.2 Environmental Health And Safety ......................................................................................16
2.2.3 Good Practice And Safety..................................................................................................16
3 INSTALLATION INSTRUCTIONS .........................................................................................................17
3.1 Levelling ..................................................................................................................................17
3.2 Door Hinging (Tasman Models Only) .....................................................................................18
3.3 Air Space Requirements .........................................................................................................18
3.4 Temperature Adjustment ........................................................................................................18
4 THEORY OF OPERATION ....................................................................................................................19
4.1 Terms ......................................................................................................................................19
4.2 Internal Air Flow ......................................................................................................................20
4.2.1 Ice & Water Models............................................................................................................20
4.2.2 Non Ice & Water Models ....................................................................................................21
4.3 Defrost Cycle...........................................................................................................................22
4.3.1 R134a System....................................................................................................................22
4.3.2 R600a System....................................................................................................................23
4.4 The Refrigeration Circuit .........................................................................................................24
4.5 Evaporator...............................................................................................................................24
4.6 Condensate Disposal..............................................................................................................25
4.7 Filter Drier ...............................................................................................................................25
4.8 Internal Condenser .................................................................................................................26
4.8.1 Condenser Lay Out 635 / 680 / 790 "T" Models ................................................................27
4.8.2 Condenser Lay Out 635 / 680 / 790 / 900 "B" Models .......................................................28
4.9 Compressor Compartment Layout..........................................................................................29
4.10 Cross Rail................................................................................................................................29
4.11 Door and Door Hinge ..............................................................................................................29
4.12 Compressor.............................................................................................................................29
4.13 Thermal Fuse ..........................................................................................................................29
4.14 Drain Heater Wire ...................................................................................................................29
4.15 Divider Partition.......................................................................................................................30
4.16 LCD Display Panel ..................................................................................................................31
4.17 Door Switches .........................................................................................................................31
4.18 Defrost Heater.........................................................................................................................31
4.19 Low Ambient Heater................................................................................................................32
4.20 PC / FC Fans ..........................................................................................................................32
4.20.1 “B” Model Fan.....................................................................................................................32
4.20.2 “T” Model PC Fan...............................................................................................................33
4.21 Interior Light ............................................................................................................................34
4.22 Thermistor Temperature Sensors ...........................................................................................35
4.23 Basic Operation.......................................................................................................................36
4.23.1 Temperature Adjustment – Ice & Water Models ................................................................36
4.23.2 Temperature Adjustment – Non-Ice & Water Models ........................................................36
5 ELECTRONICS SECTION.....................................................................................................................37
5.1 Diagrammatic Overview Function Description........................................................................37
5.2 Control and Peripheral Functions ...........................................................................................38
5.3 Power/Control Module ............................................................................................................38
4
Display Module .......................................................................................................................39
5.4
6 VARIABLE CAPACITY COMPRESSOR ..............................................................................................40
6.1 Variable Capacity Compressor Control Overview .................................................................. 40
6.2 Built-in Electronic Protections (Within the Module/Inverter) ...................................................40
6.2.1 Compressor Start-up..........................................................................................................40
6.2.2 Overload Detection and Protection....................................................................................40
6.2.3 Power Limitation (Temperature Protection) ....................................................................... 41
6.2.4 Short Circuit Protection ......................................................................................................41
6.3 VCC Module/Inverter Identification.........................................................................................41
6.4 Fault Finding ...........................................................................................................................41
6.4.1 High Voltage Power Supply Circuit....................................................................................41
6.5 VCC-3 Inverter With Diagnostic Function...............................................................................42
6.5.1 Diagnostic Procedures.......................................................................................................42
6.5.2 Testing The VCC3 Inverter (With Diagnostic Function).....................................................44
7 DISPLAY INTERFACE – ICE & WATER MODELS .............................................................................48
7.1 Display Functional Schematic ................................................................................................48
7.2 Display Interface Features...................................................................................................... 49
7.3 Features..................................................................................................................................49
7.3.1 Icemaker On/Off.................................................................................................................49
7.3.2 Freezer Chill Mode.............................................................................................................49
7.3.3 Bottle Chill Mode ................................................................................................................49
7.3.4 Water Dispensing...............................................................................................................49
7.3.5 Sabbath Mode....................................................................................................................50
7.3.6 Key Silent Mode ................................................................................................................. 50
7.3.7 Dispenser Lock ..................................................................................................................50
7.3.8 Key Lock ............................................................................................................................50
7.3.9 Filter Replacement Alert ....................................................................................................50
7.4 Key Presses............................................................................................................................51
7.5 Temperature Settings .............................................................................................................51
8 ICEMAKER ............................................................................................................................................52
8.1 Ice Production.........................................................................................................................52
8.2 Information About The Icemaker ............................................................................................52
8.3 Ice Bin Full Sequence............................................................................................................. 52
8.4 Safety First..............................................................................................................................53
8.5 Icemaker Fill Tube Heater ......................................................................................................53
8.6 Pressure Limiting Valve ..........................................................................................................53
8.7 Water Inlet Valves...................................................................................................................53
8.8 Noises .....................................................................................................................................54
8.9 Ice & Water Common Complaints ..........................................................................................54
9 WATER DISPENSER ............................................................................................................................55
9.1 Installation Precautions / Warning ..........................................................................................55
9.2 Pressure Dispensing Pad .......................................................................................................55
9.3 Initial Use ................................................................................................................................55
9.4 Water Filter and Cartridge ......................................................................................................55
9.5 Changing The Water Filter......................................................................................................56
9.6 To Reset The Filter Icon .........................................................................................................56
9.7 To Disable The Filter Alarm ....................................................................................................56
10 DIAGNOSTICS ......................................................................................................................................57
10.1 Ice & Water Models................................................................................................................57
10.1.1 Fault Codes........................................................................................................................57
10.1.2 Testing Icemaker Sensor ...................................................................................................61
10.1.3 Testing Icemaker Motor .....................................................................................................61
10.1.4 Testing Water Valve...........................................................................................................62
10.1.5 Diagnostic Modes ..............................................................................................................63
10.1.6 Input / Output Status ..........................................................................................................65
10.1.7 Fault History ....................................................................................................................... 65
10.1.8 To Manually Force A Defrost .............................................................................................65
10.1.9 LCD Display .......................................................................................................................65
10.1.10 To Manually Force The Icemaker......................................................................................66
10.1.11 Data Download ..................................................................................................................66
10.2 Non-Ice & Water Models.........................................................................................................67
10.2.1 Fault Codes........................................................................................................................67
5
Diagnostic Mode For Service .............................................................................................70
10.2.2
10.2.3 Sensor Temperature Conversion .......................................................................................70
10.2.4 Input / Output Status ..........................................................................................................71
10.2.5 Data Download...................................................................................................................72
10.2.6 To Manually Force A Defrost .............................................................................................72
10.2.7 Show Room Mode..............................................................................................................72
10.2.8 Special Option Mode (Israel)..............................................................................................73
10.3 Problem Solving Checklist ......................................................................................................74
11 ICEMAKER & WATER DISPENSER SERVICE PROCEDURES .........................................................75
11.1 Component Replacement .......................................................................................................75
11.1.1 Icemaker PCB Replacement ..............................................................................................75
11.1.2 Icemaker Unit Removal ......................................................................................................75
11.1.3 Refitting Icemaker ..............................................................................................................75
11.1.4 Icemaker Temperature Sensor Replacement ....................................................................75
11.1.5 Water Valve Replacement .................................................................................................75
11.1.6 Display Module Replacement ............................................................................................76
11.1.7 Water Dispenser Pad Replacement...................................................................................77
11.1.8 Removing Water Tank........................................................................................................77
11.1.9 Refitting Water Tank...........................................................................................................78
11.1.10 Replacing Icemaker Fill Tube Heater ................................................................................78
11.1.11 Replacing PC Door On Ice & Water Models......................................................................81
11.1.11.1 Designer Doors.........................................................................................................81
11.1.11.2 Classic Doors............................................................................................................84
12 SERVICING PROCEDURES.................................................................................................................88
12.1 Safety Considerations .............................................................................................................88
12.2 Electrical Safety Test ..............................................................................................................88
12.3 Doors and Door Gaskets ........................................................................................................89
12.4 Removal Of Power/Control Module ........................................................................................89
12.4.1 Initialisation Of The Power/Control Module After Installation – Non-Ice & Water Models .90
12.5 Freezer Bin, Runner and Air Deflector Removal - E402B and E372B Models.......................90
12.6 FC Bin Removal - 900 Models ................................................................................................90
12.7 FC Drawer Removal - 900 Models .........................................................................................91
12.7.1 Refitting Of The FC Drawer................................................................................................91
12.8 PC Fan Motor - “T” Models .....................................................................................................92
12.9 PC Fan Motor - “B” Models .....................................................................................................92
12.10 Defrost Element Replacement ................................................................................................92
12.11 Thermal Fuse ..........................................................................................................................92
12.12 Cross / Base Rail Door Switches ............................................................................................93
12.13 Removal Of Display Module – Non-Ice & Water Models........................................................93
12.14 PC Sensor Replacement ........................................................................................................93
12.15 FC Sensor Replacement- “T” and “B” Models........................................................................93
12.16 FC Sensor Replacement - 900 Models...................................................................................93
12.17 Icemaker Temperature Sensor Replacement.........................................................................93
12.18 Replacement Of Low Ambient Heater - “T” Model..................................................................94
12.19 Replacement Of Low Ambient Heater - “B” Models ...............................................................94
12.20 Replacement Of Low Ambient Heater - “B” Model (In Return Grill) .......................................94
12.21 Interior LED Light Replacement..............................................................................................94
12.22 Flapper Element Replacement ...............................................................................................95
12.23 Block/Edge Connectors ..........................................................................................................97
12.24 Fan Cover Removal Tool (T Models Only) .............................................................................99
12.25 Active Smart® PC/FC Fan Motor Tester .................................................................................99
13 WORKING ON THE SEALED SYSTEM............................................................................................. 101
13.1 Safe Work Practices ............................................................................................................ 101
13.2 Leak Detection ..................................................................................................................... 101
13.3 R600a Operating Pressures ................................................................................................ 101
13.4 Reclaiming ........................................................................................................................... 101
13.5 Brazing Off The System....................................................................................................... 102
13.6 Pressure Testing Of The Refrigeration System ................................................................... 102
13.7 Transporting Of Refrigerators .............................................................................................. 104
13.8 Evaporator Replacement ..................................................................................................... 105
13.9 Refilling A Void In Foam Insulation After System Service Or Adjustment ........................... 105
13.9.1 Polyurethane Foam ......................................................................................................... 106
13.9.2 Safe Practices ................................................................................................................. 106
6
Removing Back Panel For Access To Water Lines And Joints............................................ 107
13.10
13.11 Embraco Compressor Fitted With External Overload ..........................................................108
13.12 Matsushita “D” Series Compressor Fitted With External Overload And Run Capacitor ......109
13.13 Compressor Replacement ....................................................................................................110
13.14 Compressor Fault Diagnosis ................................................................................................111
13.14.1 Compressor Won't Start - Dead (PTC Relay Fitted) ....................................................111
13.14.2 Compressor Won't Start - Hums......................................................................................112
13.14.3 Compressor Starts, Runs And Then Stops .....................................................................112
14 WIRING DIAGRAMS...........................................................................................................................113
14.1 Non Ice & Water Models Power Module Wiring Connections ..............................................113
14.2 Non-Ice & Water Models Wiring Diagram.............................................................................114
14.3 Ice & Water Models Power Module Wiring Connections...................................................... 115
14.4 Ice & Water Models Wiring Diagram ....................................................................................116
14.5 900 Models Power Module Wiring Connections - Reciprocating Compressor ....................117
14.6 900 Models Wiring Diagram - Reciprocating Compressor ...................................................118
14.7 900 Models Power Module Wiring Connections – VC Compressor..................................... 119
14.8 900 Models Wiring Diagram - VC Compressor....................................................................120
14.9 “B” Model Wiring Route ........................................................................................................121
14.10 “T” Model Wiring Route.........................................................................................................122
15 SERVICE REFERENCE ......................................................................................................................123
15.1 Service Reference ‘B’ Models ..............................................................................................123
15.2 Service Reference ‘T’ Models...............................................................................................127
16 FAULT FINDING FLOW CHART - SERVICING .................................................................................130
16.1 Refrigerator Not Operating ...................................................................................................131
16.2 No Power To Power/Control Module And/Or Display Module.............................................. 132
16.3 PC/FC Warm.........................................................................................................................133
16.4 FC Too Cold – PC Too Warm...............................................................................................134
16.5 PC Too Cold .........................................................................................................................135
16.6 Ice/Condensation Forming....................................................................................................136
16.7 No Light.................................................................................................................................137
16.8 Door Switch Not Operating ...................................................................................................138
16.9 Defrost Heater Faults............................................................................................................139
16.10 Compressor Faults ...............................................................................................................140
16.11 Compressor Runs Continuously...........................................................................................140
16.12 Compressor Will Not Run And Is Hot To Touch...................................................................141
16.13 Compressor Electrical Tests.................................................................................................141
16.14 Refrigeration System Faults .................................................................................................142
16.15 Not Dispensing Water...........................................................................................................143
16.16 Not Producing Ice .................................................................................................................144
7
1 SPECIFICATIONS

1.1 Cabinet Specifications – 230 - 240 Volt

DIMENSIONS
E331T E372B E381T E402B E406B E411T E413T E415H E440T
Height with Standard Door
Height with Designer Door
Depth 700 mm 700 mm 700 mm 700 mm 700 mm 700 mm 700 mm 700 mm 700 mm Width 635 mm 635 mm 635 mm 635 mm 680 mm 635 mm 680 mm 635 mm 680 mm
CAPACITY GROSS VOLUME IN LITRES (AS 1430)
Refrigerator PC 232 litres 250 litres 283 litres 280 litres 271 litres 314 litres 314 litres 229 litres 342 litres Freezer FC 97 litres 123 litres 97 litres 123 litres 133 litres 97 litres 97 litres 97 litres 99 litres Humidity Dr N/A N/A N/A N/A N/A N/A N/A 85 litres N/A
TOTAL
ELECTRONICS – 230 – 240V (FOR SPARE PARTS)
Display Module P/No. 881218P P/No. 881218P P/No. 881218P P/No. 881218P P/No. 881218P P/No. 881218P P/No. 881218P P/No. 881218P P/No. 881218P Display Module -
Ice & Water Power/Control
Module - Non RoHS (AUS/NZ/ROW)
Power/Control Module - RoHS (UK/IRE/EU)
1425 mm 1595 mm 1595 mm 1700 mm 1700 mm 1700 mm 1595 mm 1700 mm 1700 mm
N/A N/A N/A 1710 mm N/A N/A N/A N/A N/A
329 litres 373 litres 380 litres 403 litres 404 litres 411 litres 411 litres 411 litres 441 litres
N/A N/A N/A P/No. 821074P N/A N/A N/A N/A N/A
P/No. 820817P P/No. 820817P P/No. 820817P P/No. 820817P P/No. 820817P P/No. 820817P P/No. 820817P P/No. 820817P P/No. 820817P
P/No. 820818P P/No. 820818P P/No. 820818P P/No. 820818P P/No. 820818P P/No. 820818P P/No. 820818P P/No. 820818P P/No. 820818P
SUCTION LINE ASSY (FOR SPARE PARTS)
R134a Models P/No. 813374 P/No. 817862 P/No. 813374 P/No. 817862 P/No. 817865 P/No. 817863 P/No. 817866 P/No. 817863 P/No. 817866 R600a Models N/A P/No. 821189 N/A P/No. 821149 P/No. 821149 N/A P/No. 821151 N/A P/No. 821150
DEFROST ELEMENT – 230 - 240V (FOR SPARE PARTS)
R134a Models Wattage
R600a Models Wattage
P/No. 820673
295W
N/A
P/No. 820673
295W
P/No. 821875
178W
P/No. 820673
295W
N/A
P/No. 820673
295W
P/No. 821875
178W
P/No. 820675
322W
P/No. 821876
196W
P/No. 820673
295W
N/A
P/No. 820675
322W
P/No. 821876
196W
P/No. 820673
295W
N/A
P/No. 820675
322W
P/No. 821876
196W
8
DIMENSIONS
E442B E521T E522B RF540A/RF610A
Height with Standard Door
Height with Designer Door
Depth 700 mm 700 mm 700 mm (27.6”) 730 mm (28.7”) Width 680 mm 790 mm 790 mm (31.1”) 900 mm (35.4”)
1700 mm 1700 mm 1700 mm (67”) 1780 mm (70.1”)
1710 mm N/A 1710 mm (67.3”) 1790 mm (70.5”)
CAPACITY GROSS VOLUME IN LITRES (AS 1430)
Refrigerator PC 307 litres 400 litres 360 litres (12.7 c/ft) 433 litres (15.3 c/ft) Freezer FC 135 litres 117 litres 159 litres (5.6 c/ft) 181 litres (6.4 c/ft) Humidity Dr N/A N/A N/A N/A
TOTAL
442 litres 517 litres 519 litres (18.3 c/ft) 614 litres (21.7 c/ft)
ELECTRONICS – 230 - 240V (FOR SPARE PARTS)
Display Module P/No. 814321P P/No. 814321P P/No. 814321P N/A Display Module ­Ice & Water
Power/Control Module - Non RoHS (AUS/NZ/ROW)
Power/Control Module –RoHS (UK/IRE/EU)
P/No. 821074P N/A P/No. 821074P P/No. 821074P
P/No. 820817P P/No. 820817P P/No. 820817P
P/No. 820818P P/No. 820818P P/No. 820818P
(RF610A)
P/No. 821024P
(RF540A)
P/No. 821025P
SUCTION LINE ASSY (FOR SPARE PARTS)
R134a Models P/No. 817865 P/No. 817866 P/No. 817864 P/No. 817864 R600a Models P/No. 821149 P/No. 821150 P/No. 821148 P/No. 821148
DEFROST ELEMENT – 230 - 240V (FOR SPARE PARTS)
R134a Models Wattage
R600a Models Wattage
P/No. 820675
322W
P/No. 821876
196W
P/No. 860686
355W
P/No. 821877
240W
P/No. 860686
355W
P/No. 821877
240W
P/No. 860686
355W
P/No. 821877
240W
9

1.2 Cabinet Specifications – 110 - 115 Volt

DIMENSIONS
E402B E415H
Height with Standard Door
Height with Designer Door
Depth 694 mm 694 mm Width 635 mm 635 mm
CAPACITY GROSS VOLUME IN LITRES (AS 1430)
Refrigerator PC 280 litres 226 litres Freezer FC 123 litres 97 litres Humidity Dr N/A 88 litres
TOTAL
ELECTRONICS – 100 - 110V (FOR SPARE PARTS)
Display Module P/No. 881218P P/No. 881218P Display Module -
Ice & Water Power/Control
Module
SUCTION LINE ASSY (FOR SPARE PARTS)
R134a Models P/No. 817862 P/No. 817863
DEFROST ELEMENT –100 - 110V 321W (FOR SPARE PARTS)
R134a Models 100V 110V
1700 mm 1700 mm
1710 mm N/A
403 litres 411 litres
P/No. 820174P N/A
P/No. 820819P P/No. 820819P
P/No. 820821P P/No. 820699P
P/No. 820821P P/No. 820699P
10

1.3 Compressor Specifications – R134a – 220 - 240 Volt

E331T E372B E381T E402B E406B E411T E413T E415H
Make Matsushita Matsushita Matsushita Matsushita Embraco Matsushita Matsushita Matsushita Matsushita Model DHS73C10RAW DHS73C10RAW DHS66C88RAW DHS73C10RAW EGZS90HLC DB77C14RAY DB77C14RAY DHS73C10RAW DHS66C88RAW Part number 207216P 207216P 207215P 207216P 207188P 209492P 209492P 207216P 207215P Volts 220 - 240 220 - 240 220 - 240 220 - 240 230 230 - 240 230 - 240 220 - 240 220 - 240 Hertz 50 50 50 50 50 - 60 50 50 50 50 Input Watts 123 123 113 123 129 / 153 147 147 123 113 Output Watts 210 210 190 210 226 / 278 213 213 210 190 Nominal BTU 717 717 649 717 770 / 950 742 742 717 649 Run current 0.57 amps 0.57 amps 0.53 amps 0.57 amps 0.71 amps 1.2 amps 1.2 amps 0.57 amps 0.53 amps Refrigerant type R134a R134a R134a R134a R134a R134a R134a R134a R134a Start Resistance 18.5 ohms 18.5 ohms 23.3 ohms 18.5 ohms 21.7 ohms 16.43 ohms 16.43 ohms 18.5 ohms 23.3 ohms Run Resistance 18.4 ohms 18.4 ohms 19.7 ohms 18.4 ohms 10.4 ohms 11.62 ohms 11.62 ohms 18.4 ohms 19.7 ohms Oil charge (cm3) 280 (Ester) 280 (Ester) 280 (Ester) 280 (Ester) 280 (Ester) 310 (Ester) 310 (Ester) 280 (Ester) 280 (Ester)
Relay PTC
Overload
Gas charge 120 Grams 130 Grams 120 Grams 140 Grams 150 Grams 150 Grams 130 Grams 140 Grams 130 Grams Start Capacitor N/A N/A N/A N/A N/A N/A N/A N/A N/A
Run Capacitor
Inverter N/A N/A N/A N/A N/A N/A N/A N/A N/A
PTHTM330MD3 207276
5TM22NFBYY 207224
4µF 814809P
E440T E442B E521T E522B RF540A/RF610A RF540A/RF610A
Make Matsushita Matsushita Matsushita Matsushita Embraco Embraco Model DB77C14RAY DB77C14RAY DHS77C13RAW DHS77C13RAW EGZS100HCL VEGY6H Part number 209492P 209492P 207217P 207217P 207253P 819639P Volts 230 - 240 230 - 240 220 - 240 220 - 240 220 - 240 220 - 240 Hertz 50 50 50 50 50 / 60 53 - 150 Input Watts 147 147 133 133 143 / 171 55.7 - 177 Output Watts 213 213 222 222 251 / 308 97 - 283 Nominal BTU 742 742 758 758 855 / 1050 330 - 965 Run current 1.2 amps 1.2 amps 0.64 amps 0.64 amps 0.8 amps 0.8 - 2.23 amps Refrigerant type R134a R134a R134a R134a R134a R134a Start Resistance 16.43 ohms 16.43 ohms 18.2 ohms 18.2 ohms 25.8 ohms 6.4 ohms Run Resistance 11.62 ohms 11.62 ohms 15.2 ohms 15.2 ohms 9.84 ohms 6.4 ohms Oil charge (cm3) 310 (Ester) 310 (Ester) 280 (Ester) 280 (Ester) 280 (Ester) 430 (Ester)
Relay PTC
Overload
Gas charge 140 Grams 150 Grams 155 Grams 150 Grams (5.3 oz) 180 Grams 180 Grams Start Capacitor N/A N/A N/A N/A N/A N/A
Run Capacitor
Inverter N/A N/A N/A N/A N/A 207213
MM8-5DDT33M 209988
MM3-18GCF 209083
4µF 814809P
PTHTM330MD3 207276
5TM22NFBYY 207224
4µF 814809P
MM8-5DDT33M 209988
MM3-18GCF 209083
4µF 814809P
PTHTM330MD3 207276
5TM205NFBYY 207222
4µF 814809P
PTHTM330MP3 207276
5TM232NFBYY 207226
4µF 814809P
PTHTM330MD3 207276
5TM22NFBYY 207224
4µF 814809P
PTHTM330MP3 207276
5TM232NFBYY 207226
4µF 814809P
PTH7M220MD3 207080
4TM283NFBYY-53 207289
4µF 814809P
207080 7M220MD3
4TM302KFBYY 207259
4µF 814809P
MM8-5DDT33M 209988
MM3-18GCF 209083
4µF 814809P
N/A
N/A
N/A
MM8-5DDT33M 209988
MM3-18GCF 209083
4µF 814809P
PTHTM330MD3 207276
5TM22NFBYY 207224
4µF 814809P
PTHTM330MD3 207276
5TM205NFBYY 207222
4µF 814809P
11

1.4 Compressor Specifications – R600a – 220 - 240 Volt

E372B E402B E406B E413T E440T
Make Embraco Embraco Embraco Embraco Embraco Embraco Model EMB55CLC EMB66CLC VEMC9C EMB66CLC EMB66CLC EMB66CLC Part number 207314P 207278P 207308P 207278P 207278P 207278P Volts 220 - 240 220 - 240 220 - 240 220 - 240 220 - 240 220 - 240 Hertz 50 50 53 - 150 50 50 50 Input Watts 86 102 33 - 117 102 102 102 Output Watts 162 190 62 -210 190 190 190 Nominal BTU 553 648 213 - 715 648 648 648 Run current 0.4 amps 0.5 amps 0.28 - 0.86 amps 0.5 amps 0.5 amps 0.5 amps Refrigerant type R600a R600a R600a R600a R600a R600a Start Resistance 11.6 ohms 12.7 ohms 8.1 ohms 12.7 ohms 12.7 ohms 12.7 ohms Run Resistance 21 ohms 15.9 ohms 8.1 ohms 15.9 ohms 15.9 ohms 15.9 ohms Oil charge (cm3) 150 (Alquib/ISO5) 150 (Alquib/ISO5) 210 (Alquib/ISO5) 150 (Alquib/ISO5) 150 (Alquib/ISO5) 150 (Alquib/ISO5)
Relay PTC
Overload
Gas charge 50 Grams 50 Grams 50 Grams 55 Grams 52 Grams 52 Grams Start Capacitor N/A N/A N/A N/A N/A N/A
Run Capacitor
Inverter N/A N/A 207309 N/A N/A N/A
EMB66QP2 20A 207292
4TM232KFBYY-53 207243
4µF 814809P
EMB66QP2 20A 207292
4TM232KFBYY-53 207243
4µF 814809P
E442B E521T E522B RF540A RF610A
Make Embraco Embraco Embraco Embraco Embraco Embraco Embraco Model EGX80CLC VEMC9C EGX80CLC EGX90CLC VEMB11C VEMB11C EGX100CLC Part number 207279P 207308P 207279P 207280P 207306P 207306P 207281P Volts 220 - 240 220 - 240 220 - 240 220 - 240 220 - 240 220 - 240 220 - 240 Hertz 50 53 - 150 50 50 53.3 – 143.3 53.3 – 143.3 50 Input Watts 107 33 - 177 107 117 58 - 161 58 - 161 133 Output Watts 199 62 - 210 199 216 108 - 283 108 - 283 248 Nominal BTU 679 213 - 715 679 737 510 - 965 510 - 965 846 Run current 0.49 amps 0.28 - 0.86 amps 0.49 amps 0.85 amps 0.43 - 1.16 amps 0.43 - 1.16 amps 0.61 amps Refrigerant type R600a R600a R600a R600a R600a R600a R600a Start Resistance 22.45 ohms 8.1 ohms 22.45 ohms 22.45 ohms 8.1 ohms 8.1 ohms 17.6 ohms Run Resistance 18.35 ohms 8.1 ohms 18.35 ohms 18.35 ohms 8.1 ohms 8.1 ohms 17.3 ohms Oil charge (cm3) 280 (Alquib/ISO5) 210 (Alquib/ISO5) 280 (Alquib/ISO5) 280 (Alquib/ISO5) 210 (Alquib/ISO5) 210 (Alquib/ISO5) 280 (Alquib/ISO5)
Relay PTC
Overload
Gas charge 55 Grams 50 Grams 60 Grams 60 Grams 55 Grams 62 Grams 70 Grams Start Capacitor N/A N/A N/A N/A N/A N/A N/A
Run Capacitor
Inverter N/A 207309 N/A N/A 207307 207307 N/A
PTH7M220MD3 207080
4TM189NFBYY-53 209890
4µF 814809P
N/A
N/A
N/A
N/A
N/A
N/A
PTH7M220MD3 207080
4TM189NFBYY-53 209890
4µF 814809P
EMB66QP2 20A 207292
4TM232KFBYY-53 207243
4µF 814809P
PTH7M220MD3 207080
4TM189NFBYY-53 209890
5µF 814812P
EMB66QP2 20A 207292
4TM232KFBYY-53 207243
4µF 814809P
N/A
N/A
N/A
N/A
N/A N/A
EMB66QP2 20A 207292
4TM232KFBYY-53 207243
4µF 814809P
PTH7M220MD3 207080
4TM283KFBYY-53 207154
5µF 814812P
12

1.5 Compressor Specifications – R134a – 110 - 115 Volt

Make Embraco Embraco Embraco Model EGZS70HLP EGZS70HLP VEGY6H Part number 207206P 207206P 819652P Volts 115 115 115 Hertz 60 60 53.3 - 150 Input Watts 116 116 55.7 - 177 Output Watts 204 204 97 - 283 Nominal BTU 695 695 330 - 965 Run current 1.04 amps 1.04 amps 0.8 - 2.23 amps Refrigerant type R134a R134a R134a Start Resistance 6.94 ohms 6.94 ohms 6.4 ohms Run Resistance 4.88 ohms 4.88 ohms 6.4 ohms Oil charge (cm3) 280 (Ester) 280 (Ester) 430 (14.54 oz) (Ester)
Relay PTC
Overload
Gas charge 140 Grams (4.9 oz) 120 Grams (4.2 oz) 180 Grams (6.3 oz) Start Capacitor N/A N/A N/A Run Capacitor N/A N/A N/A Inverter N/A N/A 207214
E402B E415H RF540A/RF610A
7M4RMD3 207068
4TM319NFBYY 207205
7M4RMD3 207068
4TM319NFBYY 207205
N/A
N/A
13

1.6 Model Number Identification – 635 / 680 / 790

1 2 3 4 5 6 7 8
E 402 B R E C FP WW Type of refrigeration system
E = Electronic
Example:
E Electronic
402 Litres
B Bottom freezer
R Right hand hinged
E Elegance
C Series
FP Fisher & Paykel brand
WW White cabinet, white doors
Approximate capacity of cabinet in litres
402 = 402 litres
Freezer location
T = Top freezer B = Bottom freezer H = Humidity drawer
Door hinging
R = Right hand L = Left hand
Style
D = Designer E = Elegance I = Inox M = Iridium T = Tasman
E402BREC FP WW
Series Brand
FP = Fisher & Paykel
Colour of the cabinet and doors
WW = White cabinet / white doors SA = Sandstone cabinet / sandstone doors SM = Silver cabinet / matt stainless doors SX = Silver cabinet / brushed stainless doors
14

1.7 Model Number Identification – 900

1 2 3 4 5 6 7 8 9
RF 610 A D U M 2 FP SG
Product Type Capacity of
cabinet in Litres 610 = 610 litres
RF Refrigerator
610 Litres/Cubic feet
A French Door
D Designer Handle
U Ice & Water
M Iridium
2 Iteration
FP Fisher & Paykel
SG Singapore
French Doors
Designer
Ice & Water Colour
Handles
RF 610 A D U M 2 FP SG
Iteration Brand Market M = Iridium X = S/S Ezkleen
15

2 SERVICING REQUIREMENTS

2.1 Specialised Service Tools

For the servicing of this product, specialised tools are needed.

2.1.1 Static Strap

To be used as ESD protection when replacing any of the electronic boards.

2.1.2 Interface Light Pen Mk 2

Used in conjunction with a diagnostic programme on a laptop computer to retrieve and download data from the electronic power/control module.

2.2 Health & Safety

2.2.1 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 evaporator to go open circuit (be careful with heat guns).

2.2.2 Environmental Health And Safety

When servicing products, consider health and safety issues and requirements that 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.

2.2.3 Good Practice And Safety

1. Take care when removing or servicing all 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 and citrus-based cleaners on all plastic parts. We advise only warm soapy water be used.
CAUTION – R600a REFRIGERANT (ISOBUTANE)
Some models of refrigerators contain R600a refrigerant within the sealed in system. This refrigerant is flammable. All care must be taken when servicing these products. Vent well before brazing. Avoid any open flames or ignition source.
16

3 INSTALLATION INSTRUCTIONS

3.1 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 cams. It is also important that the appliance sits solidly on the floor.
• Front and rear rollers are fitted ex factory. These are not adjustable.
• Cabinet levelling can be done by adjustment of the front levelling feet fitted ex factory. Refer to
Diagram
• Weight should be lifted off cabinet for ease of adjustment.
3.1B).
Diagram
Rear Roller
Diagram
Front Roller and Levelling Wheel
3.1A
3.1B
17

3.2 Door Hinging (Tasman Models Only)

The product leaves the factory hinged right hand or left hand. The door hinging can be changed by obtaining a door hinge conversion kit appropriate for the cabinet being converted. There are a number of kits changing the door hinging from RH to LH or from LH to RH. They also include two door B & T models, single door models and “H” models in the 635, 680 and 790 cabinet widths, along with handle colours of white and silver. Inox and Elegance models will require a complete door change.

3.3 Air Space Requirements

On all refrigerators and freezers it is important that an air gap is left around the product:
50mm (2 inches) clearance at the top. 20mm (¾ inch) clearance on each side.

3.4 Temperature Adjustment

Refer BASIC OPERATIONS in Section 4.23.
18

4 THEORY OF OPERATION

4.1 Terms

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 fin on tube type mounted vertically on the back wall of the FC.
SUCTION and CAPILLARY LINE
Foamed into the back of the cabinet with all joints of the evaporator having been joined by induction brazing 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/control module, this module generates the LCD or LED display.
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.
TERMS
Within this manual the following terms are used: PC = Provision compartment FC = Freezer compartment
LOW AMBIENT HEATER
Two types are used. A PCB type used in the air duct of “T” models. A blanket wire type used in the divider of “B” models.
19

4.2 Internal Air Flow

4.2.1 Ice & Water Models

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 PC compartment. The amount of air is controlled electronically by two sensors, which in turn regulate, through the power/control module, 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 FC fan motor to be recirculated again throughout the PC/FC compartments.
Diagram
4.2
20

4.2.2 Non Ice & Water Models

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 PC 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.
Diagram
“B” Model Active Smart
4.2.2A Diagram 4.2.2B
®
“T” Model Active Smart®
21

4.3 Defrost Cycle

4.3.1 R134a System

The following table outlines the defrost cycle of an R134a refrigerant system Active Smart® refrigerator.
COMPRESSOR DEFROST ELEMENT DEFROST ELEMENT COMPRESSOR BOTH PC AND FC
TURNS OFF TURNS ON TURNS OFF TURNS ON FANS TURN ON
DEFROST TIME: TARGET IS 18 MINUTES OR SENSOR REACHES 8 2 MINUTES MAXIMUM IS 40 MINUTES 4 MINUTES 30 SECONDS
NORMAL RUN WARM UP DEFROST DRIP TIME DELAY BACK TO NORMAL RUN
If 40 minutes has elapsed, defrost would be aborted if defrost sensor has not reached 8 defrosts are aborted, Fault Code 2 is displayed.
O
C (46OF). If 2
O
C.
Diagram
4.3.1
22
play

4.3.2 R600a System

The following table outlines the defrost cycle of an R600a refrigerant system Active Smart refrigerator.
COMPRESSOR
TURNS OFF DEFROST ELEMENT DEFROST ELEMENT COMPRESSOR TURNS ON TURNS OFF TURNS ON PC FAN PC FAN PC FAN FC FAN TURNS ON TURNS OFF TURNS ON TURNS ON
DEFROST TIME: TARGET IS 25 MINUTES OR SENSOR REACHES 8 MAXIMUM IS 65 MINUTES 4 MINUTES 5 MINUTES 12.8 MINUTES
NORMAL RUN DEFROST DRIP TIME BACK TO NORMAL RUN
NOTE: The FC fan runs at a
If 65 minutes has elapsed, defrost would be aborted if defrost sensor has not reached 8 are aborted, Fault Code 2 is dis
O
C. If 2 defrosts
ed.
O
C.
lower speed than the PC fan during these
12.8 minutes.
Diagram
4.3.2
23
321144

4.4 The Refrigeration Circuit

The compressor discharges high pressure, high temperature gas into the back panel condenser circuit first, returning via the oil cooler in the compressor and entering the 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 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.
SINGLE EVAPORATOR TWIN FAN SYSTEM
Diagram
4.4

4.5 Evaporator

The evaporator on R134a models is of the Fin and Tube type with the expansion and suction inlet/outlet on the left hand side. The defrost element is fitted to the left and right hand end plates of the evaporator and clamped into position.
Diagram
24
4.5.1
The evaporator on R-600a models is of the Fin and Tube type with the expansion and suction inlet/outlet on the left hand side. The defrost element is fitted to the right hand end plate of the evaporator and clamped into position. The R-600a evaporator does not have an accumulator fitted. This is to reduce the risk of oil slugging with the type of refrigerant used.
Diagram
4.5.2

4.6 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.

4.7 Filter Drier

Diagram 4.7
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.
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 R-600a.
25
321144

4.8 Internal Condenser

The internal condenser is made in three sections (refer circuit diagram below). One third of the condenser is attached to the inside if 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 three sections to locate which section is at fault. Always ease the back panel away from the cabinet slightly before pressure testing the internal pipe work. 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. On fitting a new back panel assembly always replace the mastic vapour-sealing compound before fitting the back panel into the triple fold of the cabinet.
Diagram 4.8
26

4.8.1 Condenser Lay Out 635 / 680 / 790 "T" Models

CONDENSER WITH TUBE CROSS RAIL
BACK PANEL CIRCUIT REMOVED FOR CLARITY
ALL BRAZED CONDENSER JOINTS ARE EXTERNAL IN UNIT COMPARTMENT
Diagram
4.8.1
27
321144

4.8.2 Condenser Lay Out 635 / 680 / 790 / 900 "B" Models

CONDENSER WITH TUBE CROSS RAIL
BACK PANEL CIRCUIT REMOVED FOR CLARITY
ALL BRAZED CONDENSER JOINTS ARE EXTERNAL IN UNIT COMPARTMENT
Diagram
4.8.2
28

4.9 Compressor Compartment Layout

The diagrams below will assist in identifying the various pipes within the compressor compartment. They should be read in conjunction with the full system diagram (refer to Diagram
4.4).
Diagram 4.9

4.10 Cross Rail

The cross rail contains part of the condenser copper tubing (mullion heater) providing heat to the gasket area between the PC and FC compartments, preventing sweating of the gasket. Also mounted on the cross rail is the Reed Sensor, under the plastic cover in the centre.

4.11 Door and Door Hinge

On the Designer models, the upper door hinge is concealed and cannot be seen with the door closed. The upper door height is extended past the top of the cabinet to cover the hinge area.

4.12 Compressor

The compressor is turned on when cooling is required. It is switched by a Triac (solid state switching device) on the power/control module.

4.13 Thermal Fuse

There are two thermal fuses mounted in the wiring harness of the defrost element, having a tripping temperature of 72 assembly.
These fuses in both leads of the element protect the refrigerator from any over heating through failure of the element itself or a triac failure in the power/control module. Both sides are protected in case phase and neutral are reversed.
NOTE: Care should be taken if manually defrosting the evaporator if using heat guns, that the thermal fuses are not over heated.
O
C. Once open circuit they cannot be reset. Replacement is part of the element heater

4.14 Drain Heater Wire

A drain heater wire is fitted to all cabinets except R134a B models. This drain heater helps to prevent the drain tube from blocking with ice. The wire clips onto the double-pass defrost element, with the tail of the heater wire in the drain tube, thus conducting heat from the defrost element into the drain tube area during defrost.
Diagram
29
4.14
321144

4.15 Divider Partition

This is moulded in two outer pieces and has an inner polystyrene moulded duct assembly that is wax coated. This provides a barrier between the FC and PC compartments, also allowing return air from the PC to move back to the FC evaporator in ‘T’ models. In both models it houses the PC fan motor. In ‘B’ models it houses also the low ambient heater. The divider is fitted into the cabinet as an assembly and cannot be replaced.
“B” DIVIDER PARTITION
Diagram 4.15A
“T” DIVIDER PARTITION
Diagram 4.15B
30
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