Traulsen G31310, G313XX SERVICE MANUAL

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SERVICE MANUAL
TRAULSEN G SERIES
FREEZER
G12000 Model Series
G22000 Model Series
G31300 Model Series
G22010 MODEL SHOWN
This Manual is prepared for the use of trained Hobart Service Technicians and should not be used by those not properly qualified.
This manual is not intended to be all encompassing. If you have not attended a Hobart Service School for this product, you should read, in its entirety, the repair procedure you wish to perform to determine if you have the necessary tools, instruments and skills required to perform the procedure. Procedures for which you do not have the necessary tools, instruments and skills should be performed by a trained Hobart Service Technician.
The reproduction, transfer, sale or other use of this Manual, without the express written consent of Hobart, is prohibited.
This manual has been provided to you by ITW Food Equipment Group LLC ("ITW FEG") without charge and remains the property of ITW FEG, and by accepting this manual you agree that you will return it to ITW FEG promptly upon its request at any time in the future.
A product of TRAULSEN Fort Worth, TX 76106-1988
F25393 (August 2010)
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G SERIES FREEZER
TABLE OF CONTENTS
GENERAL .........................................................................................3
Introduction ....................................................................................3
Location .......................................................................................3
Operation ......................................................................................3
Cleaning .......................................................................................3
Tools .........................................................................................3
Control Panel ...................................................................................4
Specifications...................................................................................4
REMOVAL AND REPLACEMENT OF PARTS..............................................................6
Covers & Panels ................................................................................6
Cabinet Lamp...................................................................................7
Intela-traul Control ...............................................................................8
Intela-traul Relay Module ..........................................................................8
Compressor Relay ...............................................................................9
Cabinet Air Sensor...............................................................................9
Evaporator Coil Sensor ..........................................................................10
Thermal Expansion Valve ........................................................................10
Evaporator Coil / Defrost Heater ...................................................................11
Door Gasket...................................................................................11
Door Assembly.................................................................................12
Evaporator Fan ................................................................................12
Condensing Unit Components .....................................................................13
Hot Gas Condensate Pan ........................................................................14
SERVICE PROCEDURES AND ADJUSTMENTS ..........................................................15
Check Refrigerant Charge (Superheat, Sub Cooling & Split Temperatures) ..................................15
Checking for Leaks .............................................................................16
Evacuating System .............................................................................17
Charging System ...............................................................................17
System Clean up ...............................................................................17
Software Version ...............................................................................18
Control Calibration ..............................................................................18
Control Parameters .............................................................................19
Evaporator Coil Sensor Test ......................................................................22
Cabinet Air Sensor Test ..........................................................................22
Cabinet Air, Cabinet Coil,
& Sensor Resistance Test ....................................................................22
Compressor Relay Test ..........................................................................22
Door Switch Test ...............................................................................22
ELECTRICAL OPERATION ...........................................................................23
Component Function ............................................................................23
Sequence of Operation ..........................................................................24
Component Location ............................................................................25
Wiring Diagrams................................................................................26
TROUBLESHOOTING ...............................................................................28
© Hobart 2010
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G SERIES FREEZER - GENERAL
GENERAL
INTRODUCTION
General
All G series freezers are Energy Star efficient and include a wide range of one, two, & three sectional reach in freezers. All models are capable of -10EF in up to 90EF ambient. The cabinets are equipped with anti-condensate door perimeter heaters.
These units aid in preserving food quality, texture and nutritional value.
All of the information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing.
LOCATION
Refer to the Installation Instructions for specific location requirements.
OPERATION
Refer to the Operation Manual for specific operating instructions.
CLEANING
Refer to the Operation Manual for specific cleaning instructions. The condenser coil must be cleaned every six months. This can be done with a vacuum cleaner using a fin comb or condenser coil brush.
TOOLS
Standard set of hand tools
Clamp meter Part No. 00-541069 Grainger No. 1ND81 or equivalent
Grounding kit - Static Control Kit Grainger No. 4KK44
Micro amp meter
VOM with AC current tester (sensitivity of at least 20,000 ohms per volt)
Refrigeration tool kit Part No. 00-913093-15
Digital thermometer with quad inputs Model DT304 Part No. 00-913093-12
Inficon D-Tek Select refrigerant leak detector Part No. 00-913093-2
Vacuum Cleaner - Shop Vac
Fin comb Grainger Part No. 2YJ78 or equivalent
Condenser coil brush Grainger Part No. 3HHE8 or equivalent
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CONTROL PANEL
G SERIES FREEZER - GENERAL
SPECIFICATIONS
DIMENSIONS 1 Section Cabinet 2 Section Cabinet 3 Section Cabinet
Height- overall on casters 83-1/4" (211.46cm) 83- 1/4" (211.46cm) 83- 1/4" (211.46cm)
Width 29- 7/8" (75.9cm) 52- 1/8" (132.4cm) 76- 5/16" (193.8cm)
Depth 35" (88.8cm) 35" (88.8cm) 35" (88.8cm)
Net Capacity cu. ft. 24.2 46.0 69.1
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G SERIES FREEZER - GENERAL
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS
DATA 1 Section Cabinet 2 Section Cabinet 3 Section Cabinet 3 Section Cabinet
Voltage 115/60/1 115/60/1 115/60/1 208/60/1
Amps Full Load 9.5 11.2 16.0 11.0
OPERATING DATA 1 Section Cabinet 2 Section Cabinet 3 Section Cabinet
Refrigerant Type R-404A R-404A R-404A
High Pressure (psi) 90EF Operating
Temperature
Low Pressure (psi) 90EF Operating
Temperature
500 500 500
250 250 250
BTU/HR (HP) 1930 @ -20EF Evaporator
Temp. & 90EF Ambient
(1/2HP)
REMOVAL AND REPLACEMENT OF PARTS
COVERS & PANELS
Front Panel
1. Remove lower panel screws from cabinet.
2970 @-20EF Evaporator
Temp. & 90EF Ambient
(3/4HP)
3. Remove panel from cabinet.
4. Reverse the procedure to install.
Condenser / Compressor Cover
4710 @-20EF Evaporator
Temp. & 90EF Ambient
(1HP)
2. Remove upper panel screws from cabinet. NOTE: Upper panel screws are accessed from the
back side of front panel.
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1. Access condenser cover at top of cabinet.
2. Remove all screws securing condenser cover to cabinet.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS
3. Lift cover from cabinet.
4. Reverse the procedure to install.
Evaporator Cover
1. Access evaporator cover at top of cabinet.
2. Remove bolts securing evaporator cover to cabinet.
4. Reverse the procedure to install.
NOTE: Replace adhesive seal as needed. Harness Raceway Cover
1. Access harness raceway cover at top of cabinet.
2. Remove screws securing cover to raceway housing.
3. Lift cover up from raceway housing.
4. Reverse the procedure to install.
Control Box Cover
1. Access control box cover at top of cabinet.
2. Remove screws securing cover to cabinet.
3. Use of a screw driver to aid in prying up cover to break adhesive seal then lift cover from cabinet.
3. Lift cover up from control box.
4. Reverse the procedure to install.
CABINET LAMP
1. Open cabinet door to gain access to cabinet light.
2. Reach up and carefully squeeze lamp lens inward to release lens from mounting tabs.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS
3. Remove lens from cabinet.
4. Turn lamp to remove from lamp socket.
5. Reverse the procedure to install.
INTELA-TRAUL CONTROL
other mounting clip.
7. Push Intela-Traul control out from front top panel.
Removal
1. Remove front panel as outlined under COVERS & PANELS.
2. Access control at top of cabinet.
3. Remove control box cover as outlined under COVERS & PANELS.
NOTE: Use care not to damage lead wires.
4. Loosen screws securing harness connector to Intela-Traul Control.
5. Disconnect harness connector from Intela-Traul Control.
8. Reverse the procedure to install.
INTELA-TRAUL RELAY MODULE
Removal
1. Remove front panel as outlined under COVERS
2. Access Intela-Traul relay module at top of
6. Compress in both sides of mounting clip, while sliding clip off Intela-Traul control. Repeat for
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3. Remove control box cover as outlined under
& PANELS.
cabinet.
COVERS & PANELS.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS
NOTE: Use care not to damage lead wires.
4. Disconnect all lead wire connectors from Intela­Traul relay box.
5. Remove both nuts securing Intela-Traul relay module to control box cover.
6. Reverse the procedure to install.
COMPRESSOR RELAY
CABINET AIR SENSOR
1. Access cabinet air sensor at top of cabinet.
2. Remove evaporator cover as outlined under COVERS & PANELS.
3. Remove screw securing sensor & mounting clip to evaporator compartment.
1. Remove front panel as outlined under COVERS & PANELS.
2. Access compressor relay at top of cabinet.
3. Remove control box cover as outlined under COVERS & PANELS.
4. Disconnect all lead wires from compressor relay.
5. Remove nuts from compressor relay.
6. Reverse the procedure to install.
4. Remove harness raceway cover as outlined under COVERS & PANELS.
5. Remove control box cover as outlined under COVERS & PANELS.
6. Route sensor out from evaporator compartment.
7. Disconnect sensor lead wire connector.
NOTE: The green insulation lead wire to green indicator tape on connector for proper connection.
8. Reverse the procedure to install.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS
EVAPORATOR COIL SENSOR
1. Access cabinet coil sensor at top of cabinet.
2. Remove evaporator cover as outlined under COVERS & PANELS.
3. Pull sensor out from evaporator fins.
NOTE: Sensor location for replacement.
THERMAL EXPANSION VALVE
1. Access thermal expansion valve at top of cabinet.
2. Remove evaporator cover as outlined under COVERS & PANELS.
3. Cut wire ties off from refrigerant line insulation.
4. Remove pipe insulation from refrigerant line.
5. Remove insulation from refrigerant line.
4. Remove harness raceway cover as outlined under COVERS & PANELS.
5. Remove control box cover as outlined under COVERS & PANELS.
6. Route sensor out from evaporator compartment.
7. Disconnect sensor lead wire connector.
NOTE: The blue insulation lead wire to blue indicator tape on connector for proper connection.
8. Reverse procedure to install.
6. Loosen bolts securing sensor from refrigerant line.
7. Pull sensor out from mounting bracket.
8. Remove expansion valve from the liquid line at inlet and outlet of valve.
9. Install replacement expansion valve into inlet and fasten sensor to suction line.
10. Recharge unit and check for leaks.
11. Put system back into operation and check the superheat as outlined under CHECK REFRIGERANT CHARGE in SERVICE PROCEDURES AND ADJUSTMENTS.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS
NOTE: Sensor must be insulated. NOTE: It is recommended that the filter/drier be
changed when this part is replaced.
EVAPORATOR COIL / DEFROST
HEATER
1. Access defrost heater at top of cabinet.
2. Remove evaporator cover as outlined under COVERS & PANELS.
3. Remove harness raceway cover as outlined under COVERS & PANELS.
4. Disconnect heater lead wire connector.
5. Remove adhesive tape over refrigeration lines.
7. Remove defrost heater mounting clips from evaporator coil to release defrost heater.
8. Route heater lead wires out from evaporator compartment.
9. Reverse the procedure to install.
DOOR GASKET
6. Lift evaporator coil up and out from evaporator compartment to expose bottom of evaporator coil.
NOTE: Do Not kink refrigeration lines or damage lead wires.
To Remove:
1. Open cabinet door to gain access to door gasket.
2. Start at one corner of the gasket and pull gasket out from the gasket retaining channel.
A. Continue to pull gasket from door until
gasket is completely out of gasket retaining channel.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS
To Install:
1. Run a small bead of food grade silicone in gasket retainer channel.
2. Install gasket starting at corners pressing into retainer gasket channel and work towards center.
DOOR ASSEMBLY
EVAPORATOR FAN
1. Access evaporator fan lead wires at top of cabinet.
2. Remove evaporator cover as outlined under COVERS & PANELS.
3. Disconnect lead wires to evaporator fans.
NOTE: Mark lead wires for later installation.
1. Remove screw from upper door hinge.
2. Lift door assembly upward off hinges and set door assembly aside.
3. Reverse the procedure to install.
NOTE: Install original hinge assemblies onto replacement door.
4. Open cabinet door to gain access to evaporator fan housing.
5. Loosen screws securing evaporator air duct to cabinet.
A. Slide evaporator air duct away from right
side cabinet wall and allow duct to lower into cabinet.
NOTE: Mounting holes in evaporator air duct are keyhole slots.
6. Remove screws securing evaporator fan
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housing to evaporator compartment.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS
7. Allow evaporator fan housing to lower out of cabinet.
8. Reverse the procedure to install.
CONDENSING UNIT
COMPONENTS
box.
NOTE: Mark wire location for installation.
5. Remove insulation from refrigerant line.
6. Disconnect suction and discharge lines from compressor.
7. Remove bolts securing compressor to cabinet.
Compressor
1. Remove condenser / compressor cover as outlined under COVERS & PANELS.
2. Evacuate refrigeration system.
NOTE: The use of reclaiming equipment is mandatory.
3. Use of screwdriver to lift retaining brace upward off junction box cover.
4. Disconnect lead wires from compressor junction
8. Install new compressor and connect wire leads at compressor junction box.
9. Install new filter drier.
10. Evacuate refrigeration system.
11. Charge system and put unit into operation.
12. Check for proper operation.
Condenser Fan Assembly
1. Remove condenser / compressor cover as outlined under COVERS & PANELS.
2. Disconnect lead wires to condenser fan.
3. Remove screws securing condenser fan mounting bracket to cabinet.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS
4. Remove the screws securing mounting bracket to condenser fan.
5. Reverse procedure to install coil, then proceed to next step.
NOTE: It is recommended that the filter drier be changed when this part is replaced.
6. Evacuate refrigeration system.
NOTE: The use of reclaiming equipment is mandatory.
7. Charge system and put unit into operation.
Filter Drier
5. Reverse the procedure to install.
Condenser Coil
1. Evacuate refrigeration system. NOTE: The use of reclaiming equipment is
mandatory.
2. Remove condenser / compressor cover as outlined under COVERS & PANELS.
3. Disconnect inlet and outlet lines at the soldered connections nearest the condenser coil.
4. Remove screws securing coil to mounting plate.
1. Remove condenser / compressor cover as outlined under COVERS & PANELS.
2. Remove filter drier from liquid lines.
3. Install a new filter direr.
4. Evacuate refrigeration system.
NOTE: The use of reclaiming equipment is mandatory.
5. Charge system and put unit into operation.
HOT GAS CONDENSATE PAN
1. Remove condenser / compressor cover as outlined under COVERS & PANELS.
2. Remove screw securing hot gas coil retaining bracket to the cabinet.
NOTE: Do not damage the coil during removal.
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS
3. Lift the retaining bracket up out from insert slot in cabinet.
4. Lift the hot gas coil out of condensate pan.
5. Pull hot gas pan from cabinet.
6. Reverse procedure to install.
SERVICE PROCEDURES AND ADJUSTMENTS
CHECK REFRIGERANT CHARGE
(SUPERHEAT, SUB COOLING &
SPLIT TEMPERATURES)
Introduction
Superheat is the heat that the refrigerant vapor absorbs above the boiling point.
Helpful Hints
7 degrees F is a desirable superheat at coil outlet, but superheat for the TXV's are set at the factory.
Procedure
1. Superheat Temperature
2. Connect a temperature probe thermocouple to the evaporator coil outlet (D).
A. Install a piece of pipe insulation around the
thermocouple probe.
3. Connect a temperature probe thermocouple to the evaporator coil inlet (C).
A. Install a piece of pipe insulation around the
thermocouple probe.
4. If applicable, install all evaporator box covers over evaporator.
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS
5. Let refrigerant system run. Temperature readings should be taken after the cabinet is at pull down temperature & just before the compressor cycles off.
6. Take readings of evaporator coil inlet (C) & evaporator coil outlet (D) lines.
A. Subtract temperature reading of evaporator
coil outlet temperature (D) to the evaporator coil inlet temperature (C) reading to obtain a superheat temperature.
Example: evaporator outlet temp. (D) - evaporator inlet temp. (C) = superheat temp.
NOTE: TXV superheat is set at the factory and is not adjustable.
B. If superheat temperature reading is out of
spec, call Refrigeration Service Support.
7. Remove thermocouples and install all covers & panels.
Sub Cooling & Split Temperatures
B. To obtain a split temperature reading: add
condenser coil inlet (A) & condenser coil outlet (B) readings divide by 2 and then subtract ambient temperature reading.
Example: [(condenser inlet (A) + condenser outlet (B)) / 2] !ambient temp. = split temperature.
6. If split temperature reading is out of spec, call Refrigeration Service Support.
7. Remove thermocouples and install all covers & panels.
CHECKING FOR LEAKS
1. Connect a temperature probe thermocouple to the condenser coil inlet (A).
A. Install a piece of pipe insulation around the
thermocouple probe.
2. Connect a temperature probe thermocouple to the condenser coil outlet (B).
A. Install a piece of pipe insulation around the
thermocouple probe.
3. If applicable, install all evaporator box covers over evaporator.
4. Let refrigerant system run for approximately 3 to 5 minutes before taking temperature readings.
5. Take readings of condenser coil inlet (A) & condenser coil outlet (B) lines.
A. To obtain a sub cooling temperature
reading: add condenser coil inlet (A) & condenser coil outlet (B) readings divide by 2 and then subtract condenser coil outlet (B) reading.
Example: [(condenser inlet (A) + condenser outlet temp. (B)) / 2] !condenser outlet (B) = sub cooling temperature.
1. Access the refrigeration system.
2. Connect the low (blue) side of gauge manifold to schrader valve.
3. Connect refrigerant bottle to center of gauge manifold and open valve on bottle.
4. Open valve on low side of gauge manifold and charge system with a small amount of refrigerant (1 to 2 ounces).
5. Close bottle valve and gauge valve.
6. Disconnect refrigerant bottle and connect nitrogen bottle.
7. Set output valve on nitrogen bottle to 120 psi.
8. Open nitrogen bottle valve and gauge manifold valve (low side) and allow pressure to equalize.
9. Shut off both valves and disconnect the nitrogen bottle.
10. Using a leak detector or a thick soapy solution, check for leaks at all tubing connections.
A. If any leaks are detected, repair the leak
and recheck.
B. If no leaks are discovered, evacuate
system as outlined under EVACUATING SYSTEM.
11. Charge system as outlined under CHARGING SYSTEM.
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS
EVACUATING SYSTEM
Introduction
Refrigeration reclaiming equipment is required. The goal in system evacuation is to remove all the
non-condensables as possible. No evacuation method will remove 100% of the moisture and air from within the refrigeration circuit. Because of this, guidelines and methods must be developed and adhered to ensuring only harmless amounts of contaminants remain in the system.
Guidelines
Use only a two stage vacuum pump (2 CFM or greater) and electronic micron gauge integrated into a refrigeration reclaiming system.
Evacuate from high to low sides of system.
No chemical additives or alcohols are to be used to Dry Up a system.
No Flushing with solvents or any type of Freon alien to system. Blow down of system with DRY NITROGEN prior to evacuation is acceptable and many times desirable. See SYSTEM CLEAN UP.
Evacuate to 500 microns of mercury.
Procedure
7. Repeat steps 5 and 6 once.
8. Pull vacuum to 500 microns.
9. Charge system and check for proper operation.
CHARGING SYSTEM
1. Access the refrigeration system.
2. Be sure system is properly leak checked and evacuated before charging as outlined under LEAK CHECK and EVACUATING SYSTEM.
3. Connect high side of gauge manifold to the receiver valve. Make certain both valves are closed on the gauge manifold.
NOTE: Charge the system through the high side to prevent liquid refrigerant from reaching the compressor.
4. Connect refrigerant bottle to center connection of gauge manifold.
5. Turn the refrigerant bottle upside down.
6. Open valves on bottle, gauge manifold and receiver.
7. Allow the proper amount of refrigerant to enter the system, then shut the gauge and bottle valves.
8. Disconnect the hose from the receiver valve.
9. Reconnect power to the unit and check for proper operation and high pressure leaks.
10. Disconnect power to the unit and replace any covers removed.
11. Reconnect power to the unit.
1. Access the refrigeration system.
2. Connect low (blue) side of gauge manifold to schrader valve on compressor access line and high (red) side of gauge manifold to schrader valve on filter drier line.
3. Connect center line of gauge manifold to vacuum pump.
4. Turn vacuum pump on and open both sides of gauge manifold.
5. Pull a vacuum to 500 microns.
6. Break the vacuum with 3 psig of operating refrigerant. On remote systems DRY NITROGEN may be preferred.
SYSTEM CLEAN UP
Introduction
When a compressor burn-out is encountered, the service person must make the determination as to the degree of system contamination.
Normally a compressor burn-out will fit in one of three categories:
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS
Contained - compressor oil not acidic, no oil discoloration.
Contaminated compressor - oil acidic, discoloration of oil, contamination limited to compressor.
Massive contamination - contaminated oil and / or refrigerant pumped into system.
Contained
1. Replacement of liquid line drier.
2. Install suction line filter drier.
3. Replacement of compressor.
4. Evacuation (to 500 microns).
5. Charge by weight.
Contaminated Compressor
The Contaminated Compressor requires the same procedure as the Contained Burn-Out. Plus, the system must be flushed after the compressor and drier have been removed.
Massive Contamination
The replacement compressor MUST NOT installed until after system clean-up procedures have been completed.
1. Remove the burned-out compressor as outlined under COMPRESSOR in REMOVAL AND REPLACEMENT OF PARTS.
2. Remove any of the in-line refrigerant controls.
3. Flush high and low sides of system until acidic oil has been removed from the remaining components of the system.
4. Reassemble refrigeration system.
5. Evacuate refrigeration system as outlined under EVACUATING SYSTEM.
6. Charge system as outlined under CHARGING SYSTEM.
7. Reconnect power and check for proper operation.
8. Disconnect power and install any panels removed.
9. Reconnect power. After 24 hours of operation check system for acid and proper operation.
10. Once the system is determined clean, remove the suction line drier.
be
SOFTWARE VERSION
The control program software version can be determined by:
1. Turn power on to the Intela-Traul control.
2. While control powers up the control display will show the software version for a second (C32 and above).
CONTROL CALIBRATION
Certain components in this system are subject to damage by electrostatic discharge during field repairs. A field service grounding kit is available to prevent damage. The field service grounding kit must be used anytime the control board is handled.
1. Verify that the cabinet air sensor is functioning properly as outlined under CABINET AIR, & CABINET COIL, SENSOR TEST.
2. Place a thermocouple of a temperature tester in the center of right incoming air slot of the cabinet.
A. Route thermocouple through hinge side of
door to the outside of the cabinet and close the door(s).
3. Set the control temperature to 0EF.
4. Allow the cabinet temperature to stabilize (minimum 3 cycles).
5. Note temperature reading on temperature tester and control display at the exact time the refrigeration system turns off.
6. If the temperature difference between the two readings is greater than ±2EF or ±1EC, adjust if:
A. If temperature test shows a temperature
higher than control, increase.
B. If temperature test shows a temperature
lower than control, decrease.
C. If temperature difference is greater than
the range of the control, replace controller (range ±50EF. or ±10EC.).
7. Check for proper operation.
8. Remove temperature tester thermocouple from the cabinet.
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS
CONTROL PARAMETERS
NOTE: Not all control parameters can be adjusted at the customer level of access. To adjust parameters not at the
customer level it will be necessary to access the engineering level. NOTE: If 30 seconds elapse between keypad presses, the controller will revert to a cabinet temperature display
(normal operation). If the wrong security code is entered, the controller will revert to a cabinet temperature display (normal operation). To save settings & exit customer access mode, press the alarm cancel keypad or not pressing any keypads for 30 seconds.
To Access Customer Level
1. Use security code 0A1 by:
2. Pressing the Set keypad until CUS is displayed.
3. Press the Set keypad until left zero is flashing with three zeros displayed.
4. Press the Set keypad until center zero is flashing with three zeros displayed.
5. Press the Down Arrow until A is shown in center display.
6. Press Set keypad until right zero is flashing with 0A0 displayed.
7. Press the Up Arrow until 1 is flashing in right display.
8. Press the Set keypad. Display should read SP (Thermostat Set Point) indicating controller is in Customer Access Mode.
To Access Engineering Level
1. Press the Set keypad until CUS is displayed.
2. Press the DOWN ARROW keypad until ENG is displayed.
3. Press the Set keypad until 000 is displayed with the left digit flashing.
4. Press the DOWN ARROW keypad until left digit displays 9.
5. Press the Set keypad until the center digit flashes.
6. Press the DOWN ARROW keypad until center digit displays 9.
7. Press the Set keypad until the right digit flashes.
8. Press the DOWN ARROW keypad until the right digit displays E.
9. Press SET keypad then the DOWN ARROW keypad until FOC is displayed.
NOTE: Hex File GF1 (Standard) and GF3 (-10
10. Use the DOWN ARROW keypad to scroll through control parameters.
EF Freezer).
PARAMETER
DISPLAYED
SPH
software ver. C28
SPL
software ver. C28
SP
software ver. C32
& above
SPD
software ver. C32
& above
SHL
software ver. C28
SHH
software ver. C28
DEFAULT PARAMETER SETTINGS
(FREEZER MODEL SERIES)
DESCRIPTION /
ACCESS LEVEL
Temperature set point
high / Cus. level
Temperature set point
low / Cuc. level
Set point cut out
temperature
Set point differential SP TO SPD 2.0 EF4.0 EF
Set point high-low /
Eng. level
Set point high-high /
Eng. level
RANGE
Standard Freezer
Model G1, G2, & G3
Hex File GF1
SHH to SHL 0 EF-5.0EF
SLH to SLL -4.0EF -10.0EF
-3.0 EF -10.0 EF
-40EF. up to current setting for SHH
From current setting
for SHL up to
266EF.
-2.0 EF -8.0 EF
2.0 EF -5.0 EF
-10
Model G1 & G2
Hex File GF3
EF Freezer
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PARAMETER
DISPLAYED
G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS
DEFAULT PARAMETER SETTINGS
(FREEZER MODEL SERIES)
DESCRIPTION /
ACCESS LEVEL
RANGE
Standard Freezer
Model G1, G2, & G3
Hex File GF1
EF Freezer
-10
Model G1 & G2
Hex File GF3
SLL
software ver. C28
SLH
software ver. C28
RO
HI
LO
SCL
AC
DEF
IBD
DDC
Set point low-low/ Eng.
level
Set point low-high/ Eng.
level
Room ambient offset /
Cuc. level
Upper temperature limit
/ Eng. level
Lower temperature limit
/ Eng. level
Temperature scale EF
or EC / Cuc. level
Anti-cycling- minute /
Eng. level
Defrost type- ele., gas,
none, off cycle / Eng.
level
Intervals between
defrosts- hours / Eng.
level
Maximum defrost
duration- minute / Eng.
level
-40EF. up to current
setting for SLH
from current setting
for SLL up to 266 EF
±3EF. in 1/2EF.
increments
-40 EF. to 266EF. 10.0EF5.0 EF
-40 EF. to 266EF. -15.0 EF -15.0 EF
EF. or EC. EF EF
1-10 min. in 1 min.
increments
ELE, GAS, NONE or
OFF
1-9 hrs. in 1 hr.
increments
0-30 min. in 5 min.
increments
-6.0 EF -13.0 EF
-2.5 EF -10 EF
0 EF0 EF
33
ELE ELE
4.0 4.0
30 30
CDE
DDE
BDD
BSD
ODD
SD
CL
Coil temperature at end
of defrost cycle / Eng.
level
Drip time at end of
defrost cycle- minute /
Eng. level
Blower delay at drip
time-minute / Eng. level
BSD after defrost end /
Eng. level
Display hold after
defrost-minute / Eng.
level
Start-Stop defrost /
Cus. level
Set the clock time /
Cus. level
40 EF. to 80 EF. in 5
EF. increments
1-5 min. in 1 min.
increments
0-5 min. in 1 min.
increments
30 EF. to 40 EF. in 1
EF. increments
0-30 min. in 5 min.
increments
YES / NO
00:00 to 23:59
Setting for 12hr. or
24 hr. time
(H=hours, N=min.,
S=sec.)
45 EF 45 EF
44
67
20.0 EF 10.0 EF
10 10
Start a new defrost cycle at any time or stops a current defrost cycle.
Set the clock for standard time or military time.
F25393 (August 2010) Page 20 of 32
Page 21
PARAMETER
DISPLAYED
G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS
DEFAULT PARAMETER SETTINGS
(FREEZER MODEL SERIES)
DESCRIPTION /
ACCESS LEVEL
RANGE
Standard Freezer
Model G1, G2, & G3
Hex File GF1
EF Freezer
-10
Model G1 & G2
Hex File GF3
DAY
DS
DL1
DL3
DL4
DCF
software ver. C28
CON
COF
EL
Set the clock date /
Cus. level
Daylight Savings / Cus.
level
Defrost lockout 1 / Cus.
level
Defrost lockout 3 / Cus.
level
Defrost lockout 4 / Cus.
level
Dewpoint correction
factor / Cus. level
Compressor default On
time / Eng. level
Compressor Off time /
Eng. level
Evaporator coil
temperature / Cus.
level
(Y=year, N=month,
E=day # in week example: Sun=1
Sat=7)
ON / OFF ON ON
2:00 to 8:00 in. 30 min. increments &
OFF
14:00 to 20:00 in. 30
min. increments &
OFF
2:00 to 20:00 in. 30
min. increments &
OFF
0 to 100 100 100
5-30 min. in 1 min.
increments
5-30 min. in 1 min.
increments
n/a
Set the year, month, day of the month and day of the week.
OFF OFF
OFF OFF
OFF OFF
20 20
55
Displays evaporator coil temperature in real time every time an arrow keypad is pressed.
CB
PLn
software ver. C28
RCO
RdF
RFA
RDH
CEP
Ref
Sn
Cabinet air temperature
/ Cus. level
Display line voltage /
Eng. level
Cycle compressor relay
/ Eng. level
Cycle defrost relay /
Eng. level
Cycle fan relay / Eng.
level
Cycle door heater relay
/ Eng. level
Clear EPROM & load
defaults / Eng. level
Software version,
revision, step / n/a level
Cabinet serial number /
Cus. level
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a n/a
Displays cabinet air temperature in real time every time an arrow keypad is pressed.
Displays power line voltage in real time every time an arrow keypad is pressed.
Turns On/Off the compressor relay for 10 seconds or until an arrow keypad is pressed.
Turns On/Off the defrost relay for 10 seconds or until an arrow keypad is pressed.
Turns On/Off the blower relay for 10 seconds or until an arrow keypad is pressed.
Turns On/Off the door heater for 10 seconds or until an arrow keypad is pressed.
Clear all control memories and reloads the factory default parameters.
Firmware revision in the format X9.9 (X=version, 9=major revision, .9= minor revision).
11. To exit, press the alarm cancel keypad or not pressing any keypads for 30 seconds.
Page 21 of 32
F25393 (August 2010)
Page 22
G SERIES FREEZER - ELECTRICAL OPERATION
EVAPORATOR COIL SENSOR
TEST
1. Access the customer level by pressing the Set keypad until CUS is displayed.
2. Press the Set keypad until left zero is flashing with three zeros displayed.
3. Press the Set keypad until center zero is flashing with three zeros displayed.
4. Press the Down Arrow until A is shown in center display.
5. Press Set keypad until right zero is flashing with 0A0 displayed.
6. Press the Up Arrow until 1 is flashing in right display.
7. Press Up Arrow until EL is displayed then press Set keypad.
A. If display shows -40 check for loose wire
connections and retest.
B. If display shows 266 OR higher replace the
evaporator coil sensor.
NOTE: Erratic display readings indicate an open or short in the control.
4. Verify multi meter reading to the temperature conversion chart as follows.
Temperature
EF
-5.0 99.9 -20.5
0 85.2 -17.7
5.0 72.9 -15.0
10.0 62.4 -12.2
15.0 53.7 -9.4
20.0 46.2 -6.7
25.0 39.9 -3.9
30.0 34.6 -1.1
32.0 32.7 0.0
35.0 30.1 1.7
40.0 26.1 4.4
45.0 22.8 7.2
Ohm Reading
K Ohms
Temperature
EC
CABINET AIR SENSOR TEST
1. Access the customer level by pressing the Set keypad until CUS is displayed.
2. Press the Set keypad until left zero is flashing with three zeros displayed.
3. Press the Set keypad until center zero is flashing with three zeros displayed.
4. Press the Down Arrow until A is shown in center display.
5. Press Set keypad until right zero is flashing with 0A0 displayed.
6. Press the Up Arrow until 1 is flashing in right display.
7. Press Up Arrow until AA is displayed then press Set keypad.
A. If display shows 111 check for loose wire
connections and retest.
B. If display shows 32.0 correct inadequate
air flow through the condenser, replace the cabinet air sensor, or condenser fan assembly.
NOTE: Erratic display readings indicate an open or short in the control.
CABINET AIR, CABINET COIL,
& SENSOR RESISTANCE TEST
1. Gain access to the sensor.
2. Disconnect sensor lead wires from connector.
3. Set the multi meter to ohm scale and connect leads to sensor lead wires.
50.0 19.9 10.0
55.0 17.4 12.8
60.0 15.3 15.6
65.0 13.5 18.3
70.0 11.9 21.1
5. If multi meter reading indicates an open or is outside the ohm range ±10%, replace the sensor.
COMPRESSOR RELAY TEST
1. Turn supply power Off.
2. Gain access to the compressor relay.
3. Disconnect N.O. & COM lead wires from relay.
4. Set the multi meter to ohm scale and connect leads to relay N.O. & COM terminals .
5. Verify the multi meter reading indicates an open circuit. If not, replaced the relay .
DOOR SWITCH TEST
1. Turn supply power Off.
2. Open the cabinet doors.
3. Gain access to the door switch.
4. Disconnect lead wires from switch.
5. Set the multi meter to ohm scale and connect leads to switch terminals .
6. Verify the multi meter reading indicates an open circuit. If not, replaced the switch.
F25393 (August 2010)
Page 22 of 32
Page 23
G SERIES FREEZER - ELECTRICAL OPERATION
ELECTRICAL OPERATION
COMPONENT FUNCTION
Intela-Traul Control ..... Performs the following functions:
A. Displays all data for the current software revision & mode of operation. B. Cycles refrigeration system to maintain cabinet temperatures. C. Cycles defrost relay to defrost evaporator coil. D. Monitors power losses as well as component malfunctions. E. Monitors door position.
Compressor .............. Pumps refrigerant through refrigeration system lines and components.
Start Capacitor ............ Wired in series with the start windings to help start compressor motor.
Run Capacitor............. Continually in circuit to help compressor motor during operation.
Compressor Relay ......... Senses current of run winding of compressor motor. Normally open contacts
close when the run winding draws a high amperage at start and brings the start capacitor and start windings into the circuit. As the motor reaches operating speed (less amperage through run winding), the normally open contacts open and removes the start capacitor and start windings from the circuit.
Evaporator Fan ........... Draws air from the cabinet and moves the air through the evaporator coil back
into cabinet.
Condenser Fan ........... Draws air across condenser coil to aid in removing heat from the refrigerant and
move air across compressor to aid in cooling the compressor.
Defrost Heater............. Defrosts evaporator coil and prevents water droplets from evaporator coil to
freeze before they can drain to the condensate pan. Operates only during defrost cycle.
Cabinet Air Sensor ........ Monitors air temperature inside cabinet.
Cabinet Coil Sensor ....... Monitors the evaporator coil while the cabinet is powered.
...........
Door Switch .............. Monitors door for open or closed position. Evaporator fans stop when door is
open.
Solenoid Valve ............ Normally closed when energized, allows refrigerant to flow from receiver to
evaporator coil.
Door Perimeter Heater ...... Prevents condensate from forming on door frame.
Intela-Traul Relay Module . . . Controls power to the following components:
A. Evaporator fan(s). B. Door heater. C. Defrost heater. D. Compressor relay. E. Solenoid valve.
Main Switch............... Controls power to intela-traul relay box, compressor relay, door switch, &
auxiliary components. Removes power from listed components.
Heated Glass Doors ........ Auxiliary component, prevents condensate from forming on glass door.
Condensate Evaporator ..... Auxiliary component, when energized dissipates condensate in the evaporator
pan.
Page 23 of 32
F25393 (August 2010)
Page 24
G SERIES FREEZER - ELECTRICAL OPERATION
SEQUENCE OF OPERATION
Refrigeration System
1. The control must be powered on.
2. The control monitors cabinet air temperature and senses a need for cooling.
3. The compressor motor is energized and refrigerant is pumped through the system.
4. The TXV monitors the evaporator superheat and meters the amount of refrigerant entering the evaporator.
5. The control senses the cabinet air temperature requirements have been met.
6. Compressor motor de-energized by the compressor relay.
7. System is cycled by control.
Freezer Mode
1. Main switch closed. A. Relay module energized. B. Control energized. C. Compressor relay. D. Condenser fan(s) energized. E. Compressor motor energized.
2. Control displays software revision & then cabinet temperature.
3. After 2-1/2 minutes evaporator fan(s) energized.
4. The refrigeration system will cycle on the air temperature of the cabinet. A. On at the high set point (SP + D) temperature. B. Off at the low set point (SP) temperature.
NOTE: Set points are selected in the parameter menu. NOTE: If the cabinet door is opened during operation, the evaporator fan(s) will shut Off.
5. Evaporator fan(s) cycled on time and or temperature.
6. Unit is cycled by control.
Defrost Mode
1. The defrost mode can be entered manually or run automatically.
2. When control initiates a defrost cycle, the control snowflake is illuminated. A. Defrost heater energized. B. Compressor motor de-energized. C. Evaporator fan(s) de-energized.
3. Defrost cycle operates until the EL temperature setting is reached or the maximum DDC time setting has elapsed.
4. Defrost mode cycled by control.
F25393 (August 2010)
Page 24 of 32
Page 25
G SERIES FREEZER - ELECTRICAL OPERATION
COMPONENT LOCATION
F25393 (August 2010)Page 25 of 32
Page 26
WIRING DIAGRAMS
115V/60HZ/1PH
G SERIES FREEZER - ELECTRICAL OPERATION
F25393 (August 2010) Page 26 of 32
Page 27
220V/50-60HZ/1PH
G SERIES FREEZER - ELECTRICAL OPERATION
F25393 (August 2010)Page 27 of 32
Page 28
G SERIES FREEZER - TROUBLESHOOTING
TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSES
Nothing runs, blank control. 1. Main circuit breaker open.
2. Main on/off switch off.
3. Power cord unplugged.
Compressor will not run, no current draw. 1. Cabinet temperature satisfied.
2. Door open or malfunction door switch, with display on control.
3. Incorrect wiring.
4. Cabinet air sensor malfunctioned.
5. Start component malfunctioned.
6. Compressor motor windings open.
7. Control malfunctioned.
8. Compressor relay malfunctioned.
9. Relay module malfunctioned.
Compressor will not run, current draw and trips breaker.
Defrost time too long. 1. Evaporator coil sensor malfunctioned.
Compressor short cycles. 1. Improper air flow over evaporator coil.
Compressor run time lengthy. 1. Partial loss of refrigerant.
Continuous compressor operation. 1. Loss of refrigerant.
Low suction pressure. 1. Restriction in refrigeration system.
High head pressure. 1. Improper air flow across condenser.
1. Start component malfunctioned.
2. Compressor motor windings shorted.
3. Locked rotor.
2. Incorrect wiring.
3. Control malfunctioned.
4. Defrost heater malfunctioned.
2. Expansion valve malfunctioned.
3. Low ambient conditions.
4. Evaporator fan(s) malfunctioned.
5. Cabinet air sensor malfunctioned.
6. Evaporator coil sensor malfunctioned.
7. Control malfunctioned.
2. High ambient conditions.
3. Improper air flow over condenser coil.
4. Excessive product load.
5. Excessive door openings.
6. Door gasket(s) need replaced.
7. Condenser fan(s) malfunctioned.
8. Cabinet air sensor malfunctioned.
9. Cabinet coil sensor malfunctioned.
10. Contaminates in refrigeration system.
11. Control malfunctioned.
12. Relay module malfunctioned.
2. Excessive door openings.
3. Cabinet air sensor malfunction.
4. Control malfunctioned.
2. Loss of refrigerant.
3. Expansion valve blocked.
2. Extreme ambient conditions.
3. Overcharge of refrigerant.
4. Air in refrigerant system.
5. Condenser fan(s) malfunctioned.
F25393 (August 2010)
Page 28 of 32
Page 29
G SERIES FREEZER - TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSES
Iced Evaporator coil. 1. Evaporator fan(s) malfunctioned.
2. Verify defrost control parameter settings.
3. Evaporator coil sensor malfunctioned.
4. Compressor relay malfunctioned.
5. Control relay module.
6. Cabinet air sensor malfunctioned.
7. Control malfunctioned.
8. Refrigerant system malfunctioned.
Will not defrost. 1. Defrost heater(s) malfunction.
2. Incorrect wiring.
3. Compressor relay malfunctioned.
4. Evaporator coil sensor malfunctioned.
5. Control malfunctioned.
Control display blank. 1. Main power supply.
2. Relay module malfunctioned.
3. On/off switch malfunctioned.
4. Control malfunctioned.
Page 29 of 32
F25393 (August 2010)
Page 30
G SERIES FREEZER - TROUBLESHOOTING
-NOTES-
F25393 (August 2010) Page 30 of 32
Page 31
G SERIES FREEZER - TROUBLESHOOTING
-NOTES-
F25393 (August 2010)Page 31 of 32
Page 32
G SERIES FREEZER - TROUBLESHOOTING
-NOTES-
F25393 (August 2010) Printed in U.S.A.
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