Traulsen INTELA-TRAUL Service Manual

INTELA-TRAUL

®

Quality Refrigeration

MASTER SERVICE MANUAL

Form Number TR35705, revised 10/04

Traulsen

4401 Blue Mound Road - Fort Worth, Texas 76106

Phone: [phone] or [phone]

Fax-Service [phone]

For All Full Size Undercounter, G-Series and

R&A Series Refrigerator, Freezer, Dual-Temp

and Hot Food Unit Controllers

TABLE OF CONTENTS

-1-

I. General Information

a) How To Use This Manual Page 2
b) About INTELA-TRAUL Page 2
c) Operating The Controller Page 2

II. Basic Service Procedures

a) Adjusting The Temperature Page 3
b) Starting A Manual Defrost Cycle (R & A Series) Page 4
c) Starting A Manual Defrost Cycle (G-Series) Page 5

III. Troubleshooting

a) Checking For Defective Sensors Page 6
b) Checking For Failed Relays Page 7
c) Checking For Other Failed Components Page 8
d) Checking For Iced Evaporator Coil Page 9
e) Proper Sensor Placement Page 10

IV. Control Architecture

a) R & A Series Refrigerator & Freezer Vertical Controllers Page 11-14
b) Undercounter Refrigerator & Freezer Horizontal Controllers Page 15
c) G-Series Refrigerator & Freezer Vertical Controllers Page 16-17
d) R & A Series Heated Cabinet Vertical Controllers Page 18-20

V. Removal/Installation

a) All Vertical Controllers Pages 21-22
b) All Horizontal Controllers Page 23

VI. Problem Diagnosis

a) How To Use Troubleshooting Trees Page 24
b) Hi-Temp Alarm (all HT/RI & LT/IF models) Page 25
c) Lo-Temp Alarm (all HT/RI & LT/IF models) Page 26
d) Door Open Alarm (all HT/RI, LT/IF HF/IH models) Page 27
e) Power Loss Alarm (all HT/RI, LT/IF HF/IH models) Page 28
f) System Leak Alarm (all HT/RI & LT/IF models) Page 29
g) Condenserclean Alarm (all HT/RI & LT/IF models) Page 30

VII. Accessing The Engineering Level Page 31

VIII. Control Parameters

a) Parameter Descriptions Page 32-33
b) Parameter Access & Units Of Measurement Page 34
c) G-Series Parameter Settings Page 35
d) R-Series Parameter Settings - Refrigerator Models Page 36
e) R-Series Parameter Settings - Freezer Models Page 37
f) Undercounter Parameter Settings Page 38

I. a - HOW TO USE THIS MANUAL:

Traulsen provides this manual as an aid to the service technician in installation,
operation, and maintenance of INTELA-TRAUL® Controllers. When used
properly, this service manual can help the service technician maintain,
troubleshoot and diagnose most of the problems and malfunctions that may occur
with the Controllers.

This manual covers the four different types of Controllers (Full Size Undercounter,
G-Series, R&A Series Refrigerator & Freezer, and R&A Series Hot Food). These
vary slightly from one another, all exceptions are noted, and where appropriate
separate sections are provided.

While we believe that most aspects of the controllers are covered in this manual,
should you encounter a condition not addressed, or require a wiring diagram please
contact:

All service communication must include:

 Model Number & Serial Number Of Unit
 A detailed explanation of the problem

Traulsen

4401 Blue Mound Road Fort Worth, TX 76106

Attn: Service Department

Phone: [phone] or [phone]

Fax: [phone]

-2-

I. GENERAL INFORMATION

I. b - ABOUT INTELA-TRAUL:

The Traulsen INTELA-TRAUL and G-Series microprocessor controls are
microprocessor based systems which replace several electromechanical
components typically built into refrigeration products, such as: time clocks,
thermometers, defrost limit switches and temperature controls, all combined into
one solid state modular unit.

These microprocessor controls both monitor a cabinet air sensor and a coil
sensor. The INTELA-TRAUL on the R & A Series also includes a discharge line
sensor and a relative humidity sensor (H1 versions only). In conjuction with the
programmed parameters of the control, and the information received, it cycles the
refrigeration system ON and OFF at set temperatures, initiates and/or terminates
defrost cycles, and initiates one of several alarm features if a problem is sensed
(R & A Series only). R & A Series controls also allow the operator to cycle the door
perimeter heaters ON/OFF as needed.

I. c - OPERATING THE CONTROLLER:

When operating the controller it is important to note that you only have
approximately 20-30 seconds between button pushes. If you take longer than 30
seconds, the controller will revert back to displaying the cabinet temperature.If you
enter the wrong security code, the controller will revert back to displaying the
cabinet temperature. You can exit the parameters at any time by waiting 20-30
seconds for the control to return to normal operation.

Step 1: Press . Display will read “CUS.”

Step 2: Press . Display will read “000” with the left digit flashing.

Step 3: Press . Display will read “000” with the center digit flashing.

Step 4: Press until the center digit changes to an “A”.

Step 5: Press . Display will read “0A0” with the right digit flashing.

Step 6: Press until the right digit changes to an “1”.

Step 7: Press . Display will read “SPH”.

Step 8: Press again.

Step 9: Press or to adjust temperature to desired setting.

(NOTE: SPH should be set at 38 to 40°F for refrigerators and 0°F for freezers)

Step 10: When display reads the desired temperature press .

Step 11: Press until display reads “SPL”.

Step 12: Press .

Step 13: Press or to adjust temperature to desired setting.

(NOTE: SPL should be set at 34°F for refrigerators and -4°F for freezers)

Step 14: Press .

Step 15: Press to exit (R & A Series only). On G-Series models the

controller will automatically revert back to normal temperature display operation

after a delay of approximately 20-30 seconds.

SET

II. BASIC SERVICE PROCEDURES

The Display

Will Read

II. a - ADJUSTING THE TEMPERATURE:

SET

SET

SET

SET

SET

SET

SET

SET

-3-

-4-

II. BASIC SERVICE PROCEDURES

II. b - STARTING A MANUAL DEFROST CYCLE (R & A Series):

The Display

Will Read

Step 1: Press . Display will read “CUS.”

Step 2: Press . Display will read “000” with the left digit flashing.

Step 3: Press . Display will read “000” with the center digit flashing.

Step 4: Press until the center digit changes to an “A”.

Step 5: Press . Display will read “0A0” with the right digit flashing.

Step 6: Press until the right digit changes to an “1”.

Step 7: Press . Display will read “SPH”.

Step 8: Press until the control reads “Sd,” Start Manual Defrost.

Step 9: Press . Display will read “n” (NO).

Step 10: Press or . Display will read “4” (YES).

Step 11: Press . Controller will display “SPH” for 30 seconds and

then “DEF” will appear.

SET

SET

SET

SET

SET

SET

NOTE:
Traulsen R & A Series refrigerator models also include an off-
cycle defrost feature, which occurs once an hour. This is
indicated by the control display, is time or temperature
terminated, and generally is of 3 - 10 minutes in duration.

NOTE: The controller will automatically revert back to normal operation

after a delay of approximately 20-30 seconds.

SET

-5-

II. BASIC SERVICE PROCEDURES

II. c - STARTING A MANUAL DEFROST CYCLE (G-Series):

The Display

Will Read

NOTE:
Traulsen G-Series refrigerator models also include an off-cycle
defrost feature, which occurs once an hour. This is
indicated by the control display, is time terminated, and is
generally of 3 - 10 minutes in duration.

The defrost cycle on Traulsen G-Series freezer models can
be either time or temperature terminated.

Step 1: Press . Display will read “CUS.”

Step 2: Press . Display will read “000” with the left digit flashing.

Step 3: Press . Display will read “000” with the center digit flashing.

Step 4: Press until the center digit changes to an “A”.

Step 5: Press . Display will read “0A0” with the right digit flashing.

Step 6: Press until the right digit changes to an “1”.

Step 7: Press . Display will read “SPH”.

Step 8: Press until the control reads “Sd,” Start Manual Defrost.

Step 9: Press . Display will read “n” (NO).

Step 10: Press or . Display will read “4” (YES).

Step 11: Press . Display will then read “SPH,” Start Manual Defrost.

Step 14: Press or to scroll to the next parameter, otherwise the

controller will automatically revert back to normal operation after a delay of

approximately 20-30 seconds.

SET

SET

SET

SET

SET

SET

SET

-6-

III. TROUBLESHOOTING

Step 1: Press . Display will read “CUS.”

Step 2: Press . Display will read “000” with the left digit flashing.

Step 3: Press . Display will read “000” with the center digit flashing.

Step 4: Press until the center digit changes to an “A”.

Step 5: Press . Display will read “0A0” with the right digit flashing.

Step 6: Press until the right digit changes to an “1”.

Step 7: Press .

Step 8: Press until display reads “EL”. Press .

If the display now reads “-40,” check for loose connection on the EVAPORATOR
sensor. If the display has a very high reading such as “266,” replace the evaporator
sensor.

NOTE: Erroneous readings may be the result of a faulty sensing circuit (open or

shorted) in the Controller.

Step 9: Press until the display reads “DL

1

”. Press .

In the event that the display now reads “-40,” check for a loose connection on the
DISCHARGE LINE sensor. If the display has a reading of “220” or higher, check for lack
of adequate air-flow through the condenser, a bad condenser motor, or any other
condition around the unit which could cause a high temperature, such as a steam
table or a crossdraft. Otherwise, proceed with replacing the DISCHARGE LINE sensor.

NOTE: Erroneous readings may be the result of a faulty sensing circuit (open or

shorted) in the Controller.

Step 10: Press until the display reads “AA

2

”. Press .

Display should read the approximate ambient air temperature behind the louver panel.
If the display reads “111” check for a loose connection on the RH/AMBIENT AIR sensor.
If the display reads “32.0” check the sensor for a short circuit.

NOTE: If display reads -40 or 266 the cabinet sensor is defective and requires

replacement.

NOTE: Ambient Air Sensor not included on MIT version controllers.

NOTE: Erroneous readings may be the result of a faulty sensing circuit (open or

shorted) in the Controller (on H1 control version only).

The Display

Will Read

III. a - CHECKING FOR DEFECTIVE SENSORS:

SET

SET

SET

SET

SET

SET

SET

SET

1= DL is not included on G-Series controllers.
2= AA is not available with MIT version controllers.

-7-

III. TROUBLESHOOTING

III. b - CHECKING FOR FAILED RELAYS:

Checking For A Failed Internal Controller Relay:

1. Gain access to Controller compressor relay (see REMOVAL
INSTRUCTIONS within this service manual for the specific type of
controller your are servicing).

2. Locate the connector with the black/blue/purple wires and unplug it.
Refer to the schematic on the side of the controller, or refer to the
appropriate wiring diagram (to obtain this please contact the factory,
referencing the serial numberof the unit involved).

3. Using a volt/ohm meter (VOM) with the power OFF, check the resistance
across the black to blue wires of the Controller connector. If completed
circuit is indicated (with no power to the Controller), the contacts are
stuck closed and the Controller should be replaced (on MIT versions
either the relay box or one of the other relays within the unit need to be
replaced).

Checking For A Failed External “Slave” Relay or Solid State Relay (SSR),
p/n 337-60360-01 (MIT II Only):

1. Gain access to the controller compressor relay (see REMOVAL
INSTRUCTIONS within this service manual for the specific type of
controller your are servicing).

2. Locate the external “slave” relay and unplug the harness connectors.

3. Using a volt/ohm meter (VOM), check the resistance from the “COM”
terminal to the “NO” terminal. If a completed circuit is indicated, the
contacts are stuck closed and the slave relay should be replaced.

4. For the SSR, remove the black and blue wires from terminals 3 & 4. Using
a volt/ohm meter, and with the power OFF, measure the resistance across
the terminals. A completed circuit indicates that the circuit is closed and
that the relay should be replaced. A reading of 25 mΩ to 35 mΩ is
considered normal for an open circuit in the SSR.

Checking For A Failed Door/Light Relay (R & A Series models only):

1. Gain access to Controller door relay (see REMOVAL INSTRUCTIONS
within this service manual for the specific type of controller your are
servicing).

2. Remove the wire from the door relay coil.

3. Using a volt/ohm meter (VOM), check across the relay contacts. If an
open across the contacts is not indicated, replace the door relay.

NOTE: Equipment manufactured with the MIT II controller version do not
include a Door/Light relay).

4. Physically check the switch for evidence of water. If switch has water in
it, proceed with replacing the switch.

-8-

III. TROUBLESHOOTING

III. c - CHECKING FOR OTHER FAILED COMPONENTS:

Checking For A Failed Door Switch:

1. Remove the door(s) from the unit involved.

2. Locate the door switch, which is located behind the top door hinge(s).

3. Remove the switch from the cabinet.

4. Using a volt/ohm meter (VOM), check across the switch contacts. “COM”
to “NO” should read open. If not, replace the switch.

5. Reinstall the switch and hinge onto the cabinet.

NOTE: If the unit has more than one door, check ALL door switches in the
same manner as described in steps 1 thru 5 above.

Checking For A Failed Controller Transformer

(H1 & MIT I control versions only)

:

1. Check incoming voltage. Voltage at the unit must be within the ranges
shown in the table below.

2. If the controller display does not come back on, use a volt/ohm meter
(VOM) and check the output voltage of the controller transformer.

3. If the output voltage from the transformer is not within the range
shown in the table above, replace the transformer. If the transformer
tests OK, replace the controller instead.

4. For equipment manufactured with the MIT II controller version the
transformer is mounted inside the relay module. Check between 17 and
8 on 18 pin connector on relay module for 12V DC.

Checking Cabinet, Coil or Discharge Line Sensors:

1. Gain access to CABINET, COIL or DISCHARGE LINE sensor and
disconnect it.

2. Place tip if sensor probe in a mixture of icewater for several minutes.
Allow enough time for sensor probe to aclimate to the icewater.

3. At 32°F, probe resistance shoud be 32.7K Ohms, +/- 10%. If resistance
is not within this range, repalce the sensor.

VOLTAGE
MIN MAX STANDARD
104 VAC 126 VAC 115/60/1
187 VAC 253 VAC 208-230/60/1

10.2 Volts 13.8 Volts Transformer
(MIT 12.4) (MIT 14.7) Output Voltage

Replace

controller*

(see note below).

III. TROUBLESHOOTING

III. d - CHECKING FOR ICED EVAPORATOR COIL:

With

evaporator

clear of ice is

there proper

air-flow?

Check evaporator

blower motor for

proper operation.

Replace

evaporator

blower motor.

Evap’r

or ducting

restriction.

Remove restriction.

Check DEF settings in

controller parameters.

Go to pages 33-36.

Check coil sensors.

Go to pages 6, 7 & 8.

Reset

control

parameters

NO NOT OK

YES

OK

NOT OK

Replace

failed

sensor.

NOT OK

OK

Will unit
enter manual
defrost cycle?

Does

compressor

shut-off in

defrost?

Check defrost heater.

YES

Replace

compressor

relay or module.

NO

YES

Will control

cycle unit at set

temps?

OK

YES

Problem

with ref’n

system.

Check cabinet sensor.

Go to pages 6, 7 & 8.

OK

NOT OK

-9-

Replace

failed

cabinet sensor.

*NOTE: See the corresponding pages to
remove and replace the controller:

• R & A Series Refrigerator & Freezer
Pages 21 - 22.

• G-Series Refrigerator & Freezer
Pages 21 - 22.

• Undercounter Refrigerator & Freezer
Page 23.

• R & A Series Hot Food Cabinets
Pages 21 - 22.

III. TROUBLESHOOTING

III. e - PROPER SENSOR PLACEMENT:

Coil Sensor:

The coil sensor should be inserted into
the return air side of the evaporator coil.
On freezer models only this sensor
should be centered approximately 2”
(two inches) from the top (horizontally
through coil - centered in coil).

On refrigerator models this sensor
should be mounted on top of the coil.

Cabinet Air Sensor:

The cabinet air sensor should be
mounted inside the evaporator housing
(hump) on the return air side of the
evaporator coil.

Discharge Sensor (R & A Series Only):

The discharge air sensor should be
mounted on the hot gas side of the
compressor. Placement should be as
close to the compressor as possible
and must be placed prior to the
beginning of the hot gas loop. Please
note that discharge sensors must be
insulated.

-10-

Correct
Sensor

Location

Correct

Sensor

Location

Correct

Sensor

Location

-11-

IV. CONTROL ARCHITECTURE

IV. a -

R & A SERIES REFRIGERATOR & FREEZER VERTICAL CONTROLLER:

NOTES: IRDA not included on equipment

manufactured with the MIT II control
version.

See parts assembly on pages 12-13.