Thermo Electron 8600 Series Manual de usuario
7998600 Rev. 4
ii
The material in this manual is for information purposes only. The contents and the product it describes
are subject to change without notice. Thermo Electron Corporation makes no representations or
warranties with respect to this manual. In no event shall Thermo be held liable for any damages, direct
or incidental, arising out of or related to the use of this manual.
MANUAL NO. 7998600
4 FR-1789 6/27/05 Revised VRP troubleshooting section for Release 3 aks
3 22216 3/22/04 Added 120V 23 cu. ft. units aks
2 22179 2/24/04 Revised electrical schematic, start capacitor part number aks
-- 8/21/03 Door gap, high stage revisions aks
-- 8/13/03 Revised compressor information page B-1 aks
-- 6/27/03 Revisions per A. Thomas aks
1 21605 5/29/03 Wrong power alarm modifications aks
0 3/21/03 New manual aks
REV ECR/ECN DATE DESCRIPTION BY
iii
Table of Contents
Section 1 – General Operation
1.1 Initial Start Up......................................1-1
1.2 Equipment Explanation.........................1-1
1.3 Operating Pressure
“High and low stage systems”...............1-1
Section 2 – Troubleshooting Charts
2.1 Probe 1,2,3, and 4 failure alarm
(Single) ...............................................2-1
2.2 Probe 1,2,3, and 4 failure alarm
(All probes)..........................................2-1
2.3 Unit will not communicate with alarm
system .................................................2-2
2.4 Display/Keyboard not functioning .......2-3
2.5 Door ajar alarm....................................2-4
2.6 No door access ....................................2-5
2.7 Low battery alarm................................2-6
2.8 Noise ...................................................2-6
2.9 Hot condenser alarm ............................2-7
2.10 High stage system failure alarm ...........2-8
2.11 Power failure alarm..............................2-9
2.12 Wrong power.......................................2-10
2.13 Low Temperature.................................2-10
2.14 High temperature alarm or system not
maintaining temperature ......................2-11
2.15 Troubleshoot compressor.....................2-13
2.16 Voltage Compensation Failure.............2-14
Section 3 – Charts and Schematics
3.1 Analog Output Reference Table.............3-1
3.2 RTD Temperature vs. Resistance ...........3-2
3.3 Pressures vs. Cabinet Temperature.........3-3
3.4 Refrigeration Schematics.......................3-4
3.5 Electrical Schematics ............................3-6
3.6 Micro Board ..........................................3-8
3.7 High Voltage Board...............................3-8
Section 4 -Hidden Functions
4.1 Hidden Test...........................................4-1
4.2 Hidden Calibration ................................4-2
Appendix A - Glossary
Glossary of terms ........................................A-1
Appendix B
Compressor Information..............................B-1
1 - 1
General Operation
1.1 Initial Start Up
1. Power Switch on.
2. Cabinet temperature 0.5°C or warmer than set point.
3. Fans 1 and 2 turn ON.
4. High stage compressor turns ON, after ten seconds delay.
5. Low stage compressor turns ON when:
A. Thirty seconds after high stage starts and heat exchanger probe reads
–41°C or colder or
B. Five minutes after high stage starts and heat exchanger probe reads
between –33°C to –40°C.
If heat exchanger probe warms-up to –20°C or warmer, the low stage
compressor shuts down until either condition 5A or 5B is met. After thirty
minutes, if condition 5A or 5B is not met, the high stage system failure will be
activated.
6. Once the cabinet temperature reaches –50°C, the*expansion tank solenoid is
opened (de-energized). The vacuum relief heater and mullion heater on double
door units, are energized and operate continuously until the cabinet is warmer
than –50°C.
7. Set point achieved, fans and compressors cycle off.
8. Steps 2 though 7 repeat (cycle).
*Items or functions unique to this system
1.2 Expansion Tank Assembly and Solenoid Valve
Location: Suction side of low stage system.
Purpose: Tank assembly increases low stage system refrigeration
capacity. Prevents excessive low stage pressures at
temperatures warmer than –50°.
Operation: The tank assembly solenoid valve is normally open. The
solenoid valve is energized (closed) when the control probe
senses temperature warmer than –50°C. The solenoid valve is
de-energized (open) when the control probe senses
temperature colder than –50°C.
1.3 Operating Pressure “High and low stage systems”
The suction side pressure for both systems typically runs in a vacuum. Prior to
opening a system for a pressure reading, always purge your lines according to the
manufacturer’s recommended procedure. For further information, call Thermo Forma
Service Department.
230 Volt Freezers
Only the compressors require 230 volts. The remaining high voltage components
operate using 115 volts.
2 - 1
2.1 Symptom: Probe 1, 2, 3, or 4 Failure Alarm - SINGLE PROBE FAILURES
Order Possible Cause Verification Action
Probe
Unplugged. Re-seat connector. Re-seat all connections.
1
Not fully seated Verify wires are fully seated in connectors and
connectors are seated together
Replace probe if necessary.
Bad probe
Short.
Open. Display reads 99. Verify probe resistance. See
Temperature vs. Resistance Chart (Page 3-2).
Replace probe.
2
Wrong value. Verify probe resistance. See Temperature vs.
Resistance Chart (Page 3-2).
Replace probe.
3 Micro board.
Temporarily switch suspect probe with control or
heat exchanger probe.
If the same error exists, replace micro board.
2.2 Symptom: Probe 1, 2, 3, and 4 Failure Alarm – (ALL PROBES FAIL)
Order Possible Cause Verification Action
Re-seat connector.
1 Control probe not installed.
Startup only.
Verify wires are fully seated in connectors and
connectors are seated together.
Reinitialize (re-start) unit.
Reseat all connections.
Replace probe if necessary.
Bad control probe Display reads 99. Bad control probe will also
cause a high temperature alarm and lock both
compressors on.
2
Short.
Open.
Wrong value.
Verify probe resistance with Temperature vs.
Resistance Chart (page 3-2).
Replace probe.
3 Micro board.
Temporarily switch control probe with heat
exchanger probe.
If the same error exists, replace micro board.
4 Micro board EEPROM Problem still exists after re-initializing unit. Re-initialize eeprom in test mode. If problem
remains, replace the micro board. Note: all
calibration, set points and configuration are set to
default.
2 - 2
2.3 Symptom: Unit will not communicate with alarm system (Remote Alarm Contacts/Analog
System/Serial communication)
Order Possible Cause Verification Action
Check that all connections are tight and properly
wired. Missing wires?
Tighten and / or correct wiring.
1 Remote Alarm Contacts
Measure continuity of alarm contacts between
pins 6 & 7 and 6 & 8 while toggling in test mode
(pin 6 is common).
Replace micro board if contacts do not change
state.
Verify the setting is correct in hidden calibration
and corresponds to the dip switch settings on the
micro board per the electrical schematic.
Make changes so the dip switch settings and hidden
calibration settings match.
Measure output. Compare with Analog Output
Reference Table (page 3-1).
Call the factory service department 888-213-1790.
See section 4.2.p Analog Calibration (page 4-3).
2 Analog Output
Check that all connections are tight and properly
wired. Missing wires?
Tighten and / or correct wiring.
Verify address is correct in configuration menu
and matches the 1535 address.
Change so that the unit address of the freezer
matches the 1535 address.
Verify the setting is correct in hidden calibration
and corresponds to the dip switch settings on the
micro board per the electrical schematic.
Make changes so that the dip switch settings and
hidden calibration settings match.
Check that all connections are tight and properly
wired. Missing wires?
Tighten and / or correct wiring.
Tighten and / or correct wiring.
3 Serial Communication
Verify that the cable is a DB9 (straight through)
extension cable.
Replace cable if necessary.
2 - 3
2.4 Symptom: Display / Keyboard Not Functioning
Order Possible Cause Verification Action
1 Turned battery on before AC power is
applied.
(initial start up issue only)
Ask customer/end user. Turn unit power off. Turn battery off. Reapply AC power
before the battery is turned on.
2 No AC power and no battery power. Verify supply AC voltage is present.
Supply correct line voltage.
+14VDC on switching power supply.
If not, replace switching supply.
+14VDC on micro board at connector
labeled DC power from HV board (pins 1
and 6).
Check connector seating on ribbon cables. Replace if
required.
3 Micro board -
Micro LED LD1 on micro board not
functioning.
Is unit operating (fans, compressors)?
If no, replace micro board.
If yes, continue to step 4.
Turn unit off, then turn unit back on.
Miscellaneous characters displayed. Replace display board.
4 Micro board - Micro LED LD1
functioning / no display LED LD2.
Check connection of 25 pin D sub cable
at both ends.
Waiting Comm is displayed. Replace micro and/or display as
needed.
Display -
Missing segment Visual. Replace display board.
Keys not responding
Check continuity for buttons on overlay. Replace overlay.
LEDs not functioning
Ohm out LEDs.
Replace overlay.
5
No Alarm Press any key on overlay. If no audible, replace display board.
2 - 4
2.5 Symptom: Door Ajar Alarm
Order Possible Cause Verification Action
1 No magnet Visually inspect for magnet in door handle. Replace magnet as required.
2 Worn door handle
Inspect inside of door latch for signs of metal
(aluminum) wear (wobbly handle).
Replace latch if necessary and verify vacuum relief
port operation, as well as the door alignment.
Improper connection
Wires loose from door switch connector.
Verify wires are properly seated in connector.
If required, re-seat the wire connection.
Door switch connector not seated to board
connector.
Verify connectors are seated together.
Re-seat connection.
3
Installed in wrong connector Verify the plug is in the correct receptacle.
Re-seat plug in correct receptacle.
4 Improper door alignment Verify door gap. Single door .600”
Double door .700”, both measured from the hinge
side.
Make adjustment as required.
5 Bad door switch
Verify continuity on door switch by opening and
closing door.
If no continuity of switch during opening and
closing of door, replace door switch.
6 Defective micro board. Short out door switch connector. If alarm does not clear replace micro board. Or else
repeat starting at Step 1.
2 - 5
2.6 Symptom: No Door Access
Order Possible Cause Verification Action
1 Door locked. Check to ensure door is not locked. Unlock door.
2 Vacuum relief assembly is frozen over.
Visually inspect vacuum relief port for any
restrictions. Clean as necessary. Follow routine maintenance
instructions in user’s manual to periodically clean
the port.
Check voltage at J7 on the display board for +14V
+0.5?
YES (+14V): unplug heater harness from PCB and
measure resistance across heater leads. Heater
resistance should be between 9 and 30 Ohms.
If not between 9 and 30 Ohms, replace VRP
assembly.
3 Release 3 unit: Vacuum relief not
functioning.
Release 3 units(built after 6/2005 have
vacuum relief port in door.
NO: Check and reseat connections on heater harness.
Measure DC voltage at the switching power supply.
On the 6 pin connector, measure between pins 1 and
6 (+14V + 0.5V)
Check and reseat connectors between switching
power supply and high voltage board. Also check
and reseat connections between high voltage
board and micro board.
Verify unit is colder than –50°C. Cabinet temperature must be colder than –50°C to
activate vacuum relief heater.
90-130VAC at heater?
YES: Ohm out heater. Heater to be 1037-1210 Ohms Replace heater if required.
Release 1 unit: Vacuum relief not
functioning.
Release 2 units built between May 2003
and June 2005 do not use a heated vacuum
relief assembly.
NO: Check connections Re-seat connection(s). If problem still exists,
continue troubleshooting.
Blown fuse Check fuse. Ohm out fuse, replace fuse as required.
Micro board Check voltage between U16-13 and J11-1 on micro
board. If voltage is greater than 10VDC, replace micro
board.
High voltage board. Check DC voltage across D15 on high voltage. If voltage is less than 10VDC, replace high
voltage board.
2 - 6
2.7 Symptom: Low Battery Alarm
Order Possible Cause Verification Action
1 New battery / new unit or freezer just placed
into service?
Ask customer/end user.
Complete steps 2,3, & 4.
If yes, batteries required 36 hours for charging.
If no, continue to step 5.
2 Missing battery Visually look for battery. Install battery.
3 Battery switch turned off. Verify switch is “on”.
Turn switch on after AC power is applied.
4 Connection –
Wires making connection.
Battery wired backwards.
Ensure connections are tight at the battery,
battery switch, and micro board. Verify the red
wire is connected to the positive terminal.
Tighten and change wiring as needed.
5 Battery switch defective. Verify continuity with multimeter. Replace switch.
6 Battery Calibration Measure voltage at the battery and compare to
the value displayed in hidden calibration.
Match values.
7 Battery voltage < 12.1 during battery test. Check voltage at the battery during battery test
after 2 days (48 hours) of operation.
If voltage < 12.1, replace battery and continue to
step 8.
8 Micro board –
Battery test circuit.
Battery charging circuit
Disconnect battery and measure voltage at the
battery wires.
If 13.5 - 13.8 VDC is present, replace battery.
If not present replace micro board and battery.
2.8 Symptom: Noise
Order Possible Cause Verification Action
1 Loose screws on panels or compressors. Ensure all screws and bolts are tightly secure. Tighten as needed.
2 Missing or no sound insulation.
Remove side panels to ensure insulation is
present. Inspect the bottom of cabinet to verify
insulation is present.
Add foam panels if necessary.
3 Start capacitor on compressor.
Ensure capacitor is not touching the compressor
body and capacitor bracket securely holds the
capacitor.
Adjust as needed.
4 Electrical cover on compressors.
Ensure cover is tight.
Tighten as needed.
5 Vibrating refrigeration lines.
Inspect for lines that are touching. Adjust as necessary.
6 Solenoid Ensure that the solenoid base sits on presstite tape
and is tie wrapped to the freezer base.
Replace presstite tape and tie wraps, if necessary.
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