Service Manual - Revco - PLUS Series - 301903H15 Rev. 3
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Plus Series Revco -86CUl Revco -86C Ultra traLow LowTem Temper peratu ature re Uprigh Uprightt Freeze Freezer r Service Manual 301903H15 Rev.3
Manual Number 301903H15
-2-
Revco Plus Rev. 3
1.00 Pref 1. Prefac acee 1.1 Notices and Warnings
CAUTION Contains Parts and Assemblies Susceptible to Damage by Electrostatic Discharge (ESD)
Caution All Caution All intern internal al adjustm adjustment ents s and mai mainten ntenanc ance e mus mustt be per perform formed ed by qua qualifi lified ed servic service e personnel. ▲ personnel. ▲
Materi Mate rial al in this this ma manu nual al is for for in info form rmat atio ion n pu purp rpos oses es only only.. Th The e co cont nten ents ts and and the the prod produc uctt it desc descri ribe bes s are are subj subjec ectt to change without notice. Thermo Fisher Scientific makes no representations or warranties with respect to this manual. In this no event shall Thermo be held held liable for any damages, direct direct or incidental, arisin arising g out of or related to the use of manual.
©2009 Thermo Fisher Scientific LLC. All rights reserved.
Manual Number 301903H15
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Revco Plus Rev. 3
Importantt operating Importan operating and/or maintenanc maintenance e instruc instructions. tions. Read the accompa accompanying nying text careful carefully. ly.
Potential electrical hazards. Only qualified persons should perform procedures associated with this symbol. Equipment being maintained or serviced must be turned off and locked off to prevent possible injury.
Hot surface(s) present which may cause burns to unprotected skin, or to materials which may be damaged by elevated temperatures.
Marking of electrical and electronic equipment, which applies to electrical and electronic equipment falling under the Directive 2002/96/EC (WEEE) and the equipment that has been put on the market market after 13 August 2005. This product is required to comply with the European Union’s Waste Electrical & Electronic Equipment (WEEE) Directive 2002/96/EC. It is marked with the WEEE symbol. Thermo Fisher Scientific has contracted with one or more recycling/disposal companies in each EU Member State European Country, and this product should be disposed of or recycled through them. Further information on Thermo’s compliance with this directive, the recyclers in your country and www.thermo.com m. information on Thermo products will be available at at www.thermo.co
Always Always use the proper proper protective protective equipmen equipmentt (clothing, (clothing, gloves, gloves, gogg goggles, les, etc etc.) .)
Always Always dissipate dissipate ext extreme reme co cold ld or he heat at and wear wear protective protective clothin clothing. g.
Always follow good hygiene practices.
Each indivi individual dual iis s respo responsible nsible for his or he herr own safety safety..
Manual Number 301903H15
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Revco Plus Rev. 3
1.2 Thermo Fis Fisher her Contac Contactt Informati Information on
Do You Need Information or Assistance on Thermo Fisher Scientific Products? If so, please contact us 8:00 a.m. to 6:00 p.m. (Eastern Time) at: 1-800-438-4851 http://www.thermo.com
T o l l F r e e, U . S . a nd C an ad a Internet Worldwide Web Home Page
Our Sales Support staff can provide information on pricing and give you quotations. We can take your order and provide delivery information on major equipment items or make arrangements to have your local sales representative contact you. Our products are listed on the Internet and we can be contacted through our Internet home page. Our Service Support staff can supply technical informatio information n about proper setup, operation or troubleshooting of your equipment. We can fill your needs for spare or replacement parts or provide you with on-site service. We can also provide you with a quotation on our Extended Warranty for your Thermo products. Whatever Thermo products you need or use, we will be happy to discuss your applications. If you are experiencing technical problems, working together, we will help you locate the problem and, chances are, correct it yourself over the telephone without a service call. When more extensive service is necessary, we will assist you with direct factory trained technicians or a qualified service organization for on-the-spot repair. If your service need is covered by the warranty, we will arrange for the unit to be repaired at our expense and to your satisfaction. Regardless of your needs, our professional telephone technicians are available to assist you Monday through Friday from 8:00 a.m. to 6:00 p.m. Eastern Time. If you wish to write, our mailing address is: Thermo Fisher Scientific LLC Laboratory Laborato ry Equipment Division 308 Ridgefield Court Asheville, NC 28806 International Intern ational customers, please contact your local Thermo Fisher Scienti Scientific fic distributor. distributor.
Manual Number 301903H15
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Revco Plus Rev. 3
1.3 Table of Contents Contents
Table Of Contents Contents Title
Section 1.0 1.1 1.2
Preface Notices and W arnings Thermo Fisher Contact Information
1.3
Table Of Contents
2.0 2.1 2.2 2.3 2.3.1 2.3.2 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12
Introduction Data Plate Location Feature Group Identification How To Read Serial Numbers Previous Serial Number Format Current Serial Number Format Proper Use Recommendations Initial Loading Operating Standards Installation Pressure Equalization Port Remote Alarm Contact Use Control Panel Top Ultima Features Startup & Operation Deluxe Ultima Features Programming Mode All Models Control Panel Basic Value Features Special Service Startup Modes Key Pad Function Summary Safety W arnings Recommended Tool List
3.0 3.1 3.2 3.3 3.4 3.5
Routi tin ne Ma Maiinte ten nance Cleaning The Refrigeration System Freezer Unit Maintenance Defrost Chamber Check Vacuum Relief Port Door Adjustment
4.0 4.1 4.2 4.3
Se Sequ quen ence ce Of Oper Operat atio ion n Normal Startup Sequence Power Failure Restart Sequence Key Cycle Sequence
5.0 5.1 5.2 5.3 5.4
Tro Troubl ble eshootin oting g Error Code Troubleshooting Chart Alarms And Alerts Major Failures Guidance Chart Special Test Mode; Sequence Of Operation
5.5 5.5.1
Testing Line Voltage Components Introduction And Explanation Testing The High Voltage PCB And Connected Line Voltage Components
5.5.2
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Pa g e 3 3 5 6
9 9 9 12 12 13 13 13 13 13 15 15 16 17 19 20 21 22 25 26
27 27 27 27 27 28
29 29 29 30
-6-
31 32 34 36 37 39 39 39
Revco Plus Rev. 3
Section 5.5.3 5.5.4 5.5.5 5.5.6 5.5.7 5.6 5.6.1 5.6.2
Table Of Contents Contents Title Compressor Testing Compressor Start Components Condenser Fans Expansion Tank Solenoid High Pressure Cutout Switch Testing Control Voltage/Electronic Components Power Supply Circuit Board Power Supply Cooling Fan
5.6.3 5.6.4 5.6.5 5.7 5.8
Display Circuit Board And Key Switch Micro Control Circuit Board Temperature Sensors Refrigeration Troubleshooting Using Built-In Thermocouples Ma Manifold Gauge Diagnostic Procedures
44 45 46 47 53
6. 6.0 0 6.1 6.1.1 6.1.2 6.1.3 6.1.4
Ca Cali libr brat atio ion n & Re Repa pair ir Proc Proced edur ures es Calibration Procedures Reset Factor y Default Parameters Temperature Display Offset Adjustment Value/Elite Micro Board Calibration (line voltage monitor only) Ultima Top Micro Board Calibrations (incl. Elite W itith RS232 Opt.)
54 54 54 54 54 54
6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9 6.2.10 6.2.11 6.2.12
Instructions For Replacing Parts Replacing the Door Gasket Door Latch Replacement Exterior Door Hinge Replacement Interior Door Replacement Door Replacement and Seal Check Filter Replacement Caster Replacement Heat Exchanger Sensor Replacement Control/Display Sensor Replacement Ambient/Condenser Sensor Replacement Start Relay Capacitor
56 56 56 57 57 57 58 58 59 61 61 62 63
6.2.13 6.2.14 6.2.15 6.2.16 6.2.17 6.2.18 6.2.19 6.2.20 6.2.21 6.2.22 6.2.23 6.2.24 6.2.25 6.2.26 6.2.27 6.2.28 6.2.29
Micro Board Replacement Power Supply Board Replacement Display Board Replacement Display Harness Replacement Alarm Battery Replacement Voltage Boost Transformer Fan Motor and Blade Replacement First Stage Pressure Switch Replacement Second Stage Pressure Switch Replacement First Stage Compressor Replacement Second Stage Compressor Replacement Replacing the Oil Separator Replacing the Expansion Tank Replacing Expansion Tank Solenoid Replacing the First Stage Drier Changing the Second Stage Drier Condenser Replacement
63 64 64 65 66 66 67 67 68 69 70 71 71 72 72 73 76
Manual Number 301903H15 301903H15
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Pa g e 41 41 42 42 43 44 44 44
Revco Plus Rev. 3
Section 7. 7.0 0 7.1 7.2 7.3 7.4 7.5
Table Of Contents Contents Title Flus Flushi hing ng & Char Chargi ging ng Pr Proc oced edur ures es First Stage System Clean-up/Flushing Second Stage System Clean-up/Flushing Evacuation Refrigerant Charge Procedures Refrigerant Charge Tables
8. 8.0 0
Di Diag agra rams ms,, Dr Draw awin ings gs,, Sche Schema mati tics cs
8.1 8.2 8.3 8.4 8. 8.5 5 8.6 8. 8.7 7 8.8 8.9 8.1 .10 0 8. 8.11 11 8. 8.12 12 8. 8.13 13
Refrigeration Diagram Electrical Ladder Diagram Value Models, 115VAC Electrical Ladder Diagram Elite/Ultima Models, 115VAC Electrical Ladder Diagram Value Models, 208/230VAC 60Hz El Elec ectr tric ical al La Ladd dder er Di Diag agra ram m Elit Elite/ e/Ul Ulti tima ma Mode Models ls,, 20 208/ 8/23 230V 0VAC AC 60Hz 60Hz Electri trical Ladder Diagra ram m Value Models, 220/240 /240V VAC 50Hz El Elec ectr tric ical al La Ladd dder er Di Diag agra ram m Elit Elite/ e/Ul Ulti tima ma Mode Models ls,, 22 220/ 0/24 240V 0VAC AC 50Hz 50Hz Circuit Board Schematic For 230VAC High Voltage PCB Circuit Board Schematic For Displa y Board; All Models Circ rcu uit Board Sche hema mati tic c For 115V 5VA AC Hig igh h Volta ltage PC PCB B Ci Circ rcui uitt Bo Boar ard d Sche Schema mati tic c Back Backup up Sy Syst stem em (B (BUS US)) PCB; PCB; LN2 LN2 & CO CO2 2 Ci Circ rcui uitt Bo Boar ard d Sche Schema mati tic c Mi Micr cro o Co Cont ntro roll PC PCB, B, All All Mo Mode dels ls,, Pa Page ge 1 Ci Circ rcui uitt Bo Boar ard d Sche Schema mati tic c Mi Micr cro o Co Cont ntro roll PC PCB, B, All All Mo Mode dels ls,, Pa Page ge 2
314110H01 314531H02 314532H02 314529H01 31 3145 4530 30H0 H01 1 314529 529H0 H02 2 31 3145 4530 30H0 H02 2 191923-70-1-D 191931-70-1-D 191932 932-7 -70 0-1-D -1-D 19 1919 1933 33-7 -700-11-D D 19 1919 1936 36-7 -700-11-D D 19 1919 1936 36-7 -700-22-D D
92 93 96 99 102 102 105 108 108 111 112 113 114 114 115 115 116 116
8.14 8.15 8.16 8.17
Relay Enclosure Parts Diagram, All Models Compressor Base Parts Diagram, All Models Freezer Door Parts Diagram, All Models L Liist Of Common Parts, All Models
314049 I01 314156 314215
117 118 119 120
9. 9.0 0 9.1 9.2 9.3
Conv Conver ersi sion on & Re Refe fere renc nce e Ta Tabl bles es Fahrenheit - Centigrade Temperature Conversion 1000 ohm RTD Resistance versus Temperature 4-20ma Analog Output Reference Table
10.0 10.1 10.2
Appendix Alarm Reference Chart Has Been Alarms / Automatic Incidence Monitor (AIM)
10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 10.13 10.14 10.15 10.16
Doc.-No.
Power Failure / Time Delay Temperature Alarms Extreme Ambient Lifeguard Alert; Compressor Over-temperature Alarm Clean Filter System Battery Low (see BUS batter y note) Alarm Hold-off Alarm Transducer Alarm Ring-back Alarm Test LN2/CO2 Backup Systems Cobex Temperature Recorder Retrofit Cam Lat Latch ch In Installatio stallation n & Service Service P Parts arts Diagrams Diagrams New Cam Cam Latch Latch Description Description & Serv Service ice P Parts arts Diagrams Diagrams
Manual Number 301903H15 301903H15
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Pa g e 77 77 79 81 84 86 91
122 122 124 125 126 126 127
127 127 127 127 128 128 128 128 128 129 130 131 1005-ULTAVL-0167 135 1005-ULTAVL-0168 140
Revco Plus Rev. 3
2.0
Introduction
The purpose of this service manual is to provide service data and procedures to assist in troubleshooting and repairing the unit. The first step in that process is to correctly identify identify the specificat specifications ions and features features of the unit you are working on. The features and specifica specifications tions are tied to the model number and serial number, and these numbers should should be recorded record ed for all service event events. s. Any contact with the manufacturer manufacturer for technical technical support or parts will require both the model number and the serial number. 2.1 Data Label Locatio Location n
The model and serial numbers numbers for the Plus Series ULT freez freezers ers are printed on a data label attached to the exteriorr left side of the cabine exterio cabinet, t, about 1 foot above the ground. Other information information is included on data labels,, such as the type of refrigera labels r efrigerant, nt, voltage, frequency or Hz, and current ratings (Amps). Freezers Freezers exported from the U.S. should show Metric equivalents for the values shown when appropriate. Figure 1
2.2 Feature Gr Group oup Identification Identification
The Revco Plus series of -86C cascade freezers are available available in three t hree feature groups: groups: Value Freezer, Standard Elite Freezer, Freeze r, Deluxe Ultima Freezer. Freezer. The brand names and model numbers numbers used vary, but all freezers of this design group will fit one of these three feature groups. groups. The most accurate way to determine determine which feature group you are working with is to look at the location and the layout of the display panel. The following following illustration illustrations s describe what each feature group looks like:
Deluxe Ultima Freezer Control Panel Deluxe Alwa Al wa ys fo un d at eye le leve vell on th the e door do or..
Manual Number 301903H15
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Revco Plus Rev. 3
Standard Standa rd Elite Freezer Control Panel Usually found found at knee level on the left front of the compresso compressorr housing.
Value Freezer Control Panel Alwa Al wa ys fo un d at kn knee ee le leve vell on th e le left ft fr fron on t of th e com pre ss ssor or hou si sing. ng. 2.2.1
Primar Primary y Ser Service vice Related Differences Differences of the Three Featur Feature e Groups Groups
Value Freezers Micro circuit circuit board 19 191934H0 1934H01. 1. DIP SW3 set for Value Value freeze freezer. r. 2 RTD sensors: cabinet cabinet and heat-X sensor sensor
Standard Elite Freezers If no RS232 communication communication op option, tion, then Micro PCB PCB 191934H01 191934H01.. DIP SW3 set for Elite freezer. freezer. With RS232 communicati communication on option from factory, factory, then Micro PCB 19193 191936H01. 6H01. DIP SW3 set for Elite freeze freezerr with RS232, and DIP SW2 set for RS232 communication option. 4 RTD sensors: cabinet, cabinet, heat-X, condens condenser, er, ambient
Deluxe Ultima Freezers
Micro circuit circuit board 19 191936H0 1936H01. 1. DIP SW3 set for Ultima Ultima feature features. s. DIP SW2 set for RS2 RS232 32 communi communication cation op option. tion. DIP SW1 set as needed if 4-20ma factory option installed. st 5 RTD sensors: cabinet, cabinet, heat-X, condenser, condenser, ambient, ambient, 1 Stage Compressor (Lifegu (Lifeguard ard feature)
See the Trouble Shooting section of this manual for more details regarding the micro boards and sensors.
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Revco Plus Rev. 3
Manual Number 301903H15
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Revco Plus Rev. 3
2.3 How To Read Plus Series Serial Number Format
The Plus series freezers freezers built in Asheville Asheville,, NC will have one of two serial number formats.
2.3.1 Serial Number Number Format Prior Prior To March 24, 2008
Plus freezers freezers built before March 24, 2008 will have the followin following g serial number format: P23T-123456-PT P = manufacturing month (see chart that follows for letter codes) 23 23 = = manufacturing day of the month T = manufacturing year 123456 = 123456 = production number, unique for each unit P (at end) = month shipped T (at end) = year shipped
The serial number number shown would b be e for a unit built March 23, 2008, and shi shipped pped in March, 2008. 2008. See the chart that follows to understand understand the month and year letter codes. The chart applies to Asheville seria seriall numbers dating back to 1967, and repeats every 24 years. Serial Number Prefix and Suffix Code: for Asheville serial numbers before March 24, 2008 DATE
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003
NA NB NC ND NE NF NG NH NJ NK NL NM NN
OA OB OC OD OE OF OG OH OJ OK OL OM ON
PA PB PC PD PE PF PG PH PJ PK PL PM PN
RA RB RC RD RE RF RG RH RJ RK RL RM RN
SA SB SC SD SE SF SG SH SJ SK SL SM SN
TA TB TC TD TE TF TG TH TJ TK TL TM TN
UA UB UC UD UE UF UG UH UJ UK UL UM UN
VA VB VC VD VE VF VG VH VJ VK VL VM VN
WA WB WC WD WE WF WG WH WJ WK WL WM WN
XA XB XC XD XE XF XG XH XJ XK XL XM XN
YA YB YC YD YE YF YG YH YJ YK YL YM YN
ZA ZB ZC ZD ZE ZF ZG ZH ZJ ZK ZL ZM ZN
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
NO NP NR NS NT NU NV NW NX NY NZ
OO OP OR OS OT OU OV OW OX OY OZ
PO PP PR PS PT PU PV PW PX PY PZ
RO RP RR RS RT RU RV RW RX RY RZ
SO SP SR SS ST SU SV SW SX SY SZ
TO TP TR TS TT TU TV TW TX TY TZ
UO UP UR US UT UU UV UW UX UY UZ
VO VP VR VS VT VU VV VW VX VY VZ
WO WP WR WS WT WU WV WW WX WY WZ
XO XP XR XS XT XU XV XW XX XY XZ
YO YP YR YS YT YU YV YW YX YY YZ
ZO ZP ZR ZS ZT ZU ZV ZW ZX ZY ZZ
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Revco Plus Rev. 3
2.3.2 Current Current Serial Number Format Format
For Plus Series Serial Numbers Numbers Starting March 24, 2008, the format is as follows: PPSSSSSSNNYYMMDD
PP = Numer Numeric ic Plan Plantt Code Code (01 (01 is the As Ashe hevil ville le Pl Plan ant) t) SSSSSS = SSSSSS Pr Prod oduc uctio tion n Ord Order er Nu Numbe mber; r; uniqu unique e per per unit. unit. Use this six-digit number to distinguish units completed on the same day. NN = Sequ Sequen ence ce Nu Numb mber er (c (cur urre rent ntly ly al alwa way ys 01) 01) YY = Two digit year MM = Month DD = Day Note: The date is the date the uni unitt was completed and the data data plate created. created. Serial Number 0112345601080324 is 0112345601080324 is for a unit completed on March 24, 2008, with unique production number 123456.
2.4 Proper Use Gen General eral Recommendations Recommendations
The refrigeration system is designed to maintain ultra-low temperatures with safety safety in a +32 +32°C °C (90°F (90°F)) ambien ambientt environment, only when the freezer is used for storage. This unit unit is not not a “rapid-freez “rapid-freeze” e” device. device. Fre Freezing ezing large large quantities quantities of liquid, liquid, or hig high-water h-water conten contentt items, w will ill temporarily increase the chamber temperature and will cause the compressors to operate for a prolonged time period. Avoid opening opening the door for extended time periods since chamber chamber temperature air will escape rapidly. Also, keep the inner doors closed as much as possible. When room air, which is higher in humidity, replaces chamber air, frost may develop in the chamber more rapidly.
2.4.1 Initial Loading
After reading and completing the Safety Consideratio Considerations, ns, PreInstallation, PreInstallation, Installation, Installation, and Operation sections of this manual, start up the freezer following the instructions in Error! in Error! Reference source not found.. found.. Allow the freezer to operate operate at the desired temperature temperature for a minimum of 12 hours befor before e loading. Load the freezer one shelf shelf at a time, beginning beginning with the top shelf. After loading each shelf, allow the freez freezer er to recover to the desired setpoint before loading the next shelf. Repeat this process until the freezer is fully loaded.
Failure to follow these procedures or overloading the unit may cause undue stress on the compressors or jeopardize user product safety. 2.4.2 Operating Operating Stan Standards dards
The freezers described described in this m manual anual are classified classified for use as stationary stationary equipment in a Polluti Pollution on Degree 2 and Overvoltage Category II environment. These units are designed to operate under the following environmenta environmentall conditions: Indoor use use (59 to 9 90 0F (15 to (15 to 32C). 32C). Altitude Altitude up to 2000m 2000m Maximum Maximum relative humidity 60% for temperat temperatures ures up to 32ºC (90ºF) Main supply voltage voltage fluctuations fluctuations not to exceed 10% of the nominal voltage.
2.4.3 Installation Installation
Do not exceed the electrical electrical and temperature temperature ratings printed on the dataplate dataplate located on the lower left side of the unit.
Improper opera operation tion of th the e equipment equipment could could result result in dangerou dangerous s conditions. conditions. To preclude preclude haz hazard ard and minimiz minimize e
risk, follow all instructions and operate within the design limits noted on the data plate. Location Install the unit in a level area free from vibration with a minimum of five inches of space on the top and back, eight inches on each side. Refer to Error! to Error! Reference source not found. for found. for further instructi instructions ons on levelin leveling g cabine cabinets. ts. Allow enough clearance so that door can swing open at least 90 degrees.
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Revco Plus Rev. 3
Do not position the equipment in direct sunlight or near heating diffusers, radiators, radiators, or other sources of heat. The ambient temperature range at the location must be 59 to 90F 90 F (15 to (15 to 32C). 32C). To allow allow for p proper roper air flow, a minimum o off six inches inches o off clearance clearance space space is required on the sides, top and rear of the freezer f reezer..
Wiring
Connect Connect the e equipmen quipmentt to the correct power s source. ource. Incorrect Incorrect volta voltage ge can result in seve severe re damage to the equipment. For personal personal safety a and nd trouble-free trouble-free operatio operation, n, this unit must be pro properly perly g grounded rounded before it is u used. sed. Failure Failure to ground the equipment may cause personal injury or damage to the equipment. Always conform to the National Electrical Code and local codes. Do not connect the unit to overloaded power lines. Do not position position the the unit in a wa way y that imp impedes edes access access to the the discon disconnecting necting d device evice or c circuit ircuit b breaker reaker in the back of the unit. Always connect connect the freezer to a dedicated (separate) (separate) circuit. Each freezer is equipped with a service cord and plug designed to connect it to a power outlet which delivers the correct voltage. Supply voltage must be within +10% or 10% of the freezer rated voltage.
Never cut cut the grounding grounding pron prong g from the service service cord p plug. lug. If the the pron prong g is re removed, moved, tthe he warra warranty nty is invalid invalidated. ated.
Leveling Make sure that the floor is level. The unit must be level both front to back and side to side.
Super Insulated (HD) Cabine Cabinett Construction Construction In HD models m odels,, the cabinet cabinet walls have a vacuum vacuum insul insulation ation core encapsulated encapsulated by a sealed film laminate and wrappe wrapped d in Mylar.
Never drill drill holes in or near th the e cabinet cabinet walls. Drilling could could damage damage the in insulatio sulation n and make the uni unitt inoperable. inoperable.
Door Operation Upright freezer freezer models are equip equipped ped with an advanced advanced Cryolatch™ assembl assembly y specific specifically ally designed for ultra-low temperature freezers. Features include: One-hand operation, A front-accessible lock, keyed to t o match the freezer control lock, Hasps for a standard padlock to provid provide e additional additional security, Durable construction construction for reliable operation operation and safe product storage.
When moving moving the freezer, freezer, always always gras grasp p cabin cabinet et surfaces; surfaces; never never pul pulll the free freezer zer by the latc latch h handl handle. e.
Opening the Door Opening Remove the padlock padlock if you have one one.. Move the key into the open position by rotating rotating it counter-clockw counter-clockwise. ise. Grasp the latch handle (preferably (preferably with your left hand) and pull it toward yourself yourself until the latch disengage disengages s from the cabinet strike. Keep pulling by the latch handle handle or the integrated integrated door handle to open the main door.
Closing Closin g the door Note that the latch does not self-engage automatically when you close the door. You must rotate the latch into the open position first. Grasp the latch handle (preferably (preferably with your left hand) and pull it toward yourself, yourself, rotating the latch into the open position. Move the freezer door into the closed position position and gently push the hand handle le away from you, making sure that the latch
engages fully with the cabinet strike. Closing the door without making sure the latch engages fully with the strike can result in substantial prying forces on the door. Keep applying applying gentle pressure to the latch handle until the latch is securely in closed position position..
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Revco Plus Rev. 3
Insert the key and and rotate clockwise clockwise to lock. Replace Replace the padlock if you are using using one.
2.4.4 Pressure Pressure Equaliz Equalization ation Port
When an upright ultra-low temperature temperature freezer door is opened, opened, room tempera temperature ture air rushes into the storage compartment. When the door is closed, closed, the fixed volume of air is cooled rapid rapidly. ly. Pressure drops below atmospheric atmospheric pressure, pressure, resulting in a substantial vacuum. Re-entry into the cabinet is impossible until internal pressures are returned to atmospheric atmosph eric pressure. Without a pressure pressure equalization mechanis mechanism, m, it can take, in extreme cases, several hours before the door can easily be reopened. All upright models feature feature a port that provides vacuum relie relieff after door openings. The pressure equalization equalization port is located in the door behind the eye-lev eye-level el panel on the front of the ffreezer reezer.. Although the port is designed to self-defrost, excessive frost accumulation on the inner door could eventually restrict air flow. Therefore you should periodically inspect the inner door and brush away any loose frost using a stiff nylon brush.
2.4.5 Remote Alarm Alarm Contacts Contacts If you are using a remote alarm system, you need to install the remote alarm connector connector provided with you yourr freezer. The remote alarm alarm contacts are located located on the back of the freez freezer er above and to the left of the power swit switch. ch. These are “dry contacts”, or non-energized non-energized switches switches that change position in response to specified alarm conditions. conditions. After installing the wiring from the remote alarm to the connector, install the connecter to the freezer micro board by plugging pluggin g it into the receptacle receptacle provided. When the unit unit is in the the alarm alarm condition: condition: The leftmost pin (#7) is Open To Common; The second pin from the left (#6) is Common; The third pin from the left (#5) is Closed To Common. contacts will trip in the event of a power outage, high temper temperature ature alarm or low temperature alarm. alarm. The contacts
Manual Number 301903H15
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Revco Plus Rev. 3
2.5
Con Contro troll Panel Panel (Ultima (Ultima Plus and Elit Elite e Plus mod models) els) BACKUP SYSTEM SUPPLY ON
CABINET TEMPERATURE
LIFE-GUARDALERT
OFF
SUPPLY EMPTY
BATTERY LOW
EXTREME AMBIENTALERT
CONTROL POWERFAILURE
ALARM ON SET POINT SECURITY
WARMALARM SETPOINT
TEMPERATUREFAILURE
ALARMTEST
CLEANFILTER
SET POINT
ALARMRESET
ALARM
15
COLD ALARM
VOLTAGE
SETPOINT
16 1
22
6
7
3 4
5
8
9
13 14
18 17
Ultima Plus Series Control Panel with Optional Backup System
Before the initial start up, take some time to become familia familiarr with the controls on your freezer.
Note: shows all possible functions. These functions vary depending on the model and options. You may not have all of the functions on your equipment. Refer to the descriptions below for functions that are only available for Ultima Plus models or models that have the backup system option . 1. Three positio position n key keyed ed P Power ower On Switch. 2. Power On Ind Indicator. icator. Thi This s green LE LED D lights when power power is conne connected cted to the free freezer zer and th the e key switch iis s in the ON positi position. on. 3. Tempera Temperature ture Failure Failure Indicator. Thi This s indicator indicator lights when the freez freezer er temperatu temperature re deviates eit either her above or below the alarm temperature temperature settings. Power Fail Failure ure Indica Indicator. tor. This indi indicator cator ligh lights ts when there there is a power failure failure to the freeze freezer. r. Life-Gu Life-Guard ard Alert Indicator Indicator (Ultima Plus Mod Models els only.) This indicator indicator light lights s when the first stage co compressor mpressor ha has s gone into a cautionary state of operation to help prevent failure. 6. Alarm Alarm Test Pad. Pad. Press Press this pad pad to star startt an alar alarm m test. 7. Alarm Alarm Reset Reset Pad Pad.. Press Press this pad pad to re reset set slowly slowly blinking blinking indicators. indicators. Slowly blinking blinking indicators denote that the condition has condition has occurred occurred but is now within the given operating parameters. This pad is also depressed to temporarily temporar ily silence the audible audible alarm. 8. Cold Ala Alarm rm Setpoi Setpoint. nt. Press tthis his pad to display the cold alarm setp setpoint. oint. 9. Warm Alarm S Setpoin etpoint. t. Press thi this s pad to d display isplay the the warm alar alarm m setpoint. setpoint. 10. Control Setpoint. Press this pad to set the cabinet temperature. 11. Cabine Cabinett Temperature Indicator. Displays cabinet temperature temperature in operati operating ng mode, paramet parameters ers and value values s when in program mode. 12. Digital Temperat Temperature ure Display W Window indow.. This window displays chamber temperature temperature,, alarm values, etc. depend depending ing on the operating status of the freezer and the procedure being performed. 4. 5.
13. Increment Decremen DecrementtPad Pa (Down Arrow ). Use to decrease decrea se temperature temperature value values. s. 14. PPad add(U (Up p Arro Arrow w ). Use this this padpad to in increase crease temperature temperatu re v values. alues. 15. Extreme Ambient Alert (Ultima Plus Models only). This indicator lights when the ambient temperature has exceeded the upper limit of the recommended operating range. If the Extreme Ambient Alert is activated, the ambient environment needs to be improved for proper function of the freezer. 16. Clean Filter Indicator. This indicator lights when the air cooled condenser filter is dirty. 17. Alarm Battery Low Indicator. This indicator lights when the charge on the alarm battery is low. Press this button to display the battery charge (in volts) in the digital display window. 18. Voltage Indicator. Press this pad to display the current line voltage in the digital display window. A built-in power management system boosts voltage when it is low and lowers voltage when it is high. 22. Alarm On/Set Point Security Indicator. This indicator lights when the alarm is activated.A activated.Also lso indicates that Setpointt Securi Setpoin Security ty is activated activated (Ultima Plus Models only).
The following indicators indicators are hidden behind the display overlay overlay,, and are visible only when the LED is activated. activated. 19. Backup System Supply On Indicator 20. Backup System Empty Indicator 21. Backup System Battery Low Indicator
Manual Number 301903H15
- 16 -
Revco Plus Rev. 3
2.6
Sta Start rt Up and Operat Operation ion (Ulti (Ultima ma Plus and Elite Elite Plus) Plus)
Turning the Power On To start up your freezer, complete the following steps: Plug th the e freezer freezer into th the e power outlet. Turn the pow power er switch in back back of the freezer, freezer, on the bottom bottom right, to the ON position. position. If you do not have the CO2/LN CO2/LN2 2 backup optio option n installed, remov remove e the panel near the lower lower left corner of the front of the freezer and turn on the Battery Enable switch. Replace the panel. If you do have the CO2/LN2 ba backup ckup optio option n installe installed, d, wait until the freezer has pul pulled led down to opera operating ting setpoi setpoint nt before turning on the Battery Enable switch. Turn the key switc switch h to the POWER ON position. The Pow Power er On LED and the Cabinet Temperature Temperature LED illuminate. illuminate. The Low Batte Battery ry indicator indicator may flash during start startup, up, indicati indicating ng that the battery is recharging recharging.. Note:: The alarm function is not active at this time. In addition, for Ultima Plus units only, Note only, the Setpoint Security will be deactivated in this key position.
Error Messages If at any time during startup startup and operation operation,, an error message appears in the main display display,, be sure to call Techni Technical cal Service immediately. Error messages messages are of the form “ErXX”. ErX1 indicates indicates incorrect voltage voltage or frequen frequency, cy, and ErX2 through ErX4 indicate sensor failure.
Setting the Cabine Setting Cabinett Temperature Temperature Press and hold the the Control Setpo Setpoint int pad. The Control setpoint setpoint LED lights and the Cabinet Tempe Temperature rature LED goes out. Press Press and and hold to iincre ncrease ase the tempe temperatu rature re or or to decreas decrease e tthe he tempe temperatu rature. re. The dig digital ital display display scro scrolls lls thr through ough temperature settings. Release Release both pads when the digital temperature temperature display window shows the correct setpoin setpointt value. Note: If Note: If no keys are pressed within ten seconds, the temperature display reverts to the cabinet temperature.
Setting the Alarms (Ultima Plus and Elite Plus) On Ultima Plus and Elite Plus models, the warm and cold alarms may be set following the instructions below. Confirm that the key switch switch is at the Power On (not the Alarm On) posi position. tion. Press and hold the Cold Alarm Setpoint Setpoint pad. The LED next to this pad lights. The temperat temperature ure display sho shows ws the Cold Alarm value. value. Press Press and and hold or to adj adjust ust the Cold Alarm Alarm Setpoi Setpoint, nt, which which must be 5ºC cold colder er than the ope operati rating ng set setpoin point. t. When the cabinet temperature setpoint is changed, the alarm setpoints are adjusted automatically to maintain a 5ºC difference. Release Release both pads when the digital temperature temperature display window shows the correct setpoin setpointt value.
To set the warm alarm, complete compl thePower followi following ng steps: Confirm that the key switch switch is ete at the On (not the Alarm On) posi position. tion. Press and hold the Warm Alarm Setpoint Setpoint pad. The LED next to this pad lights. The temperature temperature display shows shows the Warm Alarm value. Press Press and and hold or to adj adjust ust the Warm A Alar larm m Setpoi Setpoint, nt, whi which ch must be 5ºC warme warmerr th than an the cab cabine inett te temper mperatur ature e setpoint. setpoin t. W hen the cabinet tempera temperature ture setpoint is changed, changed, the alarm setpoints are adjust adjusted ed automatically to maintain maintai n a 5ºC differenc difference. e. Release Release both pads when the digital temperature temperature display window shows the correct setpoin setpointt value. When the cabinet temperature drops below the Warm Alarm setting, turn the key switch to ALARM ON. The freezer is ready to operate. operate. Note: If a power failure occurs, the POWER ON light goes out, the POWER FAILURE light and digital temperature temperature display flash simultaneously, and a buzzer sounds if it has not been muted.
You must turn the three-position key switch to the ALARM ON/SETPOINT SECURITY position to activate the audible alarm and place it in security operation. Remote alarm contacts will work regardless of key position. Recording Excursions and Resetting Alarms Automatic Incident Monitor The Automatic Automatic Incident Monito Monitorr records excursions, that is extreme warm and cold temperature values.
Manual Number 301903H15
- 17 -
Revco Plus Rev. 3
You can view excursions by simultaneously simultaneously pressi pressing ng the Cabinet Temperature and Warm Alarm Setpoint pads for high excursion, and the Cabinet Temperature and Cold Alarm Setpoint pads for low excursion. Important Note: When alarms are activated becau because se of temperature failure, it is advisa advisable ble to view and record excursions excursi ons (extreme high and low temperatures) temperatures) before resetting the alarms. Alarm reset has the effect of resetting excursion excursi on values to the current cabinet temperature. temperature.
Alarm Reset The alarm reset feature, activated by pressing pressing the Alarm Reset pad, ensures ensures user acknowledg acknowledgment ment of the occurrence of certain alarm conditions. This provides greater monitoring power by alerting the user if an alarm condition has occurred during periods when the freezer must be left unattended. The alarm conditions conditions that can be reset reset are: Temperature Temperat ure Failure-Warm Failure-Warm Alarm, Temperature Failure-Cold Alarm, Power Failure, Extreme Ambient Alert (Ultima Plus only), Life Guard Alert (Ultima Plus only), Clean Filter.
During any of these alarm conditions, the corresponding corresponding indicator indicator will flash f lash quickly. quickly. If the alarm condition then disappears, the flash rate will decrease. The indicator will then remain flashing at this rate, unless the condition reoccurs, until the Alarm Reset button is pressed. Once the Alarm Reset button has been pressed, the indicator will no longer be lit. The alarm reset function function does not affect the status of remote alarms. In the case of Temperature Temperature Failure-Warm Failure-Warm Alarm And Temperature Temperature Failure-Cold Failure-Cold Alarm, if these conditions conditions have occurred but are now within the given limits, the two indicators will alternately flash (180° out of phase). Once the Alarm Reset button is pressed, pressed, the extreme temperature value is reset to the current cabinet cabinet temperature.
Alarm Test Press and hold the Alarm Test pad. The digital temperatu temperature re display indicates indicates rising temperature. temperature. When W hen the temperature reaches the warm alarm value, the audible and visual alarms will be activated, as well as remote alarms, but excursions (extreme temperatures) temperatures) will not be logged. logged. Note: The temperature temperature of the refrigerate refrigerated d space does not change during this procedure. Releas Release e the Alarm Test pad. The display returns to cabinet temperature. temperature.
Manual Number 301903H15
- 18 -
Revco Plus Rev. 3
2.7 Progr Program am Mode
You can use Program Mode to display and adjust adjust various parameters, including including the bracket used for Value Plus alarm settings. Do not change the values values of Program Program Mode Mode parameters parameters without without consul consulting ting Tec Technical hnical Service Service.. Shutd Shutdown own and and/or /or damage to the freezer could result from improper setting of parameters. To enter Program Mode, press the Cabinet Cabinet Temperatu Temperature re pad and hold for 5 seconds. “Prg” will be displayed until you release the pad. In Program Mode, parameter labels and values are display displayed ed instead of cabinet temperature. temperature. The display advances to the next item after a 1.5 second timeout, or when you press the Cabinet Temperature pad. After 10 seconds of inactivity at any point in the session, Program Program Mode is deactiva deactivated ted and the cabinet temperature is display displayed ed again.
Parameter
Plus Models (U=Ultima E=Elite, V=Value)
Micro PCB Firmware Version Number is shown first
U, E, V
Te Temp mper erat atur ure e Disp Displa lay y Of Offse fsett
U, E, V
Res tta a rrtt T iime me D e ella y
Displa y
Notes
Displays micro firmware revision in MMmm format.
Display only: “Er06” error if firmware integrity test fails.
“oFF” then “SEt”, followed by offset value.
Offsett for calibratio Offse calibration: n: Adjustable Adjustable using value is 0; range is -10ºC to 7ºC.
“tI “tI” the then “dL “dL y y”, ”, fol fol lo lo w we e d b y v al al ue ue.
Value displayed in minutes, in steps of one tenth of a minute. Default is 0.0; range is 0.0 to 20.0. Adjustable using and
U, E, V
and
. Default Default
This feature mayinbe used to have stagger restartfreezers. times following a power outage case you multiple
BUS Type
U, E, V
BUS Setpoint
U, E, V
Alarm setpoint bracket
V only
Life feg gua rrd d S etp etpo oi nt nt
U onl y
Table 1.
Displays backup system type only when a backup system is detected.
Dis Displa play y onl only. y. Use and to tog toggle gle bet betwee ween n the val values ues “Ln2” and “co2”. Changing this value automatically changes the default setpoint.
Setpoint value in display (only when a backup system is detected).
Adjustable using and range is -0ºC to -65ºC;
Value of alarm bracket (deviation from setpoint) shown in main display.
Use an and d value is 10.
Di sp spla y ys s Li fe feg u ua ard s etp etpo oi nt nt v al al u ue e.
. LN 2 range is -0ºC to -76ºC; C02
to sel select ect val value ue 5, 10, 15, or 20º 20ºC. C. Default Default
Adjustabl Adjustable e using using 70ºC to 98ºC.
and
. Default Default value is 94ºC; 94ºC; range is
Program Program M Mode ode Para Parameter meters s
Manual Number 301903H15
- 19 -
Revco Plus Rev. 3
2. 2.8 8
Value Value Pl Plus us Model Models s – Oper Operati ation on 2
5 6
7
10
11
12 BACKUP SYSTEM
SUPPLY ON
SUPPLY EMPTY
BATTERY LOW
CABINET TEMPERATURE
OFF
POWER FAILURE
CONTROL SET POINT
ALARM ON
1
3
4
8
9
Value Plus Control Panel with Optional Backup System
Value Plus Control Panel Before the initial start up, take some time to become familia familiarr with the controls on your Value Plus freezer. 1. Three positio position n key keyed ed P Power ower On Switch. 2. Power On Ind Indicator. icator. Thi This s green LE LED D lights when power power is conne connected cted to the free freezer zer and th the e key switch iis s in the ON positi position. on. 3. Alarm On In Indicato dicator. r. This indicator indicator lights lights when the the alarm is ac activate tivated. d. 4. Power Fail Failure ure Indica Indicator. tor. This indi indicator cator ligh lights ts when there there is a power failure failure to the freeze freezer. r. 5. Control Setpoint Setpoint.. Press th this is pad to s set et the cab cabinet inet temperature. temperature. 6. Cabine Cabinett Temperatur Temperature e Indicator. Indicator. Displays cabinet cabinet tempera temperature ture in operating operating mode, paramet parameters ers and value values s when in program mode. 7. Digital Te Temperature mperature Dis Display play Window Window.. This window displays displays chambe chamberr temperatur temperature, e, alarm value values, s, etc. depend depending ing on the operating status of the freezer and the procedure being performed. 8. Decreme Decrement nt P Pad ad ( ). Us Use e th this is pa pad d to d decr ecreas ease e tem tempera perature ture val values ues.. 9. Increme Increment nt P Pad ad ( ). Us Use e thi this s pad to incre increase ase temperatu temperature re value values. s.
The following indicators are hidden behind the display overlay, and are visible only when the LED is activated. 10. Backup System Supply On Indicator. 11. Backup System Empty Indicator 12. Backup System Battery Low Indicator. Turning the Power On Plug the freezer freezer into the power outlet outlet.. Turn the power switch in back of the freezer, on the bottom right, to the ON position. If you do not have have the the CO 2 /L /L N 22 backup option installed , remove the panel near the lower left corner of the front of the freezer and turn on the Battery Enable switch. Replace the panel. If you do have have the the CO 2 / /L L N 22 backup option installed , wait until the freezer has pulled down to operating setpoint before turning on the Battery Enable switch.
Turn the key switch to the POWER ON position. The Power On LED and the Cabinet Temperature Temperature LED illuminate. alarms. Note: The alarm functio function n is not active at this time. Refer to setting the alarms.
The Low Battery indicator may flash during startup, indicating that the battery is recharging. Error Messages If at any time during startup startup and operation operation,, an error message appears in the main display display,, be sure to call Techni Technical cal Service immediately. Error messages are of the form “ErXX”. ErX1 indicates indicates incorrect voltage or frequency frequency,, and ErX2 and ErX3 indicate sensor failure.
Setting the Cabine Setting Cabinett Temperature Temperature Press and hold the the Control Setpo Setpoint int pad. The Control setpoint setpoint LED lights and the Cabinet Tempe Temperature rature LED goes out. Press Press and and hold to iincre ncrease ase the tempe temperatu rature re or or to decreas decrease e tthe he tempe temperatu rature. re. The dig digital ital display display scro scrolls lls thr through ough temperature settings. Release Release both pads when the digital temperature temperature display window shows the correct setpoin setpointt value.
Manual Number 301903H15
- 20 -
Revco Plus Rev. 3
Note: If no keys are pressed within ten second seconds, s, the temperature display reverts reverts to the cabinet tempera temperature. ture. Alarm Operation Setting the Alarms Setting In Value Plus models, the warm and cold alarm setpoi setpoints nts are set automatica automatically lly with a 10ºC bracket. For example, if the operating setpoint is -75ºC, the warm and cold alarms will be -65ºC and 85ºC respectively. You can change change the bracket value in Prog Program ram Mode.
Silencing the Alarms In Value Plus models, you can silence silence alarms by turning the key switch to the ON (middle) position position..
Key Switch Summary The key switch is used to enable enable the audible alarm on the display board. board. When the key switch is in the on position, the POWER ON led (green) is illuminated. illuminated. When the key switch is in the alarms enable enabled d position, both the POWER POWER ON led and the ALARMS ENABLED led (green) are illuminated. illuminated. These two LED’s are control controlled led exclusiv exclusively ely by the key switch position. position. The key switch will not affect alarms that are associated associated with the remote alarm contacts; thus, remote remo te alarm alarm con contac tacts ts are complet completely ely indepe independe ndent nt of key positio position n except for the off position which ensures remote alarm alarm conta con tacts cts are deactivated deactivated . For the Value feature feature group, the key switch is the only metho method d to turn off the audi audible ble alarm as no alarm silen silence ce or mute button is provided. provided. For the Ultima feature group, the key switch enables Setpoi Setpoint nt Security in the 90-degree or horizontal position, locking the keypad so settings can be viewed but not changed. The key can be removed only in the ALARMS ENABLED position, position, or the Off positi position. on.
For firmwa firmware re 0200 or or late later, r, cy cling the key s witch s ta tarts rts a 6-minute 6-minute s hort cycle dela delay. y. Perform a cold cold restart (AC and battery off) to bypass this delay.
2.9
Spe Specia ciall Serv Service ice Star Startup tup Mod Modes es
The following following table describe describes s special Service special Service Startup Modes. Modes . Some of the test modes de describe scribed d are available available only for firmware 0200 or later. later. Some are activated activated only by a cold power up, with all A/C and batte battery ry power initially initially off, as described. To activate the selected Startup Mode, hold down the indicated button(s button(s)) while the keyswi keyswitch tch is off, then continue holding those those buttons for several seconds seconds while turning the key switch on. Several tries may be required to enter the desired mode.
K ey S tartup tartup Mode Modess : Hold Down The Indicated Button(S) While Turning On The Key Switch CT Factory Default Default R eset es et:: All non-volatile, non-volatile, adjustable adjustable parameters are restored to the default CT + CSP
CS + Down (down arrow)
Factory Test Mode
factory sta factory state. te. This startu startup p mode will work for any ke key y cycle cycle.. The uni unitt will cont continu inue e to run normally following this startup procedure. procedure. 100% R un “B ottom ottom Out” Mode: Mode: This This will power up the unit in BOT mode so tha thatt the unit will go to 100% continuous continuous run. This is required for Thermocouple Thermocouple Diagnostics Diagnostics as explained in the Trouble Shooting section, since the normal control set point can not be set colder than -86 °C. This startup mode first displays displays a calibra calibration tion mode, then after several seconds seconds goes to th the e BO BOT T mode. mode. Th The e di disp splay lay will flash flash betw between een “bot” “bot” and and the curr curren entt tem tempe pera ratu ture re indica ind icating ting this this mode is active. active. This mod mode e will work for any key cycle. cycle. The uni unitt will stay in this BOT run mode until the key switch is cycled (a 6 minute restart delay will initiate for firmware 0200 or later).
S ervic erv ic e Tes T estt Mode: Mod e: A diagnostic diagnostic mode available available on only ly for micro versi versions ons 020 0200 0 or later. See Trouble Shooting Shooting section section for a detailed detailed description. description. This mode may be entered and exite exited d only by performing performing a cold startup (AC and battery off). Cycling Cycling the key switch only will blank the display but not exit this test mode. (May Be Entered By Mistake; [tSt0] will flash in display ) No Field Service Application At This Time. Exit this mode mode by cycling key switch. switch.
Manual Number 301903H15
- 21 -
Revco Plus Rev. 3
2.10 2.1 0 Key Keypad pad Sum Summary mary
The keypad keypad or pus push h butt buttons ons are used to enter enter operati operating ng paramete parameters, rs, read erro errorr cod codes, es, and ini initiat tiate e oth other er con control trol feature feat ures s as described described below below.. All keypad keypad func function tions s are summarize summarized d here here.. When speci special al key keystro strokes kes are req require uired, d, that procedure is described where needed in this manual.
bbreviat bbreviations: ions: B utton/ utton/LE LE D K ey: Not all all butto buttons ns have an as as s ociat ociated ed LE D Cabinet Temp – CT, green led Control Setpoint – CS, yellow led W arm Alarm – W A, yellow led Cold Alarm – CA, yellow led Increment (up arrow) – INC (no led)
Alarm Test – AT, (no led) Alarm Reset – AR (no led) Battery Low – BL, red led Voltage – VC, yellow led
Decrement (down arrow) – DEC (no led)
NOTE: The key position will control the POWER ON and ALARMS ENA ENABLED BLED LED’s. Us er Interface Interface K eypad eypad S umma ummary Buttton But onss Pushe Pushed d Fea Featur ure e S etting Notes Group Range None (n Non (no o pushed)
but utto tons ns
U,E ,E,V ,V
N/A
CT
U,E,V
N/A
CS
U,E,V
N/A
CS + INC/DEC
U,E,V
-50 to -86 °C (defaul (defaultt is -80)
Displa lay y calibra rate ted d contr tro ol probe te temp mpe erature with CABINET NET TEMP le TEMP led d illum illumin inat ated ed.. Cer Certa tain in run mode mess messag ages es or error error codes may flash in the display. Various usage: 1) When When not not in Program Program Mod Mode, e, retu return rn im immed media iate tely ly to th the e main ma in di disp spla lay y fu func ncti tion on and and show show th the e cont contro roll pr prob obe e temperature. 2) When When hel held d fo forr 5sec 5sec an and d not not in Pr Prog ogra ram m Mo Mode de,, en ente ter r Program Mode. 3) When When in Progra Program m Mo Mode de,, adva advanc nce e to the next next scre screen en which could be a parameter label or the parameter itself. 10 sec of inactivity will return from Program Mode to the main loop. loop. Any but button ton pres press s while in Progra Program m Mod Mode e will reset the 10 sec timeout. W ill illuminate the SETPOINT LED (yellow) and display the value of th the e se setp tpoi oint nt in whole whole num numbe berr °C °C.. Auto Automat matic ic return return to mai main n loop, no buttons pushed in ~1 second. Adjusts the control setpoint in 1°C steps. Changing the control setpoint will push the warm and cold alarms if set within 5 °C of their the ir setpoints setpoints.. No pull function function is pro provid vided. ed. Automatic Automatic return return to normal display if no buttons pushed in ~1 second.
(For firmware 0102, 56°C was the warmest set) N/A
WA
U,E
WA + INC/DEC
U,E
CT + WA (Diagnostic Tool)
U,E
-40 °C to Control Setpointt + Setpoin 5°C (default is 70) N/A
CA
U,E
N/A
Manual Number 301903H15
W ill illuminate the W ARM ALARM LED (yellow) and display the value of the warm alarm in whole whole number °C. Automat Automatic ic return to normal display if no buttons pushed in ~1 second. Adjusts the warm alarm setpoint in 1 °C steps. Cannot be set warmer warm er than plus 5 deg degrees rees of the setp setpoin oint. t. Aut Automat omatic ic return to main loop, no buttons pushed in ~1 second.
W ilill illuminate the CABINET TEMP and the W A AR RM ALARM LE LED’s D’s.. The displa display y wi will ll show show the wa warme rmest st te tempe mperat ratur ure e the cabine cab inett has displa displayed yed since the Alarm Res Reset et was last pus pushed hed.. Alarm reset button will reset to current temp. W ill illuminate the COLD ALARM LED (yellow) and display the value val ue of the cold alarm in whole number number °C. Auto Automati matic c return to main loop, no buttons pushed in ~1 second.
- 22 -
Revco Plus Rev. 3
Us er Interface Interface K eypad eypad S umma ummary CA + INC/DEC
U,E
CT + CA (Diagnostic Tool)
U,E
Control Setpoint – Setpoint 55°C to -99 °C (defaul (defaultt is -90) N/A
VC
U,E
N/A
CT + CA + VC
U,E
AR
N/ N/A A
U,E
N/A
CT + CA + BL
U,E
N/A
CT + CA + BL + VC
U,E,
N/ N/A A
Check Heat-X temperature
V: special procedure described
Alarm mute. BL
reset
W ill illuminate the CABINET TEMP and the COLD ALARM LED’s. The display will show the colde coldest st temperature temperature the cabinet has display displayed ed since the Alarm Alarm Res Reset et was last push pushed. ed. Ala Alarm rm Reset button will reset to current temp. W ill illuminate the LINE VOLTAGE led and the display will show th the e calib calibrat rated ed lin line e volt voltage age rea readin ding. g. See Vol Volta tage ge Ca Cali libra bratio tion n instructions instruc tions elsewhere elsewhere in this manual if needed needed.. No Note te th that at th the e LI LINE NE VOLT VOLTAG AGE E le led d is no nott asso associ ciat ated ed with with a buck/boost buck/b oost condition as in prior models models.. LED’s will be off and the display will show the compensated voltag vol tage e stored stored after after the last sched scheduled uled update or buc buck/bo k/boost ost event in whole number Volts.
N/A
U,E U,E
Will illuminat illuminate e the COLD ALA ALARM RM LED (yellow) (yellow) and adjust the cold cold alar alarm m setp setpoi oint nt in 1 °C step steps. s. Ca Cann nnot ot be set set wa warme rmerr th than an minus min us 5 de degr gree ees s from from th the e setp setpoi oint nt.. Au Auto tomat matic ic ret return urn to mai main n loop, no buttons pushed in ~1 second.
Note that this value Note value is upd updated ated relati relativel vely y inf infrequ requentl ently; y; i.e., i.e., at volt voltag age e comp compen ensa sati tion on st sta ate chan change ge an and d ~ho hour urly ly if no compensated voltage state change. Wi Will ll re rese sett the the war arm m an and d cold cold ex excu curs rsio ions ns an and d cl cle ear al alll ha has s bee een n (past) alarm alarm conditions. conditions. Will mute the active alarm buzzer buzzer for 6 minutes. Active alarms will be muted but re-appear immediately; immediately; they cannot be cleared while active. W ill illuminate the BATTERY LOW led and the display will show the last measured battery voltage voltage.. LED’s will be off and the display will show the display offset in whole number number °C. This is adjusta adjustable ble in Program Mode Mode.. LE LED’s D’s will will be off and and the the dis displ play ay wil willl show show the Hx te tempe mperat rature ure in whole who le number number °C. “Er0 “Er03” 3” will display display if the sensor sensor input is out of range. See Trouble Shooting Shooting sectio section n for sensor test.
and
NOTE : For the Value Value fea features tures (V), B L + VC are not s hown on the overlay, but service personnel may “feel” for them to read this value.
CS + CA
U
N/A
WA + CA + BL Ch Chec eck k compr compres esso sor r temperature.
U
N/A
W ill show the lifeguard setpoint in whole number °C. This is only adjustable adjusta ble in Program Program Mode. Wil Will show the comp mprressor sensor reading in °C. If the sensor input inp ut is out of ran range, ge, “Er04” “Er04” wil willl dis display play.. See Trou Trouble ble Shoo Shooting ting section sectio n for sensor sensor testing.
Dis pla play P CB Firmwa Firmware Version This i s a special special mode mode to te tess t the Dis pl pla ay circuit boa board. rd. The Display PCB onboar Display onboard d firmw firmware are wil willl interrup interruptt all inc incomin oming g micro commands and display the firmware version as a 4 digit number. Diagnostic Tool; The Display board will run a checksum routine to verify Display Er05 firmwa firmware re in integ tegrit rity y and and di disp splay lay “Er0 “Er05” 5” on failu failure. re. Re Repla place ce the Display Dis play PCB if an Er05 is seen. seen. This tes testt is ava availab ilable le for all key positions positio ns except Off. Prog ram Mode Mode: used for entering or viewing specific parameters as described below. Hold CT for 5 secon seconds, ds, then “Prg” displays until user releases releases CT. For the Ultima feature set, the keyswitch position position determi det ermines nes if values values can be change changed d (Power (Power On), or only viewed (Set (Setpoin pointt Sec Securi urity). ty). Use the CT button to ste step p through thro ugh the Program Program step steps. s. Will exit program program mode if no button is pushed pushed for 10 second seconds, s, or aft after er last ste step p is reached. CT + CS + INC + DEC
U,E,V
N/A
Step 1: (firs Step (firstt number displayed) Micro Board Firmware Version; or “Er06”
U,E,V
N/A
Manual Number 301903H15
Displa lay ys the Mi Mic cro fi firm rmw ware versi sio on as a 4-d -dig igiit numb numbe er. Most recent version version is 0200 as of June 9, 2008. The firmware ve version rsion is also labeled on the Micro PCB CPU chip. If firmware test fails, “Er06” will be displayed; replace Micro PCB. - 23 -
Revco Plus Rev. 3
Us er Interface Interface K eypad eypad S umma ummary Step 2: Text will show “oFF” followed followed by “SEt”. This is where the Display Display Offset is calibrated. calibrated. Current Offset is U,E,V -10 to +7 Pres Press s Up or Down Down arro arrow w bu butt tton ons s to adju adjust st in st step eps s of 1°C. 1°C. shown. sho wn. Use °C (defaul (defaultt Adjustment will be retained after time out or Step advance. INC/DEC to adjust is 0) Step 3: Text will show “tI” followed by “dLy”. Restart time delay delay is set here. here. th Program m a restart delay following following a power loss. Steps of 1/10 Restartt Time Delay: Restar Delay: U,E,V 0.0 to 20.0 Progra minutes (6 seconds). seconds). Used to stage the rest restart art of a group of INC/DEC to adjust min freezers following a power loss, to reduce sudden high amperage (defaultt is (defaul draw on the power system. 0.0) Possible Possi ble Steps 4, 5, 6 follow (Only if a BUS is install installed). ed). Text will show “BUS” followed by “type” “type” Step Ste p 4: Sel Select ect BUS BUS U,E,V “Ln2” or This option will only show when a backup system is Type:: INC/DEC to Type “co2” detected at system initialization. select LN2 or CO2 (default Di Disp splay lay “Ln “Ln2” 2” or ‘c ‘co2’ o2’ to sele select ct BU BUS S ty type. pe. Whe When n th this is valu value e is “Ln2”) changed, the default setpoint for the type of BUS selected is sent to the BUS system. system. Advance to the ne next xt paramete parameterr to adjust the desired setpoint value. Step 5 if BUS detected: Text will show “BUS” followed by “SEt” This option will only show when a backup system is Step 5: Set BUS U,E,V LN2: 0 to detected at system initialization. Setpoint using Up or -76 °C Down buttons. steps. The setp setpoin ointt range is dete determin rmined ed by the BUS type CO2: CO 2: 0 tto o 1°C steps. selected select ed in the previous program step. BUS setpoint should -65 °C usually be 5 degrees warmer than Warm (defaultt (defaul Alarm setpoint. 65 °C for both) Step 6 if BUS detected: Text will show “BUS” followed by “PUrg” Purge BUS Setpoin Setpoint: t: This This op opttion ion wi willl onl only show whe when a backup ckup system system is push Up button to detected at system initialization. activate. Di Disp spla lay y wi will ll show show curr curren entt BU BUS S setp setpoi oint nt.. If th the e Up butt button on is pressed the number should change to -95C to force the supply soleno sol enoid id to ope open. n. Ide Ideally ally,, thi this s is done afte afterr the supp supply ly source valve has been closed and the supply line to the freezer needs to be purged. purged. The BUS setpoint setpoint will be restored restored at the concl conclusi usion on of Program Program Mode Mode (timeou (timeoutt or advan advance ce to end end). ). Thu Thus, s, the purge time is variab variable. le.
The us er shoul should d ensure tha hatt the tank empt ptyy wa warnin rningg is illuminat illum inated ed prior to dis connecting the lines lines bet betwee ween n the tank tank and the unit. unit. It s hould be be noted noted that that this s hould be be checked ust prior to disconnecting disconnecting the line liness to ens ens ure press ure does does not rebuild. (Next Program (Next Program Ste Step p Option Option)) Val Value ue Series Series Alarm Range Setting Setting:: Only if DIP SW 3 in micro PCB is set for a Valu Value e Series Freezer. Freezer. Text will show “VAL” “VAL” followed by “Rg” Valu Value e Only Only 5, 10 10,, 15 15,, Only for the Value Feature Feature Fr ee eezers zers.. This s te tep p will not be be Value Series Alarm forr E lite or o r Ultima feature featur e fr eezers . or 20 °C s een fo Bracket Bra cket:: Up or or Down Button to Se Selec lects ts th the e warm warm and and cold cold ala alarm rm brac bracket ket for Va Valu lue e freez freezer ers. s. adjust (default Factory default 10 degree range means if the setpoint is -80C, 10 °C) the warm alarm will be -70C and the cold alarm will be -90C. Can be set only in the program mode.
Note,, for extrem Note extreme e s et etpoint pointss , the actua actuall ala larms rms will not be allowed to exceed -40C (warm alarm) and -99C (cold alarm). For example, if the user sets to -85C with a 20 degree alarm bracket, the cold ala alarm rm will be limited limited to -99C, not -105C. (Next Program Program Step Option) Text will show “LIFE” followed by “grd” Compressor Compressor Temp Alarm Setpoin Setpointt Manual Number 301903H15
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Revco Plus Rev. 3
Us er Interface Interface K eypad eypad S umma ummary Lifeguard Alert st Setpoint Setpoi nt (1 Stage Compressor Temperature)
Ultima Features Only
70 – 98 °C (94 default)
Use Up and Down buttons buttons to adjust in 1°C steps. This feature feature has two different different affects: With firmware 010 0102 2 and earlier a Lifeguard Lifegu ard alarm will stop the compressors compressors.. Starting Starting with firmware 0200 the alarm will only show a blinking yellow LED on the controll panel, contro panel, the compressors will continu continue e running running..
2.11 Safety Warnings Electrical Safety Know the location of of the freezer’s circuit b breakers reakers or fuses. Ensure Ensure all breakers and/or and/or fuses are clea clearly rly marked for quick identification and reference. and reference. This appliance has live electrical electrical circuits whenever whenever it is connected to an energized receptacle, even when the key is turned off. Only technicians trained and experienced in handling live electrical systems, and properly trained for the particular appliance, shall perform those diagnostic diagnostic and repair procedures procedures outline outlined d in this manual which require the system to be energized. Before removing any panel or cover, unplug the appliance to avoid coming into contact with any live or improperly improperly energized component. There are no normal periodic maintenance procedures that require the unit to be energized. Be careful when handling freezer freezer access panels, parts, or any components components that may have sharp edges that may cause cau se damage to wiring and electrical connections, connections, not to mention personal injury. Always Always use the correct correct tool for a job and be sure those tools tools are in good condition. Ensure that tools to be used on electrical devices are well insulated, if applicable. Never interfere interfere with or bypass the operation operation of any switch, switch, compone component nt or feature of the unit. Interlocks, relay relays, s, and switches are designed with a specific purpose and should, therefore, not be altered. Use only approved approved replacemen replacementt parts that are the correct correct size size,, rating, and capacity as the original part. If you have a
question concerning replacementbe parts, Technical Department. When replacing any component, surecall anythe green groundServices wires are reconnected sec securely urely in their their original positions to avoid danger of shock or short circuit. Never interfere interfere with or bypass the operati operation on of any switch, component component or feature f eature of the unit. Before Before reconn reconnectin ecting g the power supply supply,, ensure uninsu uninsulated lated wires wires or terminals are not touching the cabinet Be sure and reference any applicable applicable wiring diagram(s) when reconnecting and replacing replacing electrical components. To avoid electrical shock, shock, fire, and equipment damage, ensure that any wires or terminals touching the cabinet are insulated before connecting the power supply. Electrical wiring and all grounds must be correctly reconnected reconnected and secured away from sharp edges, edges, components and moving m oving parts. All panels and covers should be reinstalled before the freezer is plugged in. Never Never alter a pow power er cord in orde orderr to make it fit an electr electrical ical o outle utlet. t. The line cord must be plugged into a grounded, three-pr three-prong ong receptac receptacle. le. Never Never cut or remove the third third (ground) (ground) prong from the power cord conne connector. ctor. Never Never sub substitu stitute te or ordina dinary ry wi wire re for for any internal internal wiring wiring of of a freeze freezer. r. The The inter nal wir wiring ing of thes e un its carr y a spec ial rating due to the somewhat high currents that they can be subjected to at times. This heavy current load
generate gene rates s heat, which can melt ordin ordinary ary wire. It is vitally important that all connections are tight and secure. Throughou Throughoutt this service manual, additional safety precautions dealing with specifi specific c procedu procedures res may be present presented. ed. This information should be carefully read and observed.
Refrigerant Safety Common refrigerants are used in this freezer series. They are R290, R404a, and R508B. asphyxiates. ▲ Caution Neither of these refrigerants will support life. Both are classified as asphyxiates. ▲ Caution Neither The following are effects of over-exposure: Lightheadedness Giddiness shortness shortness of breath unconsciousness
possibly death.
Emergency and First Aid Proced Emergency Procedures ures Remove to to fresh air. air. Call a physician. Do not give heart stimulating drugs such as epinephrine epinephrine or similar drugs drugs..
Manual Number 301903H15
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Revco Plus Rev. 3
As these refrigerants listed have a vapor density of 3.00, or over 7.00, prop proper er ventilation is mand mandatory, atory, especial especially ly in the low places places where the heavy vapor could collect. Do not have open flames in this area. These refrigerants, refrigerants, when exposed to open fla flame, me, may produce toxic compounds such as hydrogen chloride, hydrogen fluoride, and other acidic vapors. Smoking Smoking sho should uld never never take take place place around around any refrige refrigerants rants.. Deadly Deadly phosgene gas, which can kill very q uickly, is also one of the compounds that these refrigerants can break down into if they come in contact with a high enough temperature flame. Always use facial and eye protection, as well as gloves when opening opening a sy system stem th that at ha has s suffe suffered red a “burn “burn ou out”. t”. The possibility of Hydrofluoric acid is high. Also use facia faciall and eye protectio protection n and gloves when when handling liquid liquid refrigerant. refrigerant.
ventilation. The use of an air m mask ask with an indepen independent dent air supply is recommended recommended in areas areas of high conce concentrati ntrations ons and poor poor Avoid breathing any any refrigerants if possible. Treat all re refrigerant frigerant cylinders cylinders wit with h care. Store Store in clean dry dry areas. Do not store at high temper temperatures. atures. Never attempt to “unbraz “unbraze” e” a sealed system joint. Even an empty syste system m can contain high pressures pressures created by the heat of the torch.
2.12 Recommended Recommended Tool Tool List Proper tools are requi Proper required red to perform perform a job correctly. correctly. The tools listed below, below, plus common hand tools are needed to service cascade refrigeration equipment. * Safety Safety gla glasse sses, s, pro protec tectiv tive e clothi clothing, ng, and ste steelel-toe toed d * Brazing Torch Set; Air/Fuel (turbo tip) or sh shoe oes. s. Do not per perfor form m an any y proced procedure ure withou withoutt prope proper r Oxy/Fu Oxy/Fuel. el. Have adequate adequate fire suppressa suppressant nt training train ing and adeq adequate uate equipmen equipment. t. equipment and needed permits/permission before proceeding. * Electronic Digital Thermometer capable of reading readin g type “T” thermocouples. thermocouples. A “K” type only meter will give incorrect readings at cold temperatures. * Compound Gauge Set (4 way) with Hoses reserved reserv ed for ULT use. One set will be needed for each stage.
* Data Logging Logging System (recommended). (recommended). Ability to record TC’s, RTD’s, Voltage, Amps, and Pressure Pressu re is ideal.
* True RMS Digital Multi-Meter capable of 9.999 display or better, and capacitor checking to 500uF. * Hermetic Hermetic Uni Unitt Analyz Analyzer; er; “Annie” “Annie” type tester. tester.
* Electronic Refrigerant Leak Detector (CF C and HFC capable).
* True RMS Amperage Clamp meter, with InRush Current Current captu capture re feature. Milli-Amp capability ideal.
* Electro Electronic nic Refrige Refrigerant rant Char Chargin ging g Sca Scales les
* Cordless Driver-Drill Driver-Drill (Reversible), with magneti magnetic c * Flushing Flushing system and solvents. solvents. Seek facto factory ry extension, bits (Phillip extension, (Phillips, s, square, torx, Allen, and hex nut)
technical techn ical training and advice ffor or current practi practice. ce.
* Process tube adapters, capable for ¼, 5/16, and * Refrigerants; R404, R134a, R508B, and R290 3/8 inch copper copper tubing. Must allow atta attachment chment of (Instrument Grade Propane) flushing flushi ng and purging hoses. * Dry Dry Nitro Nitrogen gen Tan Tank k with with Regula Regulator tor and Hos Hoses es
* Pinc Pinch h Off Off Tools Tools.. For seal sealing ing copper copper tub tubing. ing.
* Fl Fla arin ring Set and Swa Swaging Too Tool Set
* Recov ove ery Sys System (w (wiith tanks anks))
* Stand Standard ard Hand Hand Tools Tools (Scre (Screw w Drive Drivers, rs, Wrenche Wrenches, s, Pli Pliers, ers, etc.) etc.)
* Tubing tools: cutters, deburring, benders, cleaning.
* Thermal Anemometer Anemometer (optional), (optional), for condenser condenser fan airflow airflow..
* Vacuum Vacuum Gaug Gauge e (El (Elect ectron ronic ic)) wi with th digita digitall or analog analog readout
* Vacuu Vacuum m Pump Pump (Ca (Capa pabil bility ity of 40 micro microns ns))
* In Infra frare red d Non-co Non-cont ntac actt The Thermo rmomet meter er
Manual Number 301903H15
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Revco Plus Rev. 3
3.0 Rou Routin tine e Mai Mainte ntenan nance ce 3.1 Cleanin Cleaning g the Refrigeration Refrigeration System System Caution De-energize Caution De-energize all potential sources of energy to unit. Lockout/tagout de-energized control per O.S.H.A. Regulation, Section 1910-147 before cleaning the refrigeration system. ▲ system. ▲
Clean Clean the condense condenserr at least twice a year, dependi depending ng on environme environmental ntal conditions. It is located behind the ffront ront grille. Use a vacuum or air hose to clean clean the fins of the conden condenser. ser. Dust Dust in the conden condenser ser fins slo slows ws the rate of heat dissipation a nd increases the operating temperature of the compresso compressors rs (thereb (thereby y decre decreasin asing g their effec effective tive lives). A dirty condenser will redu reduce ce the overall overall performance performance of the refrigeratio refrigeration n system in terms of recovery r ecovery time and setpoint control accuracy accuracy;; or may ultimately cause com compre presso ssorr failu failure. re. The air filter should be cleaned, or replaced, at least twice a year, dep depend ending ing on en envir vironme onmenta ntall cond conditio itions. ns. The filter is located behind the front grille. It can be replaced, or washed using water and a mild detergent and pressed between two towels to dry. Periodically Periodically clean any accumulated accumulated dirt from the compressor compressor housings and other refrigeration system parts. Compressors and fan motors are permanently lubricated and do not require routine maintenance.
3.2 Freeze Freezerr U Unit nit Mainten Maintenance ance
Remove the frost from the door gasket with a soft cloth regularly. When the door is opened,the difference in temperature between the freezer’s internal air and room ambient creates a very soft frost on the gasket of the door and the cabinet. If the door is closed without removing the soft frost, on the next opening, the soft frost melts, then turns to ice after the door is closed again. If this continues, ice builds up, which could keep the door from closing properly. Do not damage the door gasket when removing frost.
Periodically Periodically check gaskets for punctures punctures or tears. Leaks are indicated by a streak of frost at the point of gasket failure.
Replace Replace the battery every two years for a consistent and depen dependable dable charge. charge. Make sure to turn the unit off and disconnect it from the power source before attempting to replace the battery. If the freezer is not to be used for an extended extende d length of time, the battery should be disconnected. disconnected.
3.3 Defrost Chamber The type of frost formed in the chamber is generally very soft and may be easily removed with a soft cloth. Do NOT use any type of abrasive brushes. A complete defrosting may occasionally be required (once a year or whenever ice build-up reaches 3/8”). To completely defrost the chamber, follow the procedure procedure below:
Remove tthe he product product and pla place ce it in another another freezer. freezer. Discon Disconnect nect the freezer from from the pow power er source. source. Allow the freez freezer er to stand stand with with all doors doors open open for at le least ast 24 24 ho hours, urs, so that the int eri or and the foa med refrigeration system warms to ambient. Place towe towels ls on the chamber floo floor. r. Keep the floor of the chamber chamber clear clear by removing water as it accum accumulates. ulates. Allow frost to me melt lt and become become loose fro from m the interior interior chamber. To remo remove ve any o odor, dor, the the interi interior or can be washed washed with with a solution solution of of baking soda and warm water. The exterior can be cleaned with any common household cleaning wax. After defrostin defrosting g is complete, wipe interior chamber and gasket dry with a clean clean dry so soft ft clo cloth. th. 3.4 Check Va Vacuum cuum Relief Relief Port
Check vacuum relief heater for operation. If heater is apparently not working, check voltage to heater. Replace heater assembly if necessa necessary. ry. Note: Removal of ice from the vacuum relief port or the vacuum relief heater should be performed as often as visual inspection (inspect at least weekly) indicates an ice build-up. Failure to do so causes a vacuum buildup, resulting in an inability to access the cabinet after a recent door opening. ▲ opening. ▲
Manual Number 301903H15
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Revco Plus Rev. 3
3.5 Door Adjustment Adjustment The following steps will aid you in adjusting the hinges of an upright Ultra Low Temperature freezer: Ensure the freezer freezer cabinet is level from front to back, and left to right. 3-1).. Install a bar bar clamp with 2” x 4” wood wooden en blocks (Figure 3-1) Loosen the mounting screws screws that hold the hi hinge nge to the door (Figure (Figur e 3-2). Align the door so that the top and latch edges are flush flush with with the cabin cabinet. et. Tighten the bar clamp t o produce a secure gasket gasket se seal al.. Tighten all mounting screws. Figure 5-1. Freezer 5-1. Freezer Door Adjustment
Slotted holes
Figure 3-2. Hinge
Manual Number 301903H15
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Revco Plus Rev. 3
4.0 Sequen Sequence ce of Op Operatio eration n Two sequences sequences follow follow;; one for normal start-u start-up p and one for start-up after after a power failure. 4.1 Norma Normall Sta Start rt Up 1) Plug line line cord into co correct rrect AC recept receptacle. acle. Verify voltage voltage require required d on data data plate plate.. 2) Plug line cord cord into unit’ unit’s s IEC320 con connector. nector. Secure Secure with reta retaining ining bracket. bracket. 3) Turn on the battery battery switc switch h (located b behind ehind the smaller smaller pull-off pull-off panel). panel). System ba battery ttery is con connected nected to mic micro ro board electronics electronics and charging circui circuits. ts. Optional BUS battery is connecte connected d to BUS board electronic electronics s and
4)
5)
6) 7) 8)
charging chargi ng so equipped. If has unit cooled has a factory installed LN2/CO2 LN2/C O2tion backup system thesebattery batte switch should becircuit left offif until the system to below the BUS activa activation temperature. temperatu re.(BUS) Otherwise Otherwi the ry system will attempt to energize energize and the BUS battery will be depleted. depleted. The Alarm Battery Low light may turn off while the battery switch is left off. Turn on breaker breaker switch (power (power On) at rear of un unit it next to IEC320 IEC320 connector. connector. All electronics electronics (PC boards) boards) are energized energiz ed at this time. Refrige Refrigerant rant tank solenoid energizes energizes if the cabinet tempera temperature ture is warmer than -25°C. This is a normally open solenoid solenoid valve. Boost/Buck Boost/Buck relays energi energize ze to one of three states: Normal, Buck, or Boost. 5) Turn key switch to “Power On” p position osition (the (the first position). position). From the ti time me AC powe powerr is applie applied d to the un unit, it, approximately 30 seconds (with the key switch in the “Power On” position) is required before the display is illuminated. illumina ted. Display shows shows cabinet temperature, temperature, and the unit proceeds to the next sequence. a. If ER00 di displays splays for first 10 seconds seconds,, DIP SW3 has wrong mod model el sele selected. cted. After 10 s second econds, s, unit run runs s as a Value model. b. If ER06 disp displays lays for first 1 10 0 second seconds, s, there is a micro PCB PCB firmware problem. problem. Power completely completely d down own (AC and battery) and power the unit back up. If the problem persists, replace the micro board. This error indicates an issue with the integrity of the code in the microcontroller. c. If display shows E ERx1 Rx1 (‘x’ wi willll be a lette letter), r), unit is c connect onnected ed to the w wrong rong volt voltage. age. On 230V u unit, nit, corre correct ct the voltage input. input. On 11 5V unit, the buck/bo buck/boost ost transforme transformerr will have burned out or become unreliable. unreliable. Replace Replac e transforme transformerr and correct input voltage. voltage. d. If display sho shows ws ER02, check control control sens sensor. or. This error displa displays ys when a control control sensor error is dete detected. cted. e. If display doe does s not come on, check the display display board, board, micro board, or connecting connecting harne harness, ss, as describ described ed in the Trouble Troubleshootin shooting g section of the manual. Both condenser condenser fans will sta start rt (simultane (simultaneously) ously) approximately approximately 10 seconds aft after er you have both AC powe powerr and key switch in the “Power On” position. First stage compresso compressorr will start approximately approximately 10 seconds seconds after the fans start start if there is a call for cooling. Second stage stage compressor compressor will start start under on one e of the following following conditions: conditions: a. Initial S Startup: tartup: From the first first time the breaker breaker switch switch is turned turned on, firs firstt stage h has as been ru running nning for 1 10 0 minutes and the heat exchanger has reached a temperature of -38°C or colder, or the heat exchanger sensor has been at -25°C or colder for approximately 5 minutes. b. Normal Cy Cycling: cling: 52 seconds seconds has elapsed elapsed from the first stage stage st start, art, and the heat exc exchange hangerr sensor is at -38°C or colder, or the heat exchanger sensor has been at -25°C or colder for approximately 5 minutes.
The cut-on temperature might vary by a few degrees depending on which version of the micro Firmware is installed. c. Heat Exchanger Exchanger S Sensor ensor Failure Failure Mode: Mode: 2nd stage stage will start approximately approximately 5 minutes minutes after after first st stage age has has started. ER03 displays when the heat exchanger sensor is read from the keypad in this mode. d. If the heat exc exchange hange sensor sensor warms to +10C +10C durin during g the initial pull-down, pull-down, or -12C -12C during no normal rmal cyclin cycling, g, the 2nd stage compressor will cycle off until the heat exchange sensor cools to the cut-on temperatures previously described. 9) When the control control sensor sees -35 -35C, C, the expansion expansion tank solenoid solenoid valve opens, opens, releasing the ex extra tra refrige refrigerant rant trapped in the tank. Remember this is a normally open valve, voltage will be turned off to allow the valve to open. Note: if the control sensor sees -25 -25C C or warmer the valve will be reenergized reenergized closed closed.. 10) Unit will cycle off when the cabinet has reached setpoint. 4.2 Power Fail Failure ure Resta Restart rt Sequence Sequence 1) Power Failure Failure Restart Sequ Sequence ence assu assumes mes unit syst system em battery was On durin during g power loss; othe otherwise rwise resta restart rt sequence is same as Normal Start-Up Sequence above. Power is assumed to have been off for more than 60 seconds. 2) When power power resumes any programmed programmed resta restart, rt, time delay will start start timing, and expansion expansion tank and buck/boost buck/b oost relays reset to the appropriate state. 3) After any time delay setting h has as timed out, the condenser condenser fans fans start start.. Manual Number 301903H15
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Revco Plus Rev. 3
The normal cycling sequence sequence resumes as described described previously until setpo setpoint int is reached reached.
4.3 Key Cycle Sequence
The key turned off does not change the state of the expansi expansion on tank valve or the buck/boost buck/boost relays. All other components shut down when keyed off. For Firmware Version 0102 or earlier: One minute or longer after key is turned off, then back on, the condense condenser r fans restart and the unit returns to the Normal Sequence Sequence Of Operation. 2nd stage compressor compressor stagin staging g returns to either the 10-minute delay, or the time and temperature delay, depending on the cabinet temperature at the time key is turned back on. For Firmware Firmwarecontinues Versions0200 or later:for A the six-minute sh short ort cycle delay iis s activated whe when n the keyswitch is cy cycled. cled. Then the sequence continue as described previous firmware..
Manual Number 301903H15
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Revco Plus Rev. 3
5.0 Troubleshooting
Troubleshooting, or diagnostic analysis, is generally cconsidered onsidered the most challenging part of the service profess profession. ion. The information inform ation covered covered in this section of the manual is for trained t rained and experienced cascade service personnel personnel who are alreadyy familiar alread familiar with good good diagnostic diagnostic practic practices, es, and have have the proper tools and test equipment to carry it out. See the Appendix for a more general discussion of how to diagnose cascade refrigeration.
This section secti on beg ins with wi th what w hat t he uni t can tell you di directl rectly, y, Er ror Messages Messages,, then then Alarms Alarms and and Alerts Alerts,, w with ith specific spec ific recom recommen mendati dations ons for each. each. A third thi rd chart gives troubleshooting guidelines and suggestions for diagnosing the root cause of the major types of malfunction. If the failure of a specific component is suspected, proceed directly to the guidelines guidelines for testing all major components in this section.
Caution Before beginning any diagnostic troubleshooting, be sure to check for Error Messages. Most error codes display only for f or a short time on startup, startup, or only when when the correct buttons buttons are pressed pressed.. ▲
Manual Number 301903H15
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Revco Plus Rev. 3
5.1 Error Error Cod Codee Troubleshooting Chart Error Models Notes Displayed Affected Er00:: 10 second Er00 Cause:: Improper Model Selected. This indic Cause indicates ates that DIP SW SW33 on the micro PCB is se sett incorrect incorrectly; ly; display at power All usually positions positions 2 and 3 are both OFF. After a 10-second display of this error code the unit will set itself up. Models to run as a Value model, with only the Value buttons buttons operable. See Dipswitc Dipswitchh (SW3) Summary at the end of the electric electrical al ladder diagrams for correct settings. Response: This error should occur at initial Power Up. After a 10-second display of “Er00” the unit Response: will operate as a Value (-4 model) with a normal display, with no further error code shown. The symptom of this error is that only the 4 buttons of the Value model, CT, CSP, Up, Down, will work; all non-Value buttons will be disabled. Turn off all line voltage and battery power, reset DIP SW3 correctly, ErA1: ErA1: Continuous display at power up. Erb1 ErC1 Erd1 All ErE1 Models ErF1 Erg1 (looks like ”Er91”) Erh1
Cause: Improper or No Electrical Cause: Electrical Power During Power-On Sequence Description:: This group of error codes indicates a power supply problem detected during a power-on Description sequence. The most common common error is connect connection ion to the wrong vol voltage tage receptac receptacle. le. You can also get this error if the system battery switch and key switch are turned on before the main power switch (usually shows ErA1). Response : This error condition is checked ONLY when the micro PCB is energized, by activation of Response: the battery switch or main power switch (If a voltage quality problem occurs after the micro PCB is powered up, only a power loss will be detected). detected). The unit will not start th thee cooling sequence duri during ng this error condition. condition. The unit continuously continuously dis displays plays “Er_1” “Er_1” until the error is removed. removed. In additio addition, n, the audible alarm will sound even if the key switch is not in the Alarm On position. This error state should protect the circuit boards from incorrect voltage, but the buck/boost transformer may be damaged when 230VAC is connected to a 115VAC unit. ErA1 .. No pulses (zero crossings) detected detected to determine frequency (50 / 60 Hz) Erb1 .. This error code should never occur. Implemented for code readability. readability. ErC1 .. Frequency detected is below 50 Hz Erd1 .. Frequency detected is above 60 Hz (Possible noise spikes on supply voltage) ErE1 .. Unit is 230V and the voltage detect detected ed is below the low limit (180VRMS (180VRMS)) ErF1 .. Unit is 230V and the voltage detected is above the high limit (260VRMS) Erg1/”Er91” Erg1/”Er 91” .. Unit is 115V and the voltage detecte detectedd is below the low limit (85VRMS) ErH1 .. Unit is 115V and the voltage detected is above the high limit (160VRMS)
Er02: Er02: Continuous display when activated
All models Cause: Cause: Control (Cabinet) Sensor Failure Description : This condition indicates that the control Description: the control sensor has has failed to produce a valid reading for approximately approximat ely 60 seconds. Response : The display will show “Er02” during the normal running condition with no buttons Response: depressed and not in Program Mode. The unit will immediate immediately ly start the run cycle, stage both compressors on, and a nd continue to run nonstop. If the sensor recovers recovers,, the syste system m will return to to normal cycling. The remote alarm contac contacts ts will activate regardless of the key position for this failure mode.
Er03; not shown All Er03; until sensor is models read. Time delay controls 2nd stage in failure mode.
Cause:: Heat Exchange Sensor Failure Cause Description : This condition indicates that the heat Description: the heat exchange sensor has has failed to produce a valid reading for approximat approximately ely 60 seconds. Response : The display will show “Er03” only when the buttons to read the heat exchange Response: sensor are held down: CT + CA + BL + V. During this error condition condition the 2nd stage will be started 5 minutes after the first stage stage is started when cooling is needed. Normal cycling should maintain setpoint.
Manual Number 301903H15
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Revco Plus Rev.
3
Manual Number 301903H15
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Revco Plus Rev. 3
5.1 Error Codes, continued Ultima Plus Name: 1 st Stage Compressor Sensor Failure; Lifeguard Alert feature Name: only Er04; not Er04; shown until sensor is read.
Description : This condition indicates that the Description: the 1 1st stage compressor sensor has has failed to produce a valid reading for approximately 1 minute.
All Models Er05; can Press and Er05; be seen hold CT + only if key CS + Up sequence is Arrow + pressed Down Arrow while unit is to test for functioning. this error. All Models Model s Er06; Er06; displayed for 10sec. at poweron, or in Program Mode All Models Model s Er07; flash Er07; in the display when detected Er08; not used.
Response:: The display will show “Er04” only when the button sequence to read the Response compressorr sensor are held down: WA + CA + BL. The Lifeguard Alert feature compresso feature is disabled when the sensor fails, and the system will continue to operate. Name:: Display PCB Firmware Integrit Name Integrityy Failure Description:: The Display Description The Display PCB firmware has firmware has failed to pass its CRC CCITT checksu checksum m integrity test. Response: Display Response: Display boar boardd shou should ld be replace replaced. d. The display PCB performs this check at power-on startup, startu p, and if detected, the display will stay blank, blank, but the unit will start and run. Due to the blank display the error code cannot be display display in this case. This error code may be displayed when the the button sequence to read the Display firmware version is pressed while a unit is operating. The display also performs a firmware checksum test, and if this test fails, instead of viewing the version number, the user sees “Er05”. Name:: Micro PCB Firmware Integrity Failure Name Description:: The Micro Description The Micro PCB firmware has firmware has failed to pass its CRC CCITT checksu checksum m integrity test. Response: Micro board should be replaced. When Program Mode is entered the first sc Response: screen reen is the Micro firmware version number. The micro will display “Er06” “Er06” if th thee micro fails the the firmwa firmware re integrity This is10also checked at power on condition reset (including displayedcheck. for approx. seconds at startup if this exists. key cycle) and the “Er06” will be Name:: Serial Peripheral Interface Failure Name Description: This condition indicat indicates es that the the micro micro SPI bus has bus has been unable to communicate successfully with the ADC device. successfully Response: Bad Micro PCB, bad bad BUS board, or bad connecting cable. The unit will activate activate the remote alarm contacts, enable the buzzer when the key is in the alarm on position, and display ‘Er07’ . The unit will stage stage with a 10 minute delay and go to 100% run.
No Models
Name:: This error code Name code is not used at th this is time. If you observe observe Er08 call tech technical nical support support..
Model s Name: Er09; flash All Models Er09; Name: Stuck Button Button A Alert lert in the Description:: This condition Description condition indicates that th thee display board has aa stuck stuck button. button . It is activated if the display system sees a button held in the pushed state for over 5 minutes. when Response: Er09 will show on Response: on the display perio periodically. dically. Program mode may not not be entered and will detected. automatically automatic ally exit if in Program Mode. Correct what is holding the button down, or replace the display board if the button has failed.
Manual Number 301903H15
33
Revco Plus Rev. 3
5.2 Alarms and Alerts Description: See Appendix for more details on alarm theory and operation.
Recommendation
Unit may show a current or previous alarm state, depending on model. Active alarms have a continuous continuous or rapidly blinking light. Do Not Press Alarm Reset Yet! Yet! Read warm and cold excursions excursions first. Past alarm alarmss wil willl be a slo slow w bli blink. nk. The on-b oard al arm is enab led, See Keypad Summary for instructions instructions how to read excursions. excursions. or disab led, by the ke y switch p osition . Major alarms alarms will will activa activate te the remote contacts regardless of key switch position. Check for tripped breakers, interrupted power. Determine if other Power Loss Alarm; Alarm; Current indication for U; E; V (U= Ultima Plus; E = equipment nearby have have had a power interruption. Press Voltage Voltage keypad Elit Elitee Plus Plus;; V = Valu Valuee P Plus lus). ). Solid light and sound if e nable d. and note line voltage reading. See Diagnosing Over Current Faults if Remote alarm alarm contacts act activate. ivate. Past indic indication ation on U & E only. breaker tripped. Check Warm Excursion. Look for associated alarms such as Power Failure, Warm Ambient, Lifeguard Alert. Verify warm alarm setting. Determine if alarm setting may have been changed, or pushed by setWarm Alarm; Alarm; Curre Current nt indi indicat cation ion for U U;; E; V. Solid light and sound if point change. An open or shorted control sensor will not cause this enabled. Past in indicatio dicationn on U & E only. Remote al alarm arm contacts contacts alarm. Perform Thermocouple Diagnostics to determine system efficiency if no other problem is evident. activate.
Check Cold Excursion. Check for stuck control relay, unit left in Bottom Cold Alarm; Alarm; Curr Current ent indic indicat ation ion for U; E; E; V V.. Solid light and soun d if enabled. Past iindicati ndication on on U & E only only.. Remote alarm alarm Out run mode, failed micro PCB. An open or shorted control sensor will not cause this alarm. Verify cor correct rect alarm setting, accidental acci dental change ch ange of setnig. contacts activate. Extreme Ambient; Ambient; Temperature => than 98F; Ultima Plus feature only. Current is fast blink; past alarm is slow blink; no sound and no remote alarm contact activation.
Check for external causes such as HVAC issues, blocked air flow, nearby heat sources. sources. A failed sensor shoul shouldd not cause this alarm.
Look for related alarms such as Warm Alarm, Extreme Ambient, and Clean Filter Check for refrigeration issues related to 1st Stage loading and Lifeguard Alert; Alert; 1st Stage Compressor Overheated Overheated;; Ultima Plus feature efficiency. only. System will shut down until compressor cools for firmware 0102, Check for voltage and high amperage conditions or will show fast blinking blinking alarm light only for firmware firmware 0200. A past Hold down keypads WA, CA, and ABL to read compressor sensor (1K alarm with show a slow blinking light for all firmware. A failed sensor sensor ohm RTD) should not cause this alarm. Remote alarm contacts do not activate. activate. Hold down keypads CS + CA to read setpoint for this alarm (70 to
98°C is the allowed range) Clean Filter ; U and E models only. Fast blinkin blinkingg light when active, slow Check for dirty filter or condenser blinking light when when past. Open or shorted sensors should should not cause this Check for proper airflow through condenser, including fan operation Check for proper spacing in front and behind unit alarm.
System Battery Low; Low ; U and E models only. Lights when system battery startup test or periodic test (every 8 hours) shows less than 11.6VDC. See Alarm Summary Summary in appendix for details. Battery switch must be on for battery to charge.
Check for improper startup startup sequence, or battery switch switch left off. Also weak battery or bad charging circuit. Charging circuit is on Micro PCB, connector J1 6. Charging rate is vvery ery low and may take days to fully recharge. Due to its importance, replace a battery depleted after after prolonged discharge, below 10.5VDC.
Manual Number 301903H15
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Revco Plus Rev. 3
5.2 Alarms and Alerts (continued) Description
Recommendation
Backup System LED’s Are Hidden Behind Display Overlay; Inactive If BUS Is Not Installed; Unseen until lighted. This battery can become depleted and may not recharge after extended BUS Battery Low; Low; Should only light on units with a BUS installed. use. Check for charging voltage of about 14VDC at J1 on the BUS PCB; Lights when BUS battery voltage drops below 11.6VDC. System battery refer to BUS schematic in appendix. Due to the importance of this switch must be on for battery to charge. battery, replace if condition is uncertain or below 10.8VDC. BUS Supply On; On ; Lights when injection solenoid is activated to inject coolant. coolant. Leave battery swi switch tch and supply valve OFF unti untill unit has cooled below BUS activation setpoint. BUS Supply Empty; Empty; Low suppl supplyy press pressure ure activates activates tthe he LED.
Refer to BUS schematic. LED is at pin 18 of J3; solenoid power is at pi pins ns 5 & 6 of J2 and J4 in comm common on.. An open open do door or sw swititch ch wil willl deactivatee the injection deactivat injection solenoid and extinguish the LED. Check LN2/CO2 supply level, closed supply valve, leak in system, or unattended activation activation of system. BUS set point should be warmer than Warm Alarm set point so alarm always precedes system activation.
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Revco Plus Rev. 3
5.3 Major Failures Guidance Chart Symptom Unit has no power.
Suggestion
Trace line voltage from receptacle to input at Power Supply PCB. Refer to ladder and wiring diagrams. Refer to Diagnosing Over Current Faults if a safety has tripped.
Unit has power but will not start. start.
Verify Correct Voltage To Unit! Unplug key switch to see if unit will
start; replace switch if needed. Check control voltage out of Power Supply PCB with 6-wire ribbon cable on, then off. Check for over current draw in control circuit, blown fuse on Power Supply. See component level test guidelines for control components and PCB’s. Perform High Voltage PCB test to determine if problem is in control system or line voltage components.
Blank display or dashes dashes shown: fault iinn Displ Display ay circuit. circuit. See diagnosticss for Display and Power PCB. diagnostic Bad Power PCB: se seee diagnosti diagnostics cs for that boar board. d. Wrong volt voltage: age: Erx1 is displayed; displayed; see Alarms Alarms and Erro Errorr codes. Check for overheated transformer wiring in relay box. Failed kkey ey swit switch: ch: see Key Key Switch diagnostic diagnostics. s.
Unit will start but will not complete c omplete the Sequence Of Operation Refer to High Voltage Board Test and Sequence of Operation Test Mode that follows. Unit completes Sequence Of Operation, but will not achieve or maintain set point.
Verify each step. Determine if the failure is due to a control system failure or a component failur failure. e. Test and and repair repair as described in the following procedures.
Unit runs and achieves design temperature, temperature, but there is some aspect aspe ct of its operation that hinders normal use. Be use. Be alert for an issue that does not threaten the product now, but could in time. When in doubt, recommend the customer make arrangements to relocate the product until further testing can be accompli accomplished. shed.
Look for room too warm, units crowded too close, warm air currents. Inadequate airflow through the condenser due to dirt, blocked condenser, condenser fan loose or not functioning functioning.. Door sealing problems; look for ice buildup. Improper use or application: warm product overloading; too frequent door openings; is defrosti defrosting ng needed? Refrigeration Problems: Leak; Restriction; Inefficient Compressor. Perform Thermocouple Diagnostics and Manifold Gauge Diagnostics as described on the following pages.
These are usually issues associated to noise, cabinet and hardware problems, nuisance alarms, battery charging issues, chart recorder issues, and other problems not related to a failure to operate. For failures related to add-on systems, see the appropriate troubleshooting in the Options section of this manual, or at the manufacturer manufacturer’s ’s website for that option. For electrical/electronic problems, see the ladder diagrams and schematics. schematics. For noise and nuisance issues, use your best judgment, j udgment, and call for technical support if you need assistance.
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Revco Plus Rev. 3
5.4 Special Test Mode; Sequence Of Operation The normal Sequence of Operation is described in detail in Section 4 of this manual. A special diagnostic diagn ostic test mode was added with firmware revision 0200, 0200, introduced with serial number 0125668601080617. 0125668601080617. The test mode allows the service technician to manually step through through the Sequence Sequence of Operation, turning turning key components components on and off, at the normal normal step in the sequence. The step sequence can also be reversed or backed out to allow different test options as explained in the step descriptions below. Activate this test mode as follows: 1. First remove all power power from the micro board by turning turning off the key switch , the power switch, and and the battery switch. switch. 2. Turn on the battery switch and the power power switch, but but leave the key switch off at this point. point. 3. While holding down the CS CS and Down Down buttons (control (control setpoint + down arrow), arrow), turn the key switch On and hold the buttons until [St00] is displayed. This is the first step in the test as described in the chart below. 4. Push CT CT button button to advance to the next step. step. 5. Push CS button to backup to the the previous previous step. See step chart for explanation of this process. process. 6. Us the Down button button as the On/Off On/Off toggle toggle switch for for the devices devices tested in that step. step. 7. You exit this test mode mode in step 8, as described. described. The unit will stay in test mo mode de until that step is executed, or the unit unit is completely deenergized and restarted. r estarted. 5.4.1 5.4. 1 F low of test: tes t: Program Controls: CT = [CAB TEMPERATURE] button CS = [CAB SET] button [DOWN ARROW] button
Advances to next step Reverses to previous step Performs toggle action when applicable
Program Disp Displa lay y Ste
Desc Descrip ripttio ion n
Step Step 1
St St00 00
Step Step 2
St St01 01
Bo Boos ostt mo mode de (LD2 (LD2 & LD3 LD3 on on)) an and d un unus used ed he heat ater er rel relay ay on on.. Al Alll ot othe herr de devi vice cess off off.. He Heat ater er relay relay reserved reserv ed for future use. use. May be toggled toggled with Down button but but is not used at present. present. Boost mode will be maintained till ST06, where Normal mode is activated and can be carried back to ST01 for testing. testing. Press CT to advance advance Heat Heater er rel relay ay off off,, Rese Reserve rve Tank Tank so sole leno noid id on on/c /clos losed ed.. Toggle Toggle tank tank with with Dow Down n bu butto tton. n. Tank solenoid state will be remembered here forward. Normal tank state is on/closed (N.O. solenoid) until cabinet is at -35C or colder to reduce initial load on 2 d stag stage. e. Press CT to advance or CS to step back.
Step Step 3
St St02 02
Step Step 4 Step Step 5
St St03 03 St St04 04
Step Step 6
St St05 05
Step Step 7
St St06 06
Ta Tank nkDown stat statee ca carri rried ed fo forw rwar ard d fro from m ST01. ST01. Con Conde dens nser er Fan1 Fan1 tu turne rned d on (may (may be tog toggl gled ed off off/o /on n with button) Both Both co cond nden ense serr fa fans ns on; on; fa fan n 2 may may be togg toggle led d of off/ f/on on wi with th Do Down wn butt button on.. Co Cond nden ense serr fa fans ns On. Comp Compre ress ssor or 1 On, On, an and d may may be to togg ggle led d Off/On Off/On wi with th Dow Down n but butto ton. n. Hea Heatt exchange sensor sensor temperature and test state state will be alternately displayed. Avoid short-cycling compressor. comp ressor. Good oppor opportunity tunity at this step to assess assess 1 st stage efficiency by monitoring TC’s 1 & 2. Refe Referr to Thermo Thermocouple couple Diag Diagnostic nosticss in tthis his manual for more informatio information. n. Co Comp mpres resso sorr 1 and and co cond nden ense serr fans fans on on.. Compre Compress ssor or 2 is Off Off,, an and d may may be to togg ggle led d On/ On/Off Off wi with th d Down button. button. Avoid short short cycling or overloading overloading the 2 stage compressor compressor with a warm heat exchanger exch anger (warmer than -34C). Heat excha exchange nge sensor temperature temperature and test state will be alternately displayed. Co Comp mpres resso sorr 1 and and Cond Conden ense serr Fans Fans ar aree sti still ll on fro from m ST0 ST05. 5. Com Compre press ssor or 2 On On/Of /Offf stat statee carri carried ed forward forwa rd from ST05, and cannot cannot be toggl toggled ed in this step. Buck/Bo Buck/Boost ost system now changed changed to Normal mode (LD2 & LD4 o on). n). No device can be toggled t oggled in this step. Press CT to advance, or CS to step back. Pressing Pressing CS to step back will keep unit in Normal buck/boost buck/boost mode, and allow the previous steps to be tested tested using this Normal voltage mode by continuing to step backward using the CS button.
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Revco Plus Rev. 3
St Step ep 8
St St07 07
Co Comp mpres resso sorr 1 an and d Cond Conden ense serr Fans Fans ar aree sti still ll on fro from m ST0 ST05. 5. Com Compre press ssor or 2 On On/Of /Offf stat statee carri carried ed forward from ST05, and cannot forward cannot be toggl toggled ed in this step. Buck/Bo Buck/Boost ost system now changed changed to Buck mode mode (LD1 & LD4 on). No device ca can n be toggled toggled in this step. Press CT to adva advance, nce, or CS to step back. Pressi Pressing ng CS to step back will return system to previous Norm Normal al buck/boost buck/boost mode, and allow the previous steps to be tested using this Normal voltage mode by continuing to step backward using the CS button.
Step Step 9
St St08 08
Co Comp mpres resso sorr 1 and and Cond Conden ense serr Fans Fans ar aree sti still ll on fro from m ST0 ST05. 5. Com Compre press ssor or 2 On On/Of /Offf stat statee carri carried ed forward from ST05, and cannot forward cannot be toggl toggled ed in this step. Buck/Bo Buck/Boost ost system continues continues in Buck mode from ST07. Beeper turns on. Remote alarm alarm contact 6 (common (common)) to 7 is closed, 5 to 6 is open. Push the Down butt button on to toggle the beeper off and the remote alarm alarm contacts will switch posCT position, ition, 6 to 7 open and 5and to 6 initiate closed. aPress Pressing ing CS to step back will return to ST07. Pressing will exit test mode restart to normal run mode.
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Revco Plus Rev. 3
5.5 Testing 5.5 Testing Line Voltage Components 5.5.1 Introduction And Explanation
compressors run at full data plate voltage. All other “line voltage” voltage” components are nominal nominal Warning: Only the compressors 115VAC components, components, regardless of cabinet cabinet input voltage! All line vol voltage tage components components are co controlled ntrolled from from the High Voltage Voltage Circui Circuitt Board (PCB). Outlined Outlined below is a procedure to test each line voltage component and the High Voltage PCB at the same time. Unless a specific line voltage component is already suspect, it is recommended to run the High Voltage PCB Test first.
Note: During the testing of the High Voltage PCB, all the line voltage componen components ts it controls controls will also be tested. If this test indicates indicates a bad device, then proceed to the test procedure procedure for the devic device e itself.
Refer Refer to the approp appropriate riate Hi High gh Voltage Voltage and and Micro Micro PCB s schema chematic tics s to view view board level details, and tthe he wi wiring ring diagrams to view component connections.
Caution: This procedure requires close attention attention to detail and careful following of instructions, or components may be ruined. Please read the entire procedu procedure re before you begin, and seek qualified advi advice ce if you have any questions. The procedure procedure is meant to bypass the Micro PCB’ PCB’s s logic system to force the High Voltage Voltage PCB to activate one or more of its relays. This test is needed when a line voltage component will not activate during the normal sequence sequence of operation. If this jumping procedure procedure activates activates the component, then the High V Voltage oltage PCB, the component, component, and its connect connections ions are good, and the Micro PCB, PCB, or one of its inputs, should be suspect. suspect. If one of the High Voltage PCB relays can cannot not be forced on by this test, then that relay is likely bad and the High Voltage PCB needs replacing. If none of the High Voltage relays relays can be forced on by this test, then check tha thatt the High Voltage PCB is receiving correct power at connector J25 from the Power PCB (see schematic), and that the Micro PCB is receiving power at J11 from the High Voltage PCB. PCB. Look for a bad harness o orr connector before condemning condemning a PCB.
5.5.2 5.5. 2
How To Tes t T The he H ig h V oltage oltag e P C B A nd C onnected onn ected L ine in e V oltage oltag e C omponents
Each compo component nent shown in Figure Figure 5-1 can be activated, activated, simulating simulating the Micro PCB “turn on” function, function, by jumping the associated pin socket number to the ground side of J11, pins 6, 5, or 4 (interconnected) on the Micro Board.
Note: Pins 1,2, and 3 of J11 are Hot (+14VD (+14VDV) V) and shou should ld not b bee jumped, jumped, or you you will will damage damage the micro micro and High Voltage PCB’s. ▲ Pin 6 of J11 is tthe he pin op oppos posite ite th the e brown brown wire of th the e 6-wire 6-wire ribbon harness (the other 5 wires are grey). The 6-wire ribbon harness from J19 of the High Voltage PCB that connects to J11 on the Micro PCB must be in place pla ce fo forr thi this s test test to work work as itit suppli supplies es powe powerr to the Micro PCB. Slightly lift the J11 end of the ribbon harness connector to allow attachment of a micro-hook jumper to pin 6, as shown in Figure 5-2. Use a 22ga. wire (0.025”) to insert into the harness conn connect ector or of J7. A paper paper clip (0.0 (0.033”) 33”) may damage damage the connector!
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Revco Plus Rev. 3
Figure 5-2. Jumper Process
Special Special Compresso Compressorr Jumpin Jumping g Note: Note: Pins Pins 17 & 18 must must be jump jumped ed along along with with eith either er compresso compr essorr pin to activate activate that compressor compressor,, or the compresso compressorr will not start. start. Pins 17 & 18 activate the “normal” relays (K2 & K4) of the buck/boost system and must be “on” for either of the compresso compressorr relays relays to pass line voltage voltage to the compresso compressor. r. The compresso compressorr relays can still be activated, but there will be no voltage at the load side of the relay to power the compressor. Refer to the appropriate appropriate High Voltage Voltage PCB schematic schematic for more more detail. ▲
Manual Number 301903H15
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Revco Plus Rev. 3
5.5.3 Compressor Testing
This test presumes presumes the compressor compressor would not run during the High High Voltage PCB test, and that the High Voltage PCB was not the fault. Use a DMM to first check for opens opens and shorts at the compressor compressor termina terminals. ls. Be sure to disconnect disconnect the compressor wiring before testing to prevent back-feeding through a connected component. If the compre compresso ssorr shows shows normal normal internal internal Ohm reading readingss and no shorts shorts to gr ground ound,, use a dedicat dedicated ed compressor device, such assame a hermetic a “start cord” see if the the freezer, compressor will startt and run.testing star If possible, possi ble, use the poweranalyzer supply supply ororreceptacle receptacl e that to powers free zer, and look for a voltage drop during the test. Even though the correct voltage may be measured at the wall outlet with a DMM, the amperage load of a compressor start can draw the voltage so low that the compressor has inadequate power and will not start, and may cause breakers to trip, or a related malfunction. A voltage drop more than 10% below normal line voltage should be corrected if the freezer is to operate properly for its expected life. Never leave a compressor running for more than a minute when conducting this test. See the following for testing the Low Stage compressor. If the compressor compressor will run using a compressor compressor testing testing device, device, but will not run during the High Voltage PCB test, then one of the following is true: Voltage PCB has a fault fault and must be repl replaced. aced. o The High Voltage o The wiring or connectors connectors betwee between n the compressor and the High Voltage Voltage PCB have a fault. Check for opens, shorts, or bad connections, connections, and correct. correct. o
One of the start components components has failed. failed. If the start compon components ents are suspect, suspect, it is recommende recommended d to change all of them. See Start Component Testing for further explanation.
5.5.3.1 2nd Stage Compressor Testing Note
Due to the high press pressure ure refrigera refrigerant nt used in the second second stage, spec special ial care must be taken whe when n testing this compressor. An otherwise good compressor may not start, or may cutout on overload, if started under high pressure. The system system is designed to allow the 2nd stage stage to start only after the first stage stage has cooled cooled the interstage he heat at exchanger to -34C. There is usually no reason to test the 2nd stage unless the 1st stage is already operating and cooling properly, so run the first stage for 10 minutes to cool the internal heat exchanger before starting the 2nd stage compressor. compressor.
5.5.4 Compressor Start Components
Failed start components often cause symptoms that are are misdiagnosed as a “locked compressor.” The proper use of a compressor tester should minimize this misdiagnosis, since that test bypasses the attached start components. Every time a compressor starts, it momentarily draws Locked Rotor Amps through the start components, placing a high level of stress on the capacitors and the potential start relay. After prolonged use, these components can break down under starting stress, causing a variety of problems such as failure to start, continuous high amperage draw, tripped breakers, and overheated connections. Low voltage starts can accelerate this breakdown process, and the failure of one of the start components can lead to failure of the others. If a run cap goes open during the starting process, the potential relay will lose its back EMF and fail to open, leaving the start cap in the circuit and showing symptoms of a locked compressor. If you were testing the potential relay during startup in this example, you would note that the relay failed to open and think the relay was bad. Meanwhile the start cap has been weakened by being left in the circuit, and the next time the compressor tries to startt the capacitor may fail. This is one of the few times it is better to just replace star replace the parts rather than trying to identify exactly which one failed.
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Revco Plus Rev. 3
Most tests of start components are limited limited to testing resistance resistance through the potential relay, and testing the capacitance of the start and run capacitors. However, these tests are normally performed with a meter powered powered by b y a 9V battery. Its has been demonstrated demonstrated that start components that test good with a low voltage tester such as a DMM may still fail when subjected to actual starting currents and full line voltage. For this reason it is recommended that if the compressor can be run using a compressor tester, bypassing the start components, and no other obvious problem is found in the compr compressor circuit, then the start components components should be changed, changed, even if they test good with a DMM.essor circuit,
Fo Forr thos thosee wi wish shing ing to perfo perform rm a more more re reli liab able le te test st of th thee star startt co compo mpone nent nts, s, fu full ll li line ne vol volta tage ge compon com ponent ent tester testerss are availa available ble,, and are incorp incorpora orated ted into into the more sophist sophistica icated ted compre compresso ssor r analyzers.
5.5.5 Condenser Fans
These fans fans are powered powered from the High High Voltage Voltage PCB at J29 pins 1 & 7 High Stage; Stage; J29 pins 2 & 8 Low Stage. The condenser condenser fans are 115V, even on 208/230V 208/230V freezers. Test them first using the High Voltage PCB Test Procedure. Procedure. Test them independent of the circuit circuit by applying applying 115VAC to their contacts. contacts. If the fans need replacing, see Section 5 for the fan replacement replacement procedure. procedure.
5.5.6 Expansion Tank Solenoid
This solenoid solenoid is powered powered from the High Voltage Voltage PCB at J29 pins 4 & 10. Test the solenoid solenoid first first using the High Voltage Voltage PCB Test Procedure. Procedure. This valve is normally normally open when the solenoid is not energized. energ ized. See the Sequence Of Operation to understand understand its function. function. To jump test with with live voltage, voltage, apply 115V to the contacts contacts and listen for a clicking clicking sound that indicates the valve is closing when voltage is applied. This is not a foolproof test, so look for other evidence that the valve may not be closing when it should. If this valve valve fails to close close during a warm pulldown, pulldown, the Low Stage compressor compressor will will have too much pressure and may show symptoms of an overcharge, including high amp draw and cycling the HPCO switch. If this valve valve fails to open when it should, should, the Low Stage system system will be starved starved of refrige refrigerant rant and the freezer freezer will not run much colder than -60 C. Replace Replace as instructed instructed elsewhere in this manual. manual.
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Revco Plus Rev. 3
5.5.7 High Pressure Cutout Switch
This safety device is part of the compressor line voltage circuits powered fr from om the High Voltage PCB at J30, pins 1 and 2 for the low stage, or pins 4 and 5 for the high stage. The only electrical test for this component is to determine that it has continuity through its contacts when it should. Check ohms with the leads disconnected disconnected,, then check for voltage when the compressor compr essor relay is energized. Check for a voltage drop across the leads while the compressor compressor is running tothis determine theresult internal contacts are high pittedpressure or corroded. Failure Failu re of device if may from previous previous press ure cycling and indicate indicate the presence of a related refrigeration problem. problem. Replace as instructed elsewhere in this manual.
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Revco Plus Rev. 3
5.6 Testing Control Voltage/Electronic Components
The PCB’s PCB’s (printed (printed circuit circuit boards) boards) should be tested tested only for for proper inputs inputs and outputs. outputs. No board level diagnostics diagnostics are recommended. recommended. For the Display and Micro Control boards subst substituti itution on of a known good PCB is the most effective effective test.
5.6.1 Power Supply Board
The same board board part number is is used for both both the 115V and 208-230V 208-230V freezers. freezers. This is a 100 to 240 volt switching power supply, calibrated to output 14VDC to power the control system. Verify Verify that line voltage voltage is being supplied supplied from J24 of the High Voltage Voltage PCB through through a 3-wir 3-wiree ribbon harness, and that 14VDC is being returned to J25 of the High Voltage PCB through the 6wire ribbon cable. The high voltage input is on pin 1 (look for the brown stripe on the cable) of the 3-wire cable. Measure from this pin 1 to both sides of the fuse and this tests the fuse as well. Test the voltage voltage output output both out of circuit circuit and under under load. If there there is no voltage from from this board board to J25, the problem could be one of four things: o 1) no line line voltage supplied supplied to to the board; board; o 2) a bad Power Power PCB; PCB; o 3) a blown blown fuse fuse on the board; board; auto reset mode due to an over curren currentt power drain. o 4) the board has gone into auto If some voltage less than than 14VDC is being supplied while connected, disconnect the output ribbon cable and check the output right from from the Power Supply. This will remove remove the power drain, and resett the board if it has gone into shut-down rese shut-down mode. If, when disconnecte disconnected, d, the voltage now reads close to 14VDC, look for a short circuit or other high current drain downstream from this board. The voltage from this board travels travels to the Display PCB through the High Voltage and Micro PCB’s; see schematics.
5.6.2 Po Powe werr Su Supp pply ly Cool Coolin ing g Fan Fan
power This 12VDC 12VD C fan is connected J26Replace on the high voltage voltage board. It shoul should d energize when the switch/breaker is turnedtoon. as needed.
5.6.3 Display Circuit Board & Key Switch
A fault in the Display Display circuit, circuit, communication communication cable, cable, or key switch can cause a failure failure to start or run. But connection connection to the Display PCB is not required required for the refrigera refrigeration tion system to operate. The first test test of a suspect Display circuit circuit is to disconnect the the communication cable from the micro PCB with all power and battery off, off, then restart the syste system. m. If the system system now runs, then a component compon ent in the display circuit circuit has failed, failed, or there is an over amp draw through this circuit circuit that is disabling disabling the power supply PCB. See Power Supply diagnostic diagnosticss for more on that issue. issue. An inoperative inoperative Display Display PCB can be the result of a problem with with either the Disp Display lay or the Micro PCB, or dashes. the DB-25 cable that links them. When communicatio communication n is lost, the display may go blank, or show
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Revco Plus Rev. 3
On the Micro PCB is a Display LED LED that blinks as sig signals nals are passed passed between the two boards. boards. When communication communication is lost this LED LED stops blinking blinking.. If the Display boar board d shows a problem problem but the communication communication LED on the micro is blinking, blinking, then the Display board should be suspect. suspect. The Display Display PCB has a basic test function function initiated initiated by pressing pressing CT + CS + INC + DEC buttons. buttons. The display interrupts all incoming micro commands and displays the firmware version as a 4 digit number. number. If the test fails, fails, an Er05 error code is displayed displayed and the Display Display PCB should be replaced. If the Display PCB passes replaced. passes this test and shows the firmware firmware number, then the Micro PCB or the communication cable is suspect.
The communicati communication on cable is an industry industry standard standard DB-25 DB-25 often used used to connect printers printers.. The simplest simpl est test for this cable cable is to substitute substitute a known good cable. Part numbers numbers for the two different styles are shown in the ladder diagrams. If the Micro PCB is suspected suspected of causing display problems, problems, proceed proceed to the diagnostics diagnostics for that board. If all testing fails to pinpoint the problem then it may be b e wise to replace all suspect components with known good parts, particularly in urgent situations or distant locations.
5.6.4 Micro Control Circuit Board 5.6.4.1 Primary Service Related Differences Of The Two Micro Boards Value Freezers Micro circuit board board 191934H01. 191934H01. DIP SW3 set for Value Value freezer. 2 RTD sensors: sensors: cabinet and and heat-X sensor
Standard Elite Freezers If no RS232 communication communication option, option, then Micro PCB 191934H01. DIP SW3 set set for Elite freezer. With RS232 communication communication option from factory, factory, then Micro Micro PCB 191936H01. 191936H01. DIP SW3 set for Elite freezer with RS232, and DIP SW2 set for RS232 communication option. 4 RTD sensors: sensors: cabinet, heat-X, condenser, ambient Top Ultima Freezers Micro circuit board board 191936H01. 191936H01. DIP SW3 set for Ultima features. DIP SW2 SW2 set for RS232 communication option. option. DIP SW1 set as needed if 4-20ma factory factory option installed. st 5 RTD sensors: sensors: cabinet, heat-X, condenser, ambient, 1 Stage Compressor (Lifeguard feature)
5.6.4.2 Micro Board Testing The Micro PCB is usually usually susp suspect ect when there is an error in the normal normal sequence sequence of operation, alarm response, response, or a failure to respond to keypad entries entries.. Whenev Whenever er the Program Mode is entered enter ed there is a test of the micro PCB firmware. firmware. A success successful ful test will show the firmware firmware version versi on as a four digit number, while a failure will show Er06, indicating indicating the micro micro PCB should be replaced.
The High Voltage Voltage PCB test, described described elsewhere elsewhere in this manual, manual, will indicate indicate a Micro PCB failure, failu re, by elimination, elimination, when the fault is related to an output to the High Voltage PCB. Other
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Revco Plus Rev. 3
Micro PCB failures such as lost communication are more accurately determined by substituting a known good Micro Micro PCB. There are no board level tests tests at this time. time.
Refer to the electrica electricall ladder diagrams diagrams at the back of the manual for proper proper connections connections to the micro PCB. Micro Micro board versus sensor sensor faults can be checked by putting a known good sensor int into o the suspect suspect connector, connector, and putting putting the suspect sensor in the control control input at J8: you can read the sensor input on the display.
A decade resistance resistance box can also be used to check if the micr micro o board is reading resista resistance nce inputs properly. A sensor input inp ut test lead useful for all Revco Plus models can be made for this purpose by cutting cutti ng the sensor sensor end off a failed failed sensor.
5.6.5 Sensors
All sensors sensors are 1000 ohm RTDs (The (The optional chart chart recorder recorder probe is 100 ohm) with color coded coded wires. wire s. The first test test is to measure measure resistance resistance between any white and colored wire, wire, then refer to the proper table (back of manual) for the corresponding temperature. Sensors should be tested at their typical operating temperatures for most reliable rresults, esults, due to the influence influence of expansion expansion and contraction. contraction. A sensor at room temperature temperature may indicate proper proper operation, but then fail at very cold temperatures due to contraction. All the sensors sensors have the same plug configurat configuration, ion, and any can be plugged into the control control sensor connector at J8 and read on the display to verify the ohm reading measured. Sensor
Models
Connector
Wire Color
Control Heat-X Ambient Condenser 1st Compressor
V, E, U V, E, U E, U E, U U
J8 J9 J21 J4 J6
Red&White Black&White Yellow&White Green&White Blue&White
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Failure Code Er02 Er03 none none Er04
Revco Plus Rev. 3
5.7 Refrigeration Troubleshooting Using Built-In Thermocouples 5.7.1 Preliminary Testing Setup Note Pertains to all Revco Plus cascade freezers built after March 2007. ▲
All Revco ultra-low ultra-low temperature freezers freezers are built with thermocouples (TC’s) (TC’s) attached at strategic points inside the refrigeration system to aid in diagnosing system performance without having to attach manifold gauges. The attachment attachment of a manifold gauge gauge set allows for possible possible loss loss of critical critical charge, entry of contaminants, and possible leaks. Attaching gauges is the final refrigeration diagnostic procedure, and is covered in a separate section of this manual. This section deals with with the identification of T TC’s C’s and how to utilize them ffor or diagnostic purposes to see if manifold gauges are needed. TC’s should should be read with with unit in 100% run or “bot” “bot” mode for for at least 12 hours hours to allow the system syst em to reach a stabile stabile running state. state. Reading the TC’s while while the unit is in normal cycle mode can give varying and misleading indications. To enter the 100% Run Mode switch off o Turn key switch o o
o
Hold down Cabinet Cabinet Temperature Temperature and Control Control Setpoint keys keys (CT & CS) While holding holding CT and CS, turn on the key switch and conti continue nue to hold the buttons unti untill the display display lights. lights. You will initially initially enter enter a calibration calibration mode. Wait for bottom bottom out mode. Look for “bot” “bot” and the temperatur temperaturee to begin flashing flashing in the display. display. The unit will now now run 100%. The unit will stay stay in this mode until the key switch switch is cycled to return return to normal run mode.
5.7.2 Introduction
Revco cascade cascade freezers freezers have built-in built-in T-type T-type thermocoupl thermocouples es (red and blue blue wires). wires). There are different types of thermocouples (TC’s) for different applications and temperature rranges. anges. The “T” type are most accurate accurate for cryogenic temperatures temperatures.. Thermometer Thermometerss built for, or set to read, otherpetypes thermocouple thermocouples s will givenception you an incorr temperature temperat reading when connect edse to a T-ty T-type TC. of The most common misconcepti misco on incorrect is thatect a “K” type ure thermometer thermom eter will connected work “close “clo enough.” enough .” This appears to be true at typical typical ambient room temperature temperatures. s. Both K and T thermometer settings will read within 1 degree of each other at temperatures in the low 70’s F. But a T-type thermocouple thermocouple at -150C will show -137C on a K-type meter. As the temperat temperature ure gets colder, the error gets larger. Thermocouple Thermocoupless may be mislabeled, mislabeled, or have lost lost their label. label. The following following guide guide will help distinguish the thermocouples on a properly running system: o
o
o
Only TC1 and TC2 sh should ould get cold w with ith the 1st stage running, running, with TC1 getti getting ng cold first and TC2 cooling coolin g second, and staying staying about 1 degrees colder. colder. TC’s 3, 4, and 5 will show little or no cooling with only the 1st stage running. running. When the 2nd st stage age is allowe allowed d to start, TC2 will get warm before TC1 (counte (counterr flow heat exchanger), exchanger), and may continue to run warmer than TC1 until the system has reached a stabilized run mode. TC3, 4, and 5 w will ill not cool until until the 2nd sstage tage is sta started. rted. TC3 will ge gett cold first an and d much soo sooner ner than TC’s 4 and 5. At stabilized stabilized Bottom Out Run Mode TC’s 4 and 5 should be within 1 degree of each other, and both should be colder than TC3 for a properly charged 2 d stage.
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Revco Plus Rev. 3
Five T-type T-type thermocouples thermocouples exist exist in all Revco Revco cascade systems systems built built since since March 1992*. 1992*. TC6 was added to the Revco Plus design introduced in 2007. TC #
Location
Typical 100% Run Values (setpoint at -95°C)
#1
1st St Stage age Heat Heat Excha Exchange nge 1/4 1/4 From From
-49°F to -58°F (-45°C to -50°C) [2nd stage not
Outlet 1st Stage Heat Exchange At Outlet #2 #3 #4 #4/5 /5
2nd St Stage age Evapo Evaporat rator or Inlet Inlet
Col Colder der tha thann -13 -130°F 0°F and withi withinn 3-4°F 3-4°F of TC #4/ #4/55 [Bottom [Botto m Out Run Mode]
2nd St Stage age Evapo Evaporat rator or Outl Outlet et
Col Colder der tha thann -13 -132°F 2°F (-91°C (-91°C)) [B [Bot ottom tom Out Out Run Run]]
Suction port 2nd Stage Stage Compressor #6 Revco Plus Only
running] -49°F to -58°F [second stage not running]
Floodback indicator indicator:: -30C to -60C -60C is typi typical cal range in bottom out run mode. During normal cyc cycling ling may get colder on initial compress compressor or startup, but should recover to this range.
The temperature temperature differenc differencee between the thermocouple thermocoupless is called a “delta T,” and is measured measured in degrees degre es Fahrenheit Fahrenheit because this allows allows for a more precise (smaller) (smaller) unit of temperatur temperaturee change.
Thermocouple Diagnostic Principles Due to the thermodynamic interdependency (heat transfer) transfer) between the 1st and 2nd stages, it is possible for a performance problem p roblem with one stage to act like a performance problem with the other stage. stage. Proper understandin understanding g and use of the thermocouples thermocouples should should allow accurate diagnosis diagnosis of the location location of the actual problem. The 1st and 2nd stage stage of a cascade sy system stem work as a team team to remove heat from from the freezer freezer interior space. system extracts heat heat from the cabinet interior interior,, and dumps that o The 2nd or Low Stage system heat onto the 1st or High Stage system in the interstage heat exchanger. o The 1st or High Stage then then carries that that heat to the fan-cooled fan-cooled condenser condenser coil where the heat gets dumped into the room air. The 2nd stage is totally totally dependent dependent on a properly working working 1st stage before before the 2nd stage can
perform its job. Therefore the 1st stage must always be diagnosed first, and repaired if necessary, neces sary, before the 2nd stage can be diagnosed. diagnosed. The reverse reverse is not true. true. The 1st stage stage may run just fine fine without without the 2nd stage, stage, since without without the 2nd stage operating, operating, the first stage stage has no heat load to carry. In fact, a weak 1st stage stage may appear to be running OK, until the 2nd stage starts and begins dumping heat onto the first stage. The resultt is that an inefficient resul inefficient 1st stage will inhibit heat transfer out of the 2nd stage, stage, making it appear that the second stage is having the problem. problem. A good understanding understanding of the working working relationsh relationship ip between the 1st and 2nd stages stages is necessary to to apply the thermocouple diagnostic procedures that follow.
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Revco Plus Rev. 3
5.7.3 First Stage Efficienc Efficiencyy Test (First Stage Running; 2 nd Stage Off)
With the condenser condenser fans fans and only the 1st stage compressor compressor running, running, the 2nd stage compress compressor or being electrically disabled (unplug the HPCO), TC’s 1 & 2 should reach -45°C to -50°C (-49°F to -58°F) in 10 minutes. If the 1st stage cannot achieve this temperature temperature range, range, in ten minutes, then suspect a problem and perform perform further testing testing as indicated. indicated. If neither neither TC makes temp as expected, then suspect a refrigerant leak, inefficient compressor, dirty condenser, failed condenser condens er fan motor, motor, a restriction restriction in the system, system, or too warm of an ambient room temperature temperature (>90F). If TC1 makes the desired desired temp but the temperatur temperaturee difference difference (delta-T) (delta-T) between between TC1 and TC2 is greater than 1°F, with TC2 being warmer, then the problem may be an inefficient compressor, low charge (due to a leak or being improperly charged), charged), or a restrictio restriction. n. If the 1st stage stage TC’s cannot reach reach the indicated temperatu temperatures res with the 2nd stage stage not running, then the system probably needs repair. repair. Connect a manifold manifold gauge set and continue continue to diagnose diagnose the system. syst em. Refer to Manifold Gauge Diagnostics Diagnostics in this section of the manual for further guidance. If the 1st stage stage appears to be running properly properly with with the 2nd stage kept off, reconnect reconnect the 2nd stage and allow it to start to complete the first stage diagnostics.
After 2nd Stage Started Check the heat exchanger exchanger sensor sensor temperature temperature at this time to verify verify 1st stage stage cooling and that the 2nd stage will start (see Sequence Of Operation for details). If TC1 and TC2 are at -45°C to -50°C,, but the heat exchanger sensor shows a warm temperature, -50°C temperature, suspect a bad heat exchanger sensor. Continue Continue to monitor TC1 and TC2 when the 2nd stage st starts arts,, and watch for the following following possibilities: stage appeared to cool properly properly with the 2nd stage stage off, then the Heat-X o If the 1st stage sensorr should be cold enough (-34C or colder) senso colder) to activate activate the 2nd stage compressor. compressor. nd When the 2 stage starts, TC2 first, then TC 1 will start to get warmer as the 2nd stage dumps its heat load onto the first stage. o The Heat-X Heat-X sensor may warm to +10C and cycle the 2nd stag stagee off. This may happen in a warm pull down at the beginning of run. When the 2nd stage cycles off, the HeatX sensor should cool back down to - 25C or colder, bringing the 2nd stage back on.
The cycle may be repeated until the cabinet is cold enough to keep the 2nd stage running. If after an hour or more more the 2nd stage keeps cycling cycling on the Heat-X sensor wi without thout the cabinet cabinet starting to cool, suspect a first stage refrigeration problem and proceed to Manifold Gauge Diagnostic Diagn ostic procedures. procedures. Whenever Whenever in doubt, give the system more time. If TC2 stays stays several degrees degrees warmer warmer than TC1, both TC’s are warmer warmer than -30C, and the cabi cabinet net will not make or will not maintain its design temperature from a warm pull down, then the 1st stagee may stag ma y need repair. repair. A properly properly running 1st stage cannot be overburdened by a malfunctioni malfunctioning ng 2nd stage. A malfunctioning malfunctioning 1st stage stage can be overheated overheated by a properly properly running 2nd stage. If the 2nd stage appears appears to be running or cycling cycling properly, properly, set unit to Bottom Out Run Mode and allow to pull down for for 8 to 12 hours. hours. A cabinet running running at 100% should be at -85°C or colde colder, r, and may reach into the -90’s depending on room ambient. Despite Despite some variation variation from the recommend recommended ed TC readings, readings, if the unit makes design design temp or colder,, and will cycle at design colder design temp, it probably does not have a refrigerati refrigeration on problem. An oil logging problem (usually in the 2nd stage) may go away after the cabinet has been warmed and
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Revco Plus Rev. 2
restarted.. See 2nd stage diagnostics restarted diagnostics below for more on this problem. problem. If the first first stage appears appears to be running properly, properly, or especially if it appears appears to be running colder colder than normal, but the unit will not make, or will not maintain, its design temperature, temperature, then proceed to the 2nd Stage thermocouple diagnostics which follow. Unlike Unlike the 1st Stage TC tests, the 2nd stage stage is diagnosed af after ter the cabinet has been been running at 100% (Bottom Out Run Mode) until a stabilized “bottom out” temperature has been achieved, usually 8 to 10 hours. The cabinet should be left undisturbed, with no door openings.
5.7.4 Troubleshooting Second Stage
If TC’s TC’s #1 and #2 function function as expected expected,, then connect connect the 2nd stage stage compresso compressor. r. Place a T-type T-type thermocoupl therm ocouplee inside the cabinet cabinet to monitor center center air temperature. temperature. Sometimes Sometimes what appears to be a poor performing cabinet is really an inaccurate display temperature. temp erature. Set the cabinet to run at Bottom Out and let the unit stabilize, stabilize, then measure all the TC’s. Depending Depending on the actual cabinet temperature temperature,, TC#3 and #4/5 usually have a delta-T no greater than 3F to 4F, and both should be colder than the display displ ay temperature. temperature. At the same time, TC 1 and 2 should show a warmer temperatu temperature re than they did when the 2nd stage was kept off. of f. This ismode. due to the heat load from the 2nd stag stagee being dumped onto the 1st stage, which is the normal operation
The following charts show thermocouple temperature patterns that will help in determining the most likely refrigeration problem. Remember that the charts reflect reflect both stages running at 100% 100%,, or bottom out run mode.
T/ C
Reading
Indication: Normal Readings
TC1
TC2
-35 to -45C -35 to -45C
All the TC’s are in a normal operating range. TC’s 1 & 2 are warmer than when the 1st stage is running without the 2nd stage, showing that the 1st stage is receiving a heat load from the 2nd stage, which is how the cascade system is supposed to work. TC1 is probably a little warmer than TC2 due to Plus series flooded charge.
TC3
-90 to -95C
TC4
-92 to -96C
TC5
-92 to -96C
Dis Displa playy Temp. Temp.
-85 to -95C -95C
Manual Number 301903H15
TC3 is cold showing that the interstage interstage condenser is working well. TCs 4 & 5 are colder than TC3, reflecting the floodedd evaporator floode evaporator and the extra charge boost from the expansion tank.
The delta T between TC3 and TC’s 4/5 is about 5 degree degreess F. If the door is opened, product loaded, or room ambient increases, the TC reading readingss and ddelta elta T, along with cabine cabinett ttemp, emp, may also increase until the system removes the added heat load. If the unit is cycling the readings will fluctuate, which which is why stabilized Bottom Out mode is used for these readings.
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Revco Plus Rev. 3
T /C
Reading
TC1
-20 to 40°C
T C2
-10 to 30°C
Indication: 1st Stage Flow Problem/2nd Indication: Problem/2nd Stage Uncertain. Compressors should be running running constantly regardless of run mode since the cabinet cannot achieve setpoint. TC 1 and TC 2 are too warm, indicating the 1st stage cannot handle the heat load from the 2nd stage. This is what you would expect as the final TC readings when testing a suspected weak 1st stage. TC 2 is several degrees warmer than TC1, indicating a starved 1st Stage evaporator evaporator or very heavy load from the 2nd stage.
T C3
-70 to 85°C
T C4
-60 to 75°C
TC5
-60 to 75°C
Display Temp.
-60 to 70°C
T/ C
TC1
TC 2
TC’s 3, 4, and 5 are too warm because they cannot dump their heat onto the 1st stage. Remember, you cannot di diagnose agnose the 2nd stage until the 1st stage is running properly. There is good evidence that the 2nd stage is trying to do its job, but if this situation has been going on for very long the 2nd stage may expe experien rience ce pr proble oblems ms as a result. As th e 1 st St age continues to decline all TC’s will get warme warmer, r, wi with th the the 2nd stage shutting down on a warm heat-X sensor. Refer to Manifold Gauge Diagnostics for the 1st Stage and continue the diagnosis.
Reading
Indication: Second Stage Flow Problem. Indication: Compressors should be running constantly regardless of run mode since the cabinet cannot achieve setpoint.
-45 to -60C
-45 to -60C
TC 3
-85 to -100C
TC 4
-45 to -75C
TC 5
-47 to -75C
Display Disp lay Temp Temp..
-75 to -40C
First stage stage appears to run running ning OK. TC 1 & 2 are too cold, indicating indicati ng there is too little heat load coming from the second stage. This is the first iindication ndication that the second st stage age has a problem. TC3 could be marginal, or very very cold, depending on how little refrigerant refriger ant is actually movi moving ng through the evaporat evaporator. or. TC 4 & 5, along with TC 1 & 2, show the heat load in the 2nd stage is not getting transferred to the first stage, indicating a lack of refrigerant flow. There are four main reasons for this: 1) Leak; 2) Undercharged; 3) Lack of pumping efficiency; 4) An obstruction to flow. flow. At this point read the Notes Notes below, then proceed to Manifold Gauge Diagnostics Diagnostics;; 2nd Stage Flow Problems for further guidance. Hint: If there’s a leak you sshould hould ssee ee 2nd stage TC temperatures get warmer warmer over time. If the compressor compressor has a leaking valve, valve, or theree is a restr ther restricti iction, on, the freezer freezer may maintain maintain a steady or sli slightly ghtly fluctuating cabinet temperature.
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Revco Plus Rev. 3
Notes On 2nd Stage Flow Problems:
An oil logging logging problem is a type of restriction restriction,, due to too much refrigerant refrigerant oil getting getting into the cap tube and evaporator, and then becoming thick, or even solid, in this coldest section secti on of the system. It can be caused by a large load of warm product pl placed aced in the cabinet, lack of 1st stage performance, failed oil separator, contamination build up over time, or failur failuree to defrost defrost the cabinet as needed. needed. It can be constant, constant, or varying. varying. This is because the oil logging gets worse as the cabinet cools. The increased restriction then causes the cabinet to warm, which thaws the oil allowing more refrigerant flow, and the cabinett will start to cool again, repeating cabine repeating the cycle. The cabinet temperature temperature will vary around -55°C to -75°C over a period of a day or two, warming then cooling, then warming warmi ng then cooling, continually. continually. This cycle will not continue continue if the problem is a leak, as in that case, the cabinet will get continually continually warmer. warmer. Defrosting Defrosting the cabinet cabinet over a period of 48 hours, then restarting might solve the problem. Backflushing the system, replacing repla cing the oil separator, then recharging recharging is the definite definite solution. solution. Refer to Manifold Manifold Gauge Diagnostics for further testing using gauges. A continuously increasing increasing restriction can can look like a leak over time, as the restriction restriction gets more severe. Refer to Manifold Gauge Diagnostics for further instructions instructions before making this determination.
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Revco Plus Rev. 3
5.8 Manifold Gauge Diagnostics 5.8.1 When To Use Manifold Gauges Eliminate all possible electrical/control and external problems first Dirty filter, condenser, blocked air flow Warm micro climates, adjacent heat loads
Intermittent relays and hot connections Intermittent warm ambient; HVAC timing After above have been eliminated, if the TC’s still indicate a refrigeration problem then it is time to connect the gauges
5.8.2 First & Second Stage Testing: checking for leaks, inefficient compressor, or restriction. Leak Suspected? Suspected? Add an ounce of the main main refri refrigeran gerantt and watch the TC’s. TC’s. If that that improves impro ves normal TC, pressure, pressure, and amp readings you probably hav havee a leak. If adding refrigerant somehow clears a restriction, then your gauges and amp readings should now indicate indica te a slightly overcharged overcharged system. system. To confirm on 2nd stage, warm unit and check soak pressure. pressure. Adding a small amount of refrigeran refrigerantt to a leaking leaking system will result result in a low or average soak pressure. pressure. If the system has no leak, then the added refrigerant refrigerant should show a higher than normal soak pressure. Inefficient Ineff icient compress compressor? or? Add some refrigerant refrigerant;; it won’t help. Pressures Pressures and amps won’t change, discharge vs. suction pressures will be closer together than normal, maybe equal if no pumping at all! Running amps may be lower than than normal due to compressor compressor not pumping. Suction and discharge gauges g auges may ma y equalize eq ualize quickly on shutdown. Restrictio Restr iction? n? May act like a leak. Both discharge discharge and suction suction pressures pressures will look look lower than normal, especially especially sucti suction. on. Adding refriger refrigerant ant may boost pressures for a few minutes, minute s, but only temporarily temporarily.. Shut down unit and look for slow slow or no gauge equalization. equali zation. Despite Despite acting like a leak, the soak pressure will will be normal unless refrigera refr igerant nt was added, then may be higher than normal, normal, confirming there is no leak.
5.8.3 Second Stage Gauge Diagnostics: leaks Allow unit unit to warm to room temperature temperature (24 hours hours off, door open) and check the soak soak pressure. Should be about 10 to 20% below data plate static charge pressure due to oil absorption. Adding refrigerant while the unit is running will appear to cure the performance problem, confirming confi rming a low charge and probability probability of a leak.
5.8.4 Internal or interstage interstage leak; very very rare. Confirm! Recover refrigerant from both stages. stages. Attach Attach two sets of gauges onto the 1st and 2nd stage stage suction and disc discharge harge lines where where they enter the cabinet. Pressurize Pressurize one stage stage to 150 psig psig and the other other stage stage to 200psig 200psig with N2. N2. Look for pressure loss from either side, or pressures to equalize between the two systems over time.
st
Perform Perform the same same test on the the condenser condenser for 1 and 2
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nd
stage connections.
Revco Plus Rev. 3
6.0
Calibr Calibratio ation n And And Repair Repair Proced Procedures ures
6. 6.1 1
Ca Calib libra ratio tion n Proce Procedu dure res s
6.1. 6.1.1 1 Re Rese sett Fact Factor ory y De Defa faul ultt Para Parame mete ters rs To reset the factory default settings: Turn off the key switch.
While holding down the CT (Cabinet Temperature) Temperature) button, turn the key switch on, then release. If you hold the CT button too long long you will enter Programm Programming ing Mode. Just let it time out to return to normal display. The factory default parameters are as follows: Parameter Control Setpoint Warm Alarm Cold Alarm Display Offset Restart Time Delay st 1 Compre pressor hot alarm
Default -80C
Range -50C to -86C
-70C -90C 0C 0 min. 94C
-45C to -81C -55C to -99C +7C to -10C 0 to 20 min. 70C to 98C
Comment Changing setpoint will push alarms set within 5C Cannot be set within 4 degrees of setpoint Cannot be set within 4 degrees of setpoint Change in Programming Mode Time delay to restart after a power failure Thi his s is the Ultima Plus Lif ife egua uarrd option
6. 6.1. 1.2 2 Te Temp mpera eratur ture e Displa Display y Off Offse sett Adjus Adjustme tment nt Put the unit in programming mode by pressing and holding the CT (cabinet temperature) button for 5 secon seconds. After entering Prog ramming Mode, rele release ase push ed. the CT one advance to the ds. Off Set adju adjustment stmentProgramming step step. . The current curre nt offset will then be display displayed. Usebutton the Up or time Dow Down ntoarrows to enter the desired desired display off set. The offset range range is +7 to -10C. 6.1.3 Low End Micro Board Calibration Calibration (line voltage monitor monitor only) only) For the low end micro board (Value Plus and Elite Plus w/o communication options) follow these steps: Using a true RMS volt meter, measure and record the input voltage voltage at connection connections s J4 and J5 on the high voltag voltage e board. Next, press press and hold the CT and CS (control se setpoint) tpoint) buttons buttons for 5 seconds. For the low end micro board you will immediately enter the Line Voltage Calibration mode, and [cal Llne] will be displayed, display ed, then the calibrated voltage will be displayed. Use the Up or Down arrows to adjust the calibrated voltag voltage e to your recorded measurement. measurement.
6.1.4 Ultima Top Micro Micro Board Calibration Calibrations s (Ultima Plus and and Elite Plus wi with th High End Option) Option) Analog Temperature Output (4-20ma) Press and hold the CT and CS (control setpoint) setpoint) buttons for 5 seconds to enter the calibratio calibration n mode. [cal] then [DAC] will be display displayed, ed, then the current analog outp output ut adjustment adjustment will be displayed. Use the Up or Down arrow keys to adjust adjust the analog ou output tput in 5mV steps. The range is -999 to +999; the factory default is 0.
Line Voltage Monitor Using a true RMS volt meter, measure and record the input voltage voltage at connection connections s J4 and J5 on the high voltag voltage e board. Next, press and hold the CT and CS (cabinet temperat temperature ure + control setpoint) setpoint) buttons for 5 seconds secon ds to enter the calibration mode. Press the CT button a second time and [Llne] then [cal] will be display displayed ed for the Line Voltage adjustment. Use the Up or Down arrows to adjust the calibrated voltag voltage e to your recorded measurement. measurement.
Press the Voltage button to read the calibrated voltage (Ultima Plus and Elite models only).
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Revco Plus Rev. 3
Telemetry Option (only seen if RS232 option is present) Not fully implemented implemented at this time. Reserv Reserved ed for future development. development. This is the third optio option n viewed while in the Calibration Calibration Mode for all Ultima Plus and Elite Plus with the rs232 option. It should be left OFF.
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Revco Plus Rev. 3
6.2 Instructions Instructions For Replacin Replacing g Parts 6.2.1 To replace the inner 6.2.1 inner or outer door door gasket on an upright Ultra Low Temperature Temperature freezer, se freezer, see e the procedure below. Note The Note The new gasket will be wrinkled and folded when it is unpacked. Immerse the gasket in warm water until it becomes pliable. Lay the gasket flat and allow to dry. Care should be taken not to stretch or tear the gasket during handling.
Transfer Transfer product to another freezer freezer of equal temperature. Leave the unit set for the desired operating temperature, turn the power/key switch to the Power Off position, and disconnect the unit from the power source. Remove the desired (inner or outer) gasket by pulling it straight out and away from the door. Align the corners. 5. Press Press the retainin retaining g rib (corners (corners first) first) on the new gasket into the groove in the door. using a rubber mallet if necessary. necessary. GASKET
GASKET INSTALLED
Typical Typic al Door Gasket Note: It may be easier to remove the door door and lay it on a flat surface with the gasket sid side e up. The door is heavy. heavy. Consider Consider it’s size aned weight. weight. Additional Additional help is recommended. recommended. ▲ ▲ 6.2.2 6.2 .2
Door Door Latc Latch h Rep Replace lacement ment
Before starting this procedure, scribe the top line of the current latch assembly, for reference when locating the new latch. Remove Remove and retain th the e (3) #10-32 x 3/8 truss truss screws screws securing securing th the e latch cover. Lift the cover up o over ver the latch mechanism. Remove Remove the (4) 1/4-20 x 10 screws securing the latch assemb assembly. ly. Two are located on top top,, one in the center and the fourth screw is located at the bottom. Retain the screws and washers. Warning Be Warning Be prepared for the weight of the latch assembly (~10 lbs.). ▲ lbs.). ▲ Attach the new latch assembly assembly to the door with the (4) 1/4-20 scr screws ews and (4) washers used previously. Torque to 60 in-lbs (6.75 N-m). Place a small amount of white lithium grease at the strike point. point. Adjust Adjust the rear strike horizo horizontally ntally to comp compress ress the exte exterior rior gas gasket ket to approximately 11/ 16 in (18mm) ( 18mm) thick.
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Caution: Excessive door compression could damage latch and/or cabinet. cabinet. ▲ ▲ Micro-adjustmen Micro-adjustments ts to the gasket compresson compresson can be made using the adjustment screw located in the latch. Caution: Allow only the chamfered portion of the adjustment screw to extend beyond the latch to avoid interference interference when closing door. ▲ door. ▲
Install the latch cov cover er with the (3) 10-32 x 3/8” self-threading self-threading screws used previously. previously. Align the top surfaces.
6.2.3 6.2 .3
Exteri Exterior or Door Hinge Hinge Replac Replacemen ementt
To replace the hinges on an upright freezer, follow the steps below. Strap the door door to the cabinet to prevent prevent it from movi moving ng or falling. (See Door Adjustment in Section 3 for using a large C-clamp.) Caution Make Caution Make sure the door is secure. Remove only one hinge at a time. ▲ Scribe the top and side locations locations of the current hing hinge e for positioning the new hinge. Remove Remove the screws sec securing uring the hin hinge ge to the cabinet. cabinet. Discard the hinge. Retain the screws and any washers. Install the new hinge and secure with the screws (and washers, if applicable), applicable), as previously previously.. Adjust hinges hinges per “Door Adjustment” in Section Section 3. Monitor Monitor unit for proper operation. operation.
6.2.4 6.2 .4
Int Interi erior or Doo Doorr Replac Replaceme ement nt
These ULT freezers ship from the factory with a set of inner doors attached to a single piano hinge extending the height of the cabinet. This configuration aids in replacing one or more inner doors. Transfer Transfer product to another freezer freezer of equal temperature. With the uni unitt set at the desired operating temperature, temperatur e, tur n the pow power/ er/key key swi switch tch to the Power Power Off position, and disconnect the unit from the power source. Open and secure secure the outer door. Open the inner inner door to be removed removed.. Remove the three three bolts securing securing the door to the hinge, and discard disca rd the door. Note: To replace replace the hing hinge, e, first re remove move all doo doors. rs. Then remove remove the six six bolts securing the hinge to the cabinet. Discard the hinge. ▲ hinge. ▲ Re-install components in in reverse o order. rder.
6.2.5 Door Rep Replaceme lacement nt and Seal Check Use the following steps when replacing the outer door assembly and performing a seal check. Transfer Transfer product to another freezer freezer of equal temperature. With the unit set f or the desired operating temperature, turn the pow power/k er/key ey sw switch itch tto o the Po Power wer Off position, and disconnect the unit from the power source. Remove Remove eye level co control ntrol panel panel by removing removing the three three scre screws ws at the bottom that secur secure e the panel to the door. Disconnect Disconnect the electrical con control trol cable attached attached to the display board. Route the wire down through the wiring raceway. Note : The door is heavy. Be sure to have the necessary necessary assistanc assistance e availa available ble when removing and replacing.▲ replacing. ▲ Scribe the top and and side of each hing hinge. e. Remove the three three screws from each hinge attached to the door. Discard the door. Position the new door door and secure in place with large c-cla c-clamps. mps. There should be 3/8” clearance between hinge side of door and the cabinet.
Verify the gasket is smooth and flat. Make sure it doesn doesn’t ’t roll or fold on the hin hinge ge side side.. Reinstall Reinstall eye level control pane panel. l.
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Reconnect Reconnect to power source and turn key switch to the Power On position. Chec Check k unit for proper operation.
6.2.6 Filer Replace Replacement ment It is important for the proper operation of your freezer that the grille filter be clea cleaned ned o orr rep repla laced ced e eve very ry six months, minimum. A clean filter ensures proper airflow to the components so they remain cool. To replace the grille filter, follow the steps below. Open the front grill grille e by pulling pulling outward outward on the handhold handhold in in the front grille. The grille filter f ilter is held in place with hook-and-loop squares secured to the back side of the front grille. Pull the filter loose loose from the grille. Wash Wash with a mild soa soap p and water. water. Pres Press s betwee between n two towels towels to dry. To inst install all a new filter, align the filter with the grille and press firmly at the points of the hook-and-loop squares. Close the front grille, grille, making sure the grille snaps cl closed. osed. It may be necessary to apply pressure at the top and bottom corners of the grille to secure.
6.2.7 Caster Replace Replacement ment Use the following steps when replacing the casters on a freezer:. Warning: With product removed, t he key s witch on t he unit must be tu turne rned d off off an and d th the e un unit it disconnected from the power source before starting this procedure. ▲ procedure. ▲ Caution: After installing the casters, allow 24 to 48 hours before restarting the unit. unit. ▲ ▲ Caution: Do not tilt t ilt the unit backward without blocking the rear casters. The unit could could roll, c causi ausing ng a personnel hazard. Ensure there is adequate assistance to prevent the unit from tipping. ▲ Carefully Carefully raise unit approximately two feet from the floor. Alternatively Alternatively,, block all the casters to prevent a personnel hazard caused by the unit rolling, and tilt the unit to access the caster assembly. Using a 1/2" open end wrench, remove remove the four bolts securing the caste casterr assembly to the bottom of the cabinet. cabinet. Discar Discard d caster assembly. assembly. Position Position new caster assembly in the previous location. Iinstall Iinstall the four mountin mounting g bolts. Carefully Carefully lower the unit to the floor. 5. Ensur Ensure e unit is level. Refer to the “Leveling” section.
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Revco Plus Rev. 3
6.2.8 6.2 .8
Heat Heat Exc Exchan hanger ger Sensor Sensor Replace Replacemen mentt
Caution:: When performing work inside Caution inside the electrical junction junction box, make sure the unit is de-energized, de-energized, disconnected from power, and the circuit breaker is locked and tagged out. ▲ out. ▲ Remove the six screws that secure the lower back panel panel.. Locate the black and white 4 wire RTD probe that runs into the cabinet. Trac Trace e th the e blac black k an and d whit white e 4 wi wire re RTD cable cable to the electrical relay enclosure. Disconnect this cable from the connector on the micro board. Cut the wire ties that secure secure the sensor cab cable le to the base. Rem ove the bac k pa panel nel coveri covering ng tthe he seco second nd stag stage e drier (Figure 6.2.8A). Under this panel is another another panel with cutouts (Figure 6.2.8B). Clip the top and two sides side s and fold panel down out of the way to allow Figure 6.2.8A Freezer Back Panel access to the foam. Leave panel attached on bottom side. The panel may serve serve as a chute chute to direct removed foam into a trash container.
Figure 6.2.8B Inside Panel on Freezer
The heat exchange exchange sen sensor sor is concealed concealed under the foam, on the left side of the ope opening. ning. Locate where the black and white wire for this sensor exits the cabinet and use that as a starting point point to where to remove the foam. See Figu Figure re 6.2.8C
Carefully Carefully remove th the e foam usin using g a dull putty knife or similar similar tool. The 4 wire wire blac black k an and d whit white e RT RTD D pro robe be will will ap appe pear ar as the the foam foam is removed remo ved.. As you remove remove the foam from arou around nd the wire, follow the wire until you reac reach h the copper copper tube where the sensor sensor is ins inserte erted. d. See Figure 6.2.8D Figure 6.2.8C Sensor Under Foam
Remove the sealing tape from the opening but leave some of the tape on the wire to act as an insertion inserti on depth reference. reference. Replac Replace e the failed sensor with a new part, making sure the replacement replacement slides slides all the way into the tube. tube. Use the old sensor sensor as a dep depth th refere reference nce,, but not note e that the end of the tube is the proper depth.
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Revco Plus Rev. 3
copper tube Figure 6.2.8D. 6.2.8D. Sensor Location Figure 6.2.8E. 6.2.8E. Wax or Oil Figure 6.2.8F Drill 2 holes through both plates into void
Install the new RTD probe. Reseal the the wire at th the e openi opening ng of the tube tube usin using g tape. . Before folding the inner panel into place, place a thin thi n layer of oil or wax on tthe he pa panel. nel. (Thi (This s ke keeps eps the foam from sticking to the panel so that the filling of the void can be verified.) See Figure 6.2.8E. Fold the inner panel back into place and secure the outer panel with the 12 screws removed previously. Drill two small holes into both panels in the approximate area of the foam void, large enough for the foam f oam tube t ube tto o fit into the holes. hol es. Drill one a appro pproximat ximately ely 4 inch inches es up from th the e bot bottom tom of tthe he outer outer panel panel a and nd the other hole approx approximately imately 7 inches up from the bottom. See Figure 6.2.8F 6.2.8F . Spray Spray foa foam m into tthe he lower lower hole hole until until foam shows in the upper hole. After the foam se sett up, re remove move th the eo out uter er and and iinn nner er pa pane nels ls an and d obs obser erve ve th the e foa foame med d are a fo r ga ps . Fi ll in as ne ed ed . Reinstall the inner and outer panels.
Figure 6.2.8G Foam Overflow
Attach the new RTD probe to the appropriate appropriate conne connector ctor on the micro board. Reinstall side panel.
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Revco Plus Rev. 3
6.2.9 Control/Display Control/Display Sensor The cabinet control/display sensor is located in the lower right rear corner of the chamber in the sensor shield. Caution: High voltages voltages may be present. Service Service should be performed by qualified personnel only. ▲ only. ▲ Note: The freezer must be at room temperature befo before re beginning this procedure. procedure. ▲ ▲
Turn the main key switch to the "OFF" "OFF" position and disc disconnect onnect the unit from the power source. Remove Remove the six screws sec securing uring the lower lower left side panel panel to access the electrical relay enclosure. Unplug the red-white red-white probe located in the cont control rol probe socket on the micro board. (Figure 6.2.9A)
Figure 6.2.9A Sensor Inputs on Micro Board
Remove the Permagum from both sides (freezer compartment and compressor compressor compa compartmen rtment) t) of the access ss hole and separate control/ contro l/ display sensor lead. acce Pull the old control/displ control /display aythe sensor out. Install the new sensor. Install the Permagum cord on both sides (freezer compartment compartment and compressor compartments) to seal the access holes. Install Install the control/di control/display splay sensor sensor in its mount on the sensor shield (Figure 6.2.9B).
Figure 6.2.9B Sensor location Inside Freezer Chamber
Install Install the sc screws rews securin securing g senso sensorr shield in the fr freezer eezer compartment. compartm ent.
6.2.10 Ambie Ambient nt & Condenser Sensor Sensors s Replacement Replacement
Remove Remove the lower lower left side panel to gain access to the electrical electrical relay enclosure. Attache Attached d to the micro mic ro board board is a yellow yellow and and white white wire in the J21 socket. See Figur e 6.2. 9A. Thi This s is is th the e ambient probe. probe. The ambient probe itself itself is located in the center of the air cooled cond condenser. enser. See Figure 6.2.10A. 6.2.10A. Discard the probe and reinstall in reverse order.
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Figure 6.2.10A Ambient Probe
Locate the green green and white wire attached to J4 socket socket on the micro board. See Figure 6.2.9A. 6.2.9A. This is th the e con conden denser ser 4 wi wire re RTD p pro robe. be. The condenser probe itself is attached to the liquid line at the bottom of the air cooled condenser. See Fi Figu gure re 6.2.1 6.2.10C 0C
Figure 6.2.10C Condenser Probe
Caution When worki Caution When working ng around the electrical relay box, make sure the unit is de-energized de-energized,, disconnected from the power source, and the circuit breake breakerr is locke locked d and tag tagged ged ou out. t. ▲ ▲ 6. 6.2. 2.11 11
St Star artt Relay Relay Repla Replace cemen mentt
Turn the unit unit off with the swit switch ch and disconnect disconnect the the power cord from from the power source. If the un it is hard-wired to a power source, de-energize and tagout the power disconnect to the unit. Reference O.S.H.A. regulations 19 10- 147 regarding tagout and de-energizing potential electrical sources.
Figure 6.2.11A Run Capacitor; Start Relay; Start Capacitor Run Capacitor
Start Relay
Start Capacitor
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Revco Plus Rev. 3
Warning: High voltages may be present. Service should be performed by qualified personnel only. ▲ Remove the electrical electrical cover attached to the compressor. Mark each wire as to its location on the relay. Using Usi ng small pliers pliers,, carefully carefully pull pull the connectors from the relay terminals. See Figure 6.2.11A. Pull straight out. Do not move from side to side, or up and down, as this may cause a loose connection. Remove the mounting mounting screw securing the start relay and discard appropriate appropriately. ly. Secure the replacemen replacementt relay. NOTE: Alway Always s replace the start and and run capacitors capacitors when replacing replacing the start relay relay!!
relay Reconnect the wires were Step 2, as noted. Push straight straight onto the terminals, beingthat sure notremoved to move in them from side to side, orthe up wire and terminals down to avoid a possible loose connection. connection. 6. Connect the power cord to the power source. Remove any lockout/ tagout tagout devi devices ces in instal stalled led and re-energize the system. Turn power switch On.
6.2.12
Run and Start Capacitor Capacitor Replace Replacement ment (Always replace replace b both) oth)
Turn the power switch Off and disconnect disconnect the unit from the power source. Warning: Before removing removing or handling handling any capacitor, make sure it is fully discharged. discharged. ▲ ▲
The start and run capacitors are connected connected to the first and second stage comp compress ressors. ors. Th The e black Start capacitor is located on the outer electrical box of the compressor. The metallic Run capacitor is located in the t he electri electrical cal box on the compressor. compressor. See Figure 6.2 6.2.11A. .11A. Before Before removin removing g any wiring, note the location of all wires for reconnection. Remove the capacitors capacitors from the holdin holding g brackets. Repl Replace ace only only with a capa capacito citorr of the same specifi specificatio cations. ns. A capac capacitor itor of the wro wrong ng spe specifica cification tion can cause cause opera tion failure fai lure and damage to other components, especially the comp compress ressor. or. NOTE: Always replace replace the potential start relay when replacing the capacito capacitors! rs!
6.2.13 Micro Board Replace Replacement ment Warning: High voltages voltages may be present. Service Service should be performe performed d by by Replacement Replacement qualified qualified personnel only. ▲ only. ▲ There are two versions versions of the m micro icro PCB, full feature (“hig (“high h end”) and value feature (“low end”). The value feature feature board has only 1 dipswitch, SW3 in the middle of the PCB. The full feature micro board also has DIP SW3 plus two extra dip switches for the RS232 and the 4-20ma options. options. When diagnosing or changing a micro board, refer to the ladder diagrams in this manual for proper dip switch settings. Disconnect Disconnect unit from powe powerr supply.
Remove the six screws screws securing the lower left side panel and remove remove the panel. Disconnect the battery. Note Always Note Always wear a personal grounding device when handling a printed circuit board. ▲ board. ▲ Locate the micro board board on top of the electrical electrical relay enclosure. enclosure. Note arrow in Figure 6.2.13A.
Figure 6.2.13A Micro Board Location Manual Number 301903H15
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Revco Plus Rev. 3
Label all wires wires before discon disconnectin necting. g. Refer to the wiring and ladder ladder diagrams in this manual. manual. Remove the single single screw in the front right corner that secures the board, then gently pull the boar board d off the mounting posts. posts. If the board is to be returned for evaluation, evaluation, label the board with the model and serial number of the unit. Before installing installing the new board, board, verify all DIP switch settings. settings. Install the new board. board. Secure with the screw. Connect the connectors, as previously labeled. Repower Repower the unit and verify prope properr operation of the board, board, then close up the cabin cabinet. et. Be sure to leave the area clean and neat.
6.2.14 Power Sup Supply ply Board Repl Replacement acement Warning: High volta voltages ges may be be present present.. Serv Service ice shoul should d be perfo performed rmed by qualifi ed pers onnel only. ▲ only.▲ Always wear a personal personal grounding device when handling a printed circuit circuit board board.. ▲ Warning Always Warning Disconnect Disconnect unit from main power supply supply.. Re Remov move e the the si six x scr screw ews s sec secur urin ing g th e l o we r l ef t s i d e pa n el . Remo Remove ve th the ep pan anel el.. Dis Disco conn nnec ectt th the e power. Locate the board board on the lower right side side of th the e relay enclosure. enclosure. Note arrow in Figure 6.2.14A. Remove the 4 screws screws securing the power supply supply board. Discard Discard the board, or return as requested. Install the new board board and secure wi with th the 4 screws. Connect the connectors, as previously labeled.
Connect Connect the freezer to power and turn the key to the Power On position.
Figure 6.2.14A Power Supply Board
6.2.15 Display Bo Board ard Repla Replacement cement The Display printed circuit board is located at eye level on the door of Ultima Plus Series (Figure 6.2.15A) and on the bottom left front on Elite and Value Plus Series (Figure 6.2.16B). present. Service shou should ld be performed by qualified personnel on only. ly. ▲ Warning: High voltages may be present. ▲ Warning: Always Always wear a personal groundi grounding ng device when handling a printed circuit board. ▲ board. ▲ Disconnect Disconnect unit from the main power supply supply.. Remove Remove the six screws that se secure cure the lowe lowerr left side panel. panel. Remove the panel and disconnect the battery. On Ultima Plus units, remove the screws from the bottom of the eye level co control ntrol panel. panel. Pu Pullll the bottom bott om of the cont control rol pane panell out and down. down. The display board is locate located d at the back of the control panel. For the Elite and Value Plus Serie Series, s, the display panel is located located on the llowe owerr le left ft front. Remove the 4 screws securing the display. Disconnect and label the wires. Replace the current display, and reattach the wires. Secure the display with the screws previously removed.
Label and disconnect disconnect the connec connectors tors on this board. Remove the screws screws that secure the board, and discard it.
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Install the new board. board. Secure as previously. previously. Assemble Assemble the connectors connectors to the new board following following the labels. Install the cove covers. rs. Connect Connect the freezer to power and turn the key to the Pow Power er On position. Allow the unit to pull down before loading.
Figure 6.2.15A Ultima Display
Figure 6.2.15B Elite and Value Display
6.2.16 Display Har Harness ness Replacement Replacement Caution: Wear a grounding strap when working with any electronic electronic controls. W ithout a grounding strap, high static electricity may damage the new controls. Before attempting to remove the control board, remove one electrical lead from the 12VDC battery post. ▲ Turn the unit Off. Off. Disconnect Disconnect it from the power sou source. rce. Follow O.S.H.A. regulations 19 1010-147 147 regarding regard ing tagout and de-ene de-energized rgized potential electrical sources. Ultima Plus units have the display at eye level on the ffront ront door (Figure 6.2.15A 6.2.15A). ). Remove th the e six screws that secure the lower left side panel. Remove the panel and disconnect the battery. Locate Locate the micro board on top of the electric electrical al relay enclo enclosure sure (Figure (Figure 6.2.13A 6.2.13A). ). On the right side of the board is the display connector. The 25 pin display cable is connected to J20. Disconnect the cable. Remove Remove the screws from the bot bottom tom of the display board board hou housing. sing. Retain the screws for reassembly. Gently pull the display display housing toward toward you from the bottom. This will allow access to the display board and harness. Locate the 25 pin harness connecto connectorr on the display board board and remove. The harness runs down through the door and is routed in at the top, in fr front ont o off the c cond onden enser ser.. Open the filter compartment and locate the tie-wrapped harness at the top of the base. Remove the tie wraps and discard the harness. Route the new harness harness through through the PVC port located in the corner corner of the display cutout in the door. Reattach Reattach the 25 pin connector to the harness and install the display housing. housing.
Reattach the 25 pin connector connector to the micro board and and tie wrap as needed.
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6.2.17 Alar Alarm m Battery Replacemen Replacementt
Remove the the six screws that secure secure the lower left side pan panel. el. Set the panel asid aside. e. Locate Locat e th e battery batt ery on the right side of the relay enclosure and mounted to the compressor base (Figure 6.2.17). Label and disconnect disconnect the two red and black leads from the battery.
Figure 6.2.17 Battery Location
Remove the screws securing the battery. Discard the battery, accordin according g to proper dispos disposal al procedures. Install new battery. battery. Red is the positive positive lead and black is the negative. Allow 4-6 days for the battery to fully charge. Monit Monitor or unit for proper operation operation..
6.2.18 Voltag Voltage e Boost Transfo Transformer rmer Warning: High voltages voltages may be present. Serv Service ice shoul should d be performed by qualifi qualified ed p ersonne l only. ▲ only. ▲ Turn Off the power switch and disconnect disconnect the unit from the power source. Remov Remove e the the si six x screw screws s that that s sec ecure ure th the e lowe lowerr le left ft sid side e pa pane nel. l. Set th e pa ne l as id e an d disconnect the battery. Remove Remove the six scre screws ws secur securing ing the enclosure cover. Locate the boost transformer transformer in the bottom of the relay enclosure (Figure 6.2.18A 6.2.18A). ).
Figure 6.2.18A Boost Transformer
Note: 120 volt units units have one transformer transformer and 230 volt volt units have two. Label each wire and a nd it’s connection conne ction to the transfo transformer. rmer. Refer to the ladder ladder diagrams in this manual. manual. Disconnect Disconnect all. all. ▲ ▲
Remove Remove the mounting scre screws ws securi securing ng the transfo transformer rmer to the enclosure. enclosure. Discard the transformer. Install the new transfor transformer mer by reversin reversing g tthis his procedure. Replace Replace the covers and monitor for proper operation. operation.
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6.2.19 Fan Motor and Blade Replace Replacement ment (115VAC on all models) Use the following procedure procedure to replace a freezer condenser fan motor. The fans are attached to a shroud that can be removed as a complete assembly.
Turn the freezer Off and disconnect disconnect it from the power source. Remove Remove the six screws that se secure cure the lowe lowerr left side panel. panel. Remove the panel. Disconnect Disc onnect the battery and remove from cabinet base. Remove the lower right side control control panel. Disconnect the wires from the bot bottom tom of each fan motor. Remove the lower front panel in two steps. First, swing the air filter compart compartment ment ope open n and remov remove e the two screws on the left side. Then, remove the recorder cover on the right side and remove the two screws. A total of four screws hold the front panel in place. When the front panel is removed, the air coo cooled led c conde ondense nserr is vi visibl sible. e. The The pa ne l , se cu r in g th e ai r co ol ed conde condens nser er,, supp suppor orts ts tthe he fa fan/ n/sh shro roud ud a asse ssembl mbly. y. T To o fre free e th the e assembly, assemb ly, unfasten the five mounting screws visible through the access holes holes.. See Figure 6.2.19A.
Figure 6.2.19A Access Points For Shroud Screws Screws..
Figure 6.2.19B Fan Mounted To Shroud
On the relay relay enc enclosu losure re side (r (right ight side), side), slide tthe he entire shroud fan assembly out out.. Re Remov move e and replace repla ce th the e de defecti fective ve fan fan motor. See Figure 6.2.19B. Re-install the assembl assembly y in reverse order. Reconnect Reconnect power supp supply ly and check for proper operation.
Reinstall access access pan panels. els.
6.2.20 First Stage Pres Pressure sure Switch Repla Replacement cement Notes: Recover the refrigerant charge from the system in accordance with current EPA and local regulations. Read and follow instructions for “Refrigerant Recovery” before proceeding. When using a torch for de-soldering or brazing, be sure to employ shields as required to prevent the flame from reaching other other componen components ts that could be affected by heat. Do not overheat the new switch when installing. Wrap the top of switch with damp cloth to prevent overheating while soldering. If procedure is being performed in a facility, comply with any fire codes for the location and the facility. Always have a fire extinguisher available whenever using a torch. Clean brazed joints using abrasive pad or cloth. Purge the system system with nitrogen.
Remove the lower lower right side panel. Separate the pressure switch switch harness at the electrical conne connections ctions to the pressure switch at the plug connector.
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Revco Plus Rev. 3
Remove Remove the curren currentt pressu pressure re switch switch (Fig (Figure ure 6.2.20 6.2.20A), A), by desoldering or cutting.
Figure 6.2.20A Pressure Switch
Prepare Prepare the replace replacement ment pressure switch for installation. installation. Verify that switch is exact replacement replacement for switch switch being removed. Remove plastic plastic cap from 1/4” copper tubing. Install replacement switch. Verify that all copper copper tubing is clean clean and free of debris. Start nitrogen flow through system (as described described in previous step steps). s). Position Position switch in original locati location. on. Wrap the top of switch with a damp cloth to prevent prevent overheating while soldering. Braze the line connection. connection. Always have nitrogen nitrogen flowing in the tube while brazing. Allow copper copper tubing to c cool. ool. Reconnect Reconnect electrical conne connections ctions the pressure the plug connector. connector. Replace thethe first stage filter drier andto pressure press ure test allswitch brazeatjoints. Evacuate and Recharge as described described in this manual.
6.2.21 Secon Second d Stage Pressure Pressure Switch Replacement Replacement Notes: Recover the refrigerant charge from the system in accordance with current EPA and local regulations. Read and follow instructions for “Refrigerant Recovery” before proceeding. When using a torch for de-soldering or brazing, employ shields as required to prevent the flame from reaching other components that could be affected by heat. Wrap the top of new switch with damp cloth to prevent overheating while soldering. If this is being done in a facility, comply with any fire codes for the location and the facility. Always have a fire extinguisher available any ttime ime a torch is being used. Purge the system system with nitrogen.
Remove lower lower right side pane panel. l. Disconnect Disconnect the electrical conn connection ections s to the pressure switch at the plug connector. Remove Remove the curre current nt pres pressure sure switch switch (Figure 6.2.21A), by desoldering or cuttin cutting. g.
Figure 6.2.21A Pressure Switch
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Prepare replacement pressure switch for installation. Verify that switch is exact replacement replacement for switch switch being removed.
Remove plastic plastic cap from 1/4” copper tubing.
Install replacement switch. copper tubing is clean clean and free of debris. Verify that all copper described in previous step steps). s). Start nitrogen flow through system (as described Position switch in original locati location. on. Position prevent overheating while soldering. Wrap the top of switch with a damp cloth to prevent Braze the line connection. connection. Always have nitrogen nitrogen flowing in the tube while brazing. Allow copper copper tubing to c cool. ool. Clean brazed joints joints using abras abrasive ive pad or cloth. Reconnect Reconnect the electrical conne connections ctions to the pressure switch at the plug connector. connector. Replace Replace the seco second nd stage dri drier er (See Replacemen Replacementt of Second Stage Stage Drier.) and pressure check all braze joints. Evacuate and Charge the second stage system system as described in this manua manual. l.
6.2.22 First Stage Compr Compressor essor Replacement Replacement Disconnect Disconnect all power from the unit. Warning Ensure Warning Ensure that the freezer components have warmed to room temperature. ▲ temperature. ▲
Remove Remove the lower lower panel panel on the back of the unit; three screws at the top and th three ree at the bot bottom. tom. Locate Locate the first stage stage compres compressor sor on the right side of this exposed area ar ea (Figure 6.2.22A). Install a line tap on the proc ess line and recover recover all refrigerant refrigerant in accordance accordance w with ith state and federal EPA regulations.
Figure 6.2.22A Compressor Location
Remove the the suct suction ion and di discha scharge rge line lines s from the compress compressor. or. The suction lline ine is at the top, and the discharge line at the bottom. The suction line has the Armaflex installation. Opposite the suction line at the top is the process tube. Mark each each wire an and d disconnect disconnect the wires wires from the compressor. compressor. Normally, tthere here will be thr three ee wire s hard-wired to the compressor. These wires will be identified as the run, start and common terminals. Note: Backflush Backflush the system any time a compressor compressor is replaced.
Remove the current first stage compressor. compressor. Retain the mounting feet and sleeves. Note: Access to the compressor compressor can also be facilitated facilitated by removing the lower left side pa panel nel,, then the relay box enclosure. Caution: Cap off off all remainin remaining g line lines s to prevent moisture contamination from migrating into the system. Caution: The compresso compressorr weights approximate approximately ly 60 pound pounds. s. Use caution caution and employ proper lifting procedures when moving the compressor. Caution: Always introduce int roduce a low volume nitrogen nitrogen flow when brazing brazing to pre prevent vent oxid oxides es from forming forming..
Install the compressor feet, sleeves, and electrical wires to the terminals of the new compressor. compressor. Attach the new compressor to the freezer deck.
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Install a new filter/drier, filter/drier, and connect all copper copper lines. Attach the molex connector.
Pressurize Pressurize the system wit with h dry nitrogen an and d leak-check. leak-check. If no leaks are detected evacuate per instructions in this manual. Note: Always Always use copper pro process cess lines lines direc directly tly to gauges and the vacuum vacuum pump. Ensure tthe he suct suction ion llines ines are insulated. Insulate Insulate the suction side from the compressor compressor to the cabinet. Charge Charge the syste system m after the system system meets blank-off blank-off standards standards (se (see e Char Charging ging Procedure in this
manual). Replace Replace panels and return system to operation. operation.
6.2.23 Secon Second d Stage Compressor Replacement Replacement Disconnect all power power from the unit. Warning: Ensure that the freezer components components have warmed to room tempera temperature. ture. A
Remove the six screws securing the lower right side side panel. Th Then en remov remove e the six scre screws ws secu securing ring the lower back panel. Remove both panels. Locate Locate the the second second st stage age c compre ompresso ssorr on the left side of the back opening (Figure 6.2.23A). The discharge line is attached to the oil separator.
Figure 6.2.23A Compressor Location
Install a line tap on the process line, and recove recoverr all refrigerant in accordan accordance ce to state and federal EPA regulations. To avoid pulling pulling contaminants in into to the system, use dry nitrogen nitrogen to break the vacuum and bring the system to a low positive pressure. Remove the suction suction and dis discharg charge e lines from the compressor. compressor. The suction line, with Armaflex, is located at the top and the discharge line at the bottom. The process tube is opposite the suction line.
The wires will be hard-wired into the compressor. There are normally three wires. wires. Befo Before re remov removing ing the wires, wire s, note the colors and connect connection ion configuration. Note: Backflush Backflush the system any time a compressor is replaced. replaced. A Remove the four (4) bolts securing securing the compressor to the freezer dec deck. k. Remove the second stage stage compressor. Retain the mounting mounting feet and sleeve sleeves. s. Caution: Cap off all remaining remaining lines to prevent moisture contamination contamination from migrating into the system. Caution: The compresso compressorr weights approximate approximately ly 60 pound pounds. s. Use caution caution and employ proper lifting procedures when moving the compressor. Caution: Oxidati Oxidation on will form at the heated joint unless a low volume nitrogen nitrogen flow is maintain maintained. ed. Such oxidation could break free and cause a restriction. Flush the system system per instructions in this manual Inspect the new oil separat separator or to ensure that that it is full and contains contains the correct type of oil (15 oz. of Zerol 150T). Plumb the oil separator with copper lengths equal to what was removed with the old oil
separator, install the oildry separator. all copper lines. Pressurize Pressuriz e and the system with nitrogen Connect an and d leak-check leak-check. . If no leaks are detected, start st art evacuation (see evacuation evacuation instruc instructions tions in this manual).
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Note: Always use copper copper lines directly to the gauges gauges and vacuum pump. Ensure the suction lines are insulated. ▲ insulated. ▲ Insulate Insulate the suction side from the compressor compressor to the cabinet. Charge the system system after the it meets blank-off blank-off standards (see charging charging instructions in this manual). Replace Replace access panels and return freezer to operation.
6.2.24 Replacing Replacing the Oil Sepa Separator rator Note: Always replace the oil separator when changing the second stage compress compressor. or. ▲ ▲
Re Remov move e the s six ix s scre crews ws th that at se secu cure re the the lower right side panel. Set the panel aside aside.. The oil separator is located behind the tube axial fan. See Figure 6.2.24A
Figure 6.2.24A Separator Location
Cut the tubin tubing g as close to the br braze azed d fittin fitting g on the current current oil separat separator or as poss ible . Rem ove the nut that secures the oil separator to the compressor base. The nut is located beneath the compressor base, (directly beneath the oil separator) and requires a 9/16” wrench or 9/16” socket. Discard the oil separator. separator. The new oil separator ships pre-charged with the correct amount of oil oil.. Alig Align n the separ separato ator. r. Clean the tubing with emery cloth. Do not use steel wool or sandpaper. Make sure the piping is configured properly; inlet to inlet tube, outlet to outlet tube, etc. Install and tighten the nut that secures the oil separator in place. Connect the tubing and braze the joints together. Always allow nitrogen to flow through the tubing while the brazing process is being performed. Once the joints are brazed, wipe off any excess flux that may have accumulated on the joints. See proper evacuation evacuation and charging procedures procedures in this manual.
6.2.25 Replac Replacing ing the Expansion Expansion Tank
Remove the six screws screws that secure the lower back panel. The tank and solenoid solenoid are located on the left side (Figure 6.2.25A).
Figure 6.2.25A Expansion Tank and Solenoid
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Using emery cloth, clean the tubing approximately approximately halfway up the vertical pipe that connects the solenoid to the top of the expansion tank. Once tube has been properly cleaned, cut the tube. Remove the nut that secures the expansio expansion n tank to the compressor compressor base. The nu nutt is loca located ted directly beneath the compressor base where the tank sits. Use either a 9/16” wrench or a 9/16” socket to remove this nut. Discard the tank. Align the new expansion tank to t he base and reinstall the nut. Pipe the tub tubing ing from from th the e expansion tank to the tube that was previously cut. Braze the tubing together. While brazing, always use a flow of nitrogen. When using a torch for de-soldering or brazing, be sure to employ shields as required to prevent the flame from reaching other components that could be affected by heat. If the procedure is being performed in a facility, comply with any fire codes that may apply for that location. Always have a fire extinguisher available whenever using a torch.
See proper evacuation evacuation and charging procedures procedures in this manual.
6.2.26 Replacing Expansion Expansion Tank Solenoid Solenoid
Remove Remove the six scre screws ws that sec secure ure the lowe lowerr back panel. panel. The tank tank and solenoid ar are e located on the left side. See Figure 6.2.25A. 6.2.25A. Remove Remove the the two elect electrica ricall wire wires s that supply power to the solenoid. Note the two terminal connections used, and avoid the unused ground terminal. Using an emery cloth, clean clean both ends of the tubing where it joins the current solen solenoid. oid. Once cleaned, clean ed, cut the tubes and remove the solenoid. solenoid. Leave Leave or repla replace ce any sound or vibration dampening material used. Install Install the new new solenoi solenoid d and braze braze the tubing tubing.. Wrap the top top of the solenoid with a damp cloth to prevent overheating while soldering. When using a torch for de-soldering or brazing, be sure to employ shields as required to prevent the flame from reaching other components that could be affected by heat. If the procedure is being performed in a facility, comply with any fire codes that may apply for that location. Always have a fire extinguisher available whenever using a torch. Once the solenoid solenoid is braz brazed ed into place, reattached reattached the two tie wraps. (Make sure the black insulat insulation ion tape is in place to prevent vibration.) Reattach the electrical connection. See proper evacuation evacuation and charging procedures procedures in this manual.
6.2.27 Replac Replacing ing the First Stage Stage Drier Notes: Recover the refrigerant charge from the system in accordance with current EPA and local regulations. When using a torch for de-soldering or brazing, be sure to employ shie shield lds s as req requi uired red to p prev reven entt the flame from reaching other components that could be affected by heat. If the procedure is being performed in a facility, comply with any fire codes for the location and the facility. Always have a fire extinguisher available whenever using a torch. Clean brazed joints using emery pad or cloth. Remove the six screws that secure the lower back panel and set the panel aside. Remove the six screws that secure the lower left side panel and set the panel aside. The drier can be accessed from both sides with these two panels removed. The first stage drier is attached to a bracket located behind the second second stage compres compressor sor (Figure 6.2.27A). This is the only drier located in the compressor base area.
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Figure 6.2.27A First Stage Filter Drier
Use an emery emery cloth cloth to cl clean ean the coppe copperr tubing tubing on each side side of the drier drier before the ttube ube is c ut. Do not use steel wool or sandpaper. Cut and remove the old drier. Discard. Install the new drier and check to make sure the arrow is pointing in the correct correct direc direction tion of of flow. The arrow will be pointing down if the tubing has not been altered from the factory design. Always purge the tubing with nitrogen while brazing. Once the joints are brazed, clean the joints with emery cloth. See proper evacuation evacuation and charging information information in this manual.
6.2.28 Changi Changing ng the Second Stage Drier Drier Notes: Recover the refrigerant charge from the system in accordance with current EPA and local regulations. s When using a torch for de-soldering or brazing, be sure to employ shields as required to prevent the flame from reaching other other componen components ts that could be affected by heat. If the procedure is being performed in a facility, comply with any fire codes for the location and the facility. Always have a fire extinguisher available whenever using a torch. Clean brazed joints using abrasive pad or cloth.
Remove the 12 12 screws from the c cover over plate atta attached ched to the center center back of the unit unit.. See Figure F igure 6.2.28A. Under the outer panel is another panel, panel, with cut out metal tabs (Figure 6.2.28B). Clip the tabs on three sides and fold this panel out of the way
Figure 6.2.28A Cover Plate
Figure 6.2.28B Two Cut Out Tabs
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With With the foam foam expo exposed sed,, scribe scribe 6 61/2 1/2 iinch nches es on the the foam from the left l eft side of the panel opening, then again at 11 inches (Figure 6.2.28C). Measure fro from m the botto bottom m edge up 1/2 inch and plac place e a mark. Scribe again at 10 inches.
Figure 6.2.28C Measure
Remove the foam carefully carefully with a putty knife. Do not exceed 3 1/2” inches deep. With the foam removed, the drier and tubing become visible (Figure 6.2.28D). Caution should be observed while removing the foam at the bottom. This is where the black and white RTD heat exchanger probe is located. When the foam is removed, clean the tubing on both sides of the drier with emery cloth and cut the tube.
Drier Figure 6.2.28D Drier Location
Install the new drier. Make sure the arrow on the drier drier is poin pointing ting in the dire directio ction n of proper flow. flow. Normally Nor mally the the drier should should be pointi pointing ng down if the tubing has not been altered from the factory design. Always purge the tubing with nitrogen while brazing. Special precautions should be used while brazing (see Figure 6.2.28E). The foam will produce a flame if the brazing tip comes into contact with the foam.
Figure 6.2.28E Brazing
See proper evacuation evacuation and charging procedures procedures in this m manual anual..
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After the drier drier is braz brazed ed into place, place, carefully carefully p push ush it into the back of the void area. Before folding folding the inner inner panel into place, place, place a thin layer of oil or wax on the panel. (This keeps the foam from sticking to the panel so that the filling of the void can be verified.) verified.) See Figure Figure 6.2.28F. 6.2.28F. Fold the inne innerr panel back into place and secure the outer panel with the 12 screws that were removed previously.
Figure 6.2.28F Wax or Oil
Drill two small holes into both panels in the approximat approximate e area of the the foam vo void, id, la large rge enou enough gh fo for r th the e foa foam m tu tube be to fit into the holes. See Figure 6.2.28G. Drill on one e hole approxim approximately ately 4 inches up from the bottom of the outer panel and the other hole approximately 7 inches up from the bottom. Spray Spray fo foam am in into to th the e void void are area. a. Wh When en th the e foam foam has has se sett up, up, re remov move e th the e ou oute terr a nd i n ne r pa ne ls an d c h e c k t h e foamed foamed area fo forr voids. voids. Fill in as as need needed. ed. Reinst Reinstall all the inner inner and ou outer ter panel panels. s.
Figure 6.2.28G Drill 2 Holes Through Both Plat Plates es into Void
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6.2.29 Condens Condenser er Replacement Replacement
Turn unit off. Disconnect Disconnect unit from the power source. Recover Recover the refrigeran refrigerantt from the system. Remove the front grille. grille. Locate the conden condenser. ser. Remove Remove the nuts s securi ecuring ng the fre freezer ezer base to the cabinet studs. Remove Remove any compone components nts obst obstructi ructing ng the conde condense nserr remova removal, l, suc such h as fans, fans, baf baffle fle s, fi filter lter door and
front deck parts (Figure 6.2.29A). Unbraze or cut the curren currentt condenser condenser tubes.
Figure 6.2.29A Components Removed
With door latch firmly closed, place 2x4’s under under the edge of the door to distri distribute bute th the e load, th then en slightly lift the front of the cabinet to free the top of the condenser (see detail in Figure 6.2.29D). Loosen the condenser condenser mounting screws (Figure 6.2.29B). If needed, needed, use the curren currentt condenser condenser as a template to loca locate te and drill the required required new mounting hole for the right rear (looking at the cabinet). See Figure 6.2.29C. Tilt condenser condenser and slide it out from under the cabinet (Figure 5-43).
Figure 6.2.29B Loosen mounting screws
Figure 6.2.29C Drill Hole
Figure 6.2.29D Slide Condenser
Install Install the ne new w condenser condenser.. Reconnect as previously. Re-install all removed removed componen components. ts. Secure base to cabinet. Install grille. Flush, evacuate and charge per instructions in this manual.
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7.0 Flushing Flushing,, Evacuation and Ch Charging arging The Plus Series of Thermo Scientific freezers are produced with two insulation systems, standard and High Density (HD), formerly known as Super Insulated. Insulated. The HD system has an extra run of copper tubing around the door perimeter, called a halo pass, to help warm the door frame and prevent condensation condensation issues. This halo pass, part of the first stage tubing, is shown on the refrigeration diagram in the Drawings section of this manual. When flushing the HD system, be sure to include this section of the tubing in the flushing process. As of April 24, 2008, the Plus Series ULT’s have a black steel liquid trap accumulator installed on the first stage. This accumula accumulator tor should not be flushed, but but should be replaced or bypa bypassed. ssed. Prior to April 24, 2008, a copper flow through accumulator accumulator was used. This accumulator accumulator can be flushed and should be left in the system for that purpose. Always use the same type accumulator accumulator as originally installed from the factory if replacement is necessary, as the two accumulators are not interchangeable. Note: The Note: The recommended recommended flushing flushing solvent is R406 or its equivalent for typical typical oil removal. An equal or more effective solvent solvent may be used if properly handled. The service techni technician cian is responsibl responsible e to have the training, understanding, and equipment needed to clean the system in a safe and any effective effectiv em manne anner, r, and appropriate appropriate for the location location where flushing takes place. The use of any hazardo haz ardous us mate material rial or procedure is prohibited. ▲
7.1 First Stage System Clean-up/Flushing Clean-up/Flushing
Turn the power off first by turning the key switch to the Off position. Unplug the power co cord rd from the wall receptacle. Follow regulations regarding tagtag-out out and de-energizing potential electrical sources.
Figure 7.1A First Stage Compressor
Locate the the first stage sy system, stem, and install install line taps taps on to the process process tubes of bo th the high and low side of the compressor. The process tubes are the 3/8 inch stubbed-off lines attached to the system.
Note: Do not pierce the line at this time. Follow line tap manufacturing manufacturing instructions instructions for instal installation lation and line piercing of system. ▲ system. ▲ Caution: When working with refrigerants, hand, eye and face protection is required. Liquid refrigerants refrigerants are very cold and may cause burns. There is also a possibility of an acid condition due to a compressor burn-out. ▲ burn-out. ▲
Recover Recover the refrigerant charge from the syste system m in accordance accordance to State and Federal EPA regulations. The line will need to be pierced after connection of the hoses to the manifold gauges. After recovering recovering the refrigerant, purge purge the system with a nitrogen charge. Only a low system charge is required. required. Clean the tubing with a sanding cloth, cloth, at the location of the planned tubing cut.
Note Do not use steel wool or sandpaper. A synthetic abrasive Note Do abrasive pad is preferred to avoid grit getting into the system. Cut the tubing on the discharge side close to the end that was attache attached d to the compre compresso ssor. r. Cut
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the tubing on the suction side close to where it was attached to the compressor. Use quickconnects, or braze copper lines with access ports, to attach the flushing tubes to the suction and discharge lines. Lines entering and leaving unit Suction Line used for entering flush
Discharge line used for exiting flush
Typical refrigeration hoses and ¼-turn ball valves, all reserved for flushing, are used for making connections and controlling flow.
Process Adapters
Direction of Liquid Returning flow
Valves
Sight Glass – to assure liquid flow into system
Sight Glass – to assure liquid exiting and see any dirt returning.
Use this valve to allow recovery of flush from both sides of system after flushing/soaking is completed.
Direction of Liquid Returning flow
Filter – to help keep clean flush entering system
Use dotted line pathway if optional dirt trap tank is not used.
Filter – to protect pump drier Liq. Vapor port of tank R11 R12 R406a Vertrel Other
Flush Source Tank
Vap.
Recovery machine or recirculating pump
Liquid port of tank
Recovery Dirt Trap Tank
Optional recovery dirt trap tank. Have liquid liquid por portt entering tank and vapor port le3aving le3av ing tank to pump pump.. Idea is to trap dirt in this tank for later evaluation and to keep flush clean.
Figure 7.1B Flushing
Reverse flow process: process: liquid flush enters thro through ugh normal suction tube and flush returns through normal discharge tube.
Remove and discard the current drier. Attach quick-connects, quick-connects, or braze a copp copper er tu tube be with with a fl flare are adapter/connector, to complete a loop so the flushing solvent will enter through the suction line and return through the discharge line. Connect the flushing flushing hoses per Figu Figure re 7.1B, using the valves, valves, drier(s), and sight glasses. Install an HH drier just before the recovery machine. This drier is used to prote protect ct the rec recove overy ry machine and aids in cleaning up the flushing solvent. Use a recovery tank to collect the re-condensed flushing flushing solvent after the recovery machine. machine. During the flushing process, it is essential essent ial to k keep eep a “li “liquid quid in” and “li “liquid quid ou out” t” flus flush. h. Use the the shut shut-off -off valve valv e before before the recov recovery ery machine to control contro l this liquid flow. View the flow through the sight glass. If liquid is not present, t hen clos close e th the e va valve lve ffor or th the e pre pressu ssure re and liquid to build up in the evaporator (this is flushing-in-reverse flow). If there is no liquid in-andout flow, then proper cleaning of the capillary tube and suction tubing has not occurred.
Note: The following flushing flushing values are only esti estimates. mates. Actual amounts amounts and times will need to b be e determined for a properly cleaned system. ▲ determined system. ▲
Cleaning/flushing time depends on the recovery r ecovery system used, the condition of the system system being flushed flus hed,, and the type of fl flushi ushing ng s solve olvent nt used. Average flushing time is i s 20 m inutes or greater, with an adequate amount of solvent to maintain a continuous liquid flow in and out through the system.
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Note: Follow Follow the requireme requirements nts of the recov recovery ery machi machine. ne. There may be filt filters ers loc locate ated d ins inside ide the machine which require replacing. Follow any applicable safety warnings for the recovery machine. ▲ During the flushing process, process, note the sight glass for clean liquid flow. If, at any time, sl sludge udge,, oil or dirt of any kind is seen, continue flushing the system until the solvent is clean and clear. Continue Continue flushing no less than 15 to 20 minutes after the sight glass is clean, clear and has a solid liquid flow.
When flushing flushin of the systemoristubing complete, alway always s install new filter drier, compressor (if manual. required required)) and any otherg components as necessary. See areplacement instructions in this See Evacuation Evacuation and Charging procedu procedures res in this section section.. Remove any lockout lockout tags or devices devices installed earlier, earlier, then connect the power cord to the power source. The system system is now ready tto o run.
7.2 Secon Second d Stage System Clean-up/ Clean-up/Flushin Flushing g
Turn the power switch Off and disconnect disconnect the unit from power. Follow regulations regulations regardin regarding g tagout and de-energizing potential electrical sources. Locate the second second stage system (Figure (Figure 7.2A), and install line taps to the process tubes of both the high and low side of the compressor. The process tubes are the 3/8 inch stubbed-off lines attached to the system.
Figure 7.2A Compressor Location
Note: Do not pierce the line at this time. Follow line tap manufacturing manufacturing instructions instructions for installation and line piercing of system. ▲ system. ▲
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Lines entering and leaving unit Suction Line used for entering flush
Discharge line used for exiting flush
Typical refrigeration hoses and ¼-turn ball valves, all reserved for flushing, are used for making connections and controlling flow.
Process Adapters
Direction of Liquid
Valves
Sight Glass – to assure liquid exiting and see any dirt returning.
Returning flow
Sight Glass – to assure liquid flow into system
Use this valve to allow recovery of flush from both sides of system after flushing/soaking is completed.
Direction of Liquid Returning flow
Filter – to help keep clean flush entering system
Use dotted line pathway if optional dirt trap tank is not used.
Filter – to protect pump drier Liq. Vapor port of tank R11 R12 R406a Vertrel Other
Flush Source Tank
Vap.
Recovery machine or recirculating pump
Liquid port of tank
Recovery Dirt Trap Tank
Optional recovery dirt trap tank. Have liquid liquid por portt entering tank and vapor port le3aving le3av ing tank to pump pump.. Idea is to trap dirt in this tank for later evaluation and to keep flush clean.
Figure 7.2B Flushing
Reverse flow process: process: liquid flush enters thro through ugh normal suction tube and flush returns through normal discharge tube. Warning: When working with refrigerants, hand, eye and face protection is required. Liquid refrigerants Warning: When are very cold and may cause burns. There is also a possibility of an acid condition due to a compressor burn-out. ▲ burn-out. ▲
Recover Recover the rrefrigera efrigerant nt charge from the system in accordan accordance ce to State and Fed Federal eral EPA regulations. The line will need to be pierced after connection of the hoses to the manifold gauges. After recovering recovering the refrigerant, purge purge the system with a nitrogen charge. Only a low pressure
chargethe is required for athe system. Clean tubing with sanding sandin g cloth, at the plann planned ed location location of the cut.
type of steel wool o orr sandpaper. A synthetic abrasive cl cloth oth is preferred to avoid Note: Do not use any type grit entering the system. When cutting the tubing, use proper proper tubing cutters. cutters. ▲ ▲
Cut the tubing on the discharge discharge side of the system, as close to the compressor as possible. possible. Do the same on the suction side. Install Install a quick-c quick-conne onnect, ct, or braze a 1/4 copper copper line and use a flare adapter/connector, for ease of connection to the flushing hoses. Remove the oil separator and the filter drier. Use quick-conne quick-connects cts or braz braze e a lin line e in pl plac ace e of th the e oil separator and drier to allow a continuous flushing loop entering at the suction line and exiting at the discharge line line.. Apply power to the solenoid solenoid at the expansion ta tank nk to close the line. Never flush through t hrough the expansion tank. Install an HH drier just before the recove recovery ry machine. This drier protects the recovery machine machine and aids a inrecovery cleaningtank the flushing solvent. Use to collect the re-condensed flushi flushing ng solvent after the recovery machine. machine. During the flushing flushing process, it is essentia essentiall to keep a “liquid in” and “liquid out” flush. Use the
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shut-off valve before the recovery machine to control this liquid flow. View the flow through the sight glass. glass. If liquid is not present present,, close the valve for the pressure and liquid to build up in the evaporator (this is flushing-in-reverse flow). If there is no liquid in-and-out flow, then proper cleaning of the capillary tube and suction tubing has not occurred. Cleaning/flushing time depends on the recovery r ecovery system used, the condition of the system system being flushed, flus hed, and the the type type of flushin flushing g solvent solvent used. Average f lushing time is 20 minute s or greater, with an adequate amount of solvent to maintain a continuous liquid flow in and out through the
system. Note: These are only estimates; estimates; actual amoun amounts ts and time need to be determin determined ed by you for a properly cleaned system. ▲ system. ▲ Note: Follow the requirements requirements of the recovery/reclaim recovery/reclaim machine machine.. There may be rreplace eplaceable able filters located inside the machine. Follow any safety warnings that may apply for the recovery machine.
During the flushing flushing process, che check ck the sight glass for clean liquid flow. If, at any time, sludge, oil or dirt of any kind is seen, continue flushing the system until the solvent is clean and clear. Flushing requires more than a few minutes. Continue Continue flushing no less than 15 to 20 minutes after the sight glass is clean, clear and has a solid liquid flow. When flushing flushing of both sides of the system is comple complete, te, always install install a new system liqu liquid id drier, expansion expan sion tank, (compre (compressor ssor if required) required) and any other components components or tubing necessa necessary. ry. Follow the procedures procedures in Section 6 for replacing the drier and compre compressor. ssor. See Evacuation Evacuation and Charging procedu procedures res in this section. Remove any lockout lockout tags or devices devices installed earlier, earlier, then connect the power cord to the power source. The system system is now ready tto o run.
7.3 Evacuation Evacuation The process described presumes the system first f irst has been backflush backflushed, ed, has all necessary new components compon ents (compressor, (compressor, accumulator accumulator or oil separator, filter/drier) with new dry refrigerant oil, and is properly sealed and leak-tested. A quick summary of the technique is to pull the system down to 1,500 microns, break the vacuum with a dry nitrogen sweep and 10 minute low pressure soak, then evacuate to 500 microns, allow another nitrogen sweep and soak, then evacuate to
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