Fisher & Paykel RB36S25MKIW, Service Manual

Page 1: ...840653 Service Manual CoolDrawer Models RB36S25MKIW RB90S64MKIW ...

Page 2: ...eynes Buckinghamshire MK10 0BD England Telephone 0845 066 2200 Facsimile 0845 331 2360 E mail customer care fisherpaykel co uk Fisher Paykel Appliances Unit D2 North Dublin Corporate Park Swords Co Dublin Ireland Telephone 1800 625 174 Facsimile 1800 635 012 E mail customer care fisherpaykel ie Fisher Paykel Appliances Inc 5900 Skylab Rd Huntington Beach California CA92647 USA Telephone 888 936 78...

Page 3: ...3 15 Check Operation 19 4 USING ALTERNATE ENERGY GENERATION 20 4 1 Product Facts 20 4 2 Using A Battery Driven Inverter Supply 20 4 3 Using A Motor Driven Generator Supply 21 4 4 Summary 21 5 USER OPTIONS 22 5 1 User Interface Display 22 5 1 1 Lock 23 5 1 2 Mode Select 23 5 1 3 Temperature Adjustment 23 5 1 4 Special Options Mode 23 5 1 5 Control Panel Beeps 24 5 1 6 Fault Alarm 24 5 1 7 User Mode...

Page 4: ... 9 3 1 Quick Guide To Fault Finding With VC Compressors 38 9 3 2 Compressor Fault Diagnosis 39 9 3 2 1 Compressor Won t Start Dead 39 10 FAULT FINDING PROCEDURE 40 10 1 Fault Display Codes Both Visual And Audible 40 10 1 1 Binary Code 40 10 1 2 Fault Codes 40 10 1 3 Diagnostic Mode 42 10 1 4 Diagnostic Mode LEDs 43 10 1 4 1 Compartment Sensor Temperature 44 10 1 4 2 Lower Sensor Temperature 44 10 ...

Page 5: ... 19 Replacement Of Defrost Sensor 67 12 3 20 Replacement Of Evaporator Inlet Sensor 67 12 3 21 Replacement Of Evaporator Outlet Sensor 67 12 3 22 Replacement Of Filter Sensor 68 12 3 23 Replacement Of Compartment Sensor 68 12 3 24 Removal And Refitment Of Air Bell 68 12 3 25 Removal Of Humidity Lid Control 69 12 3 26 Removal Of Evaporator Fan Motor 69 12 3 27 Removal Of Defrost Heating Element 70 ...

Page 6: ... Watts 882 Ohms 1 2 Compressor Specification Make type Matsushita VCC Low Back Pressure Model ENI57C13DGH Volts 240 DC Input Watts 104 watts Output Watts 173 watts Nominal BTU 591Btu h Motor Run Current 0 30 amps Winding Resistance U W U V V W 8 44 ohms 8 44 ohms 8 44 ohms Motor Overload Protector MM3 71CC Refrigerant Type R134a Gas charge R134a 85g Oil Charge cm3 215 Inverter Board 3 Phase Full B...

Page 7: ...r is drawn through the evaporator by the evaporator fan and then passes into the ducted back wall to enter the cabinet higher up It has a fan forced condenser system utilizing the benefits of electronic temperature control and has a variable speed compressor VCC For service access into the CoolDrawer refer to the servicing procedures Section 12 Removal of the complete drawer is carried out by the ...

Page 8: ...ply cord Failure to install the CoolDrawer correctly will invalidate any warranty or liability claims If the power supply cord is damaged it must be replaced Parts are available from an Authorised Fisher Paykel dealer Cabinetry must be sufficiently robust to support a combined product and food load of 100 kg 220 lb Bearers may be required to support the internal shelf Before installing the CoolDra...

Page 9: ...l height of product including installation brackets 640mm 253 16 B Overall width of product 855mm 3311 16 C Overall depth of product excluding drawer panel including power cord 557mm 2115 16 D Depth of drawer open excluding handle 520mm 201 2 ...

Page 10: ...C2 Height from frame inner face to top of internal shelf 644mm 253 8 D Minimum height of toe kick 75mm 3 E Minimum depth of toe kick 40mm 15 8 F Minimum distance from front of cabinetry to rear wall 560mm 221 16 Minimum internal height of cabinetry frame can be 644mm 253 8 if outlet duct is not used All depth measurements are taken from the front face of the cabinetry frame not drawer panel MINIMU...

Page 11: ...840653 11 3 3 Parts Supplied CAVITY PREPARATION Recommended to allow the vertical removal of the refrigerator bins ...

Page 12: ...840653 12 3 4 Integrated Panel Preparation ...

Page 13: ...al shelf and underside of benchtop Your kitchen designer C Bottom face of Drawer panel to top of internal shelf Min 152mm 6 Max 184mm 71 4 D Drawer panel height Calculated from A B C To calculate D complete the following equation D B A C Example B 686mm 27 A 20mm 13 16 C 184mm 71 4 Therefore D 686mm 20mm 184mm 482mm 27 13 16 71 4 1815 16 3 4 3 Height Of False Panel Determine the height of the fals...

Page 14: ...840653 14 3 5 Create Cut Outs In Frame 3 6 Locate And Secure Install Brackets ...

Page 15: ...840653 15 3 7 Attach Inlet And Outlet Vent Ducts 3 8 Attach Power Cord And Trim Brackets ...

Page 16: ...840653 16 3 9 Move Product Into Cavity 3 10 Fit Drawer Panel Attachment Hooks ...

Page 17: ...840653 17 3 11 Attach Drawer Panel To Front Of Drawer ...

Page 18: ...840653 18 3 12 Secure Trim Brackets To Cabinetry 3 13 Attach Trims To Sides Of Cabinetry ...

Page 19: ...840653 19 3 14 Attach False Panel 3 15 Check Operation ...

Page 20: ...uality or shape of the output waveform The only regulatory guidelines we choose to follow are safety guidelines As such we cannot guarantee the operation of a CoolDrawer running from an inverter supply if it does not comply with our Operating Voltage requirements listed above Are there existing customers who are successfully running a CoolDrawer from an inverter supply Yes There are many installat...

Page 21: ...CoolDrawer Electronics and this obviously is beyond our control 4 3 Using A Motor Driven Generator Supply Motor driven generators typically generate a 230V rms sinusoidal voltage output Whilst the voltage shape is better defined than an inverter a generator can still develop high voltage pulses due to such things as Noise of brushes Surges due to other equipment coming on off line Surges due to st...

Page 22: ...following icons and symbols can be seen on the user display Listed below is a short description of each and what they do Special Options Mode Control Beeps Fault Alarm Service required Lock Temperature Adjustment Mode Select Storage modes Function Select Freezer Functions ...

Page 23: ...food to be added into the compartment this will take between 1 and 6 hours All cabinets leave the factory set to the Freezer mode by default 5 1 3 Temperature Adjustment Used to increase or decrease the temperature range within each mode selected 5 1 4 Special Options Mode To Enter Special Options Mode Open the drawer Press the LOCK button for 3 seconds to unlock the control panel Within 15 second...

Page 24: ...refer to Section 10 1 2 The audible alarm will stop when any button is pressed but the fault icon will continue flashing When a fault occurs a fault code will be displayed in the temperature display LEDs Refer to Section 10 1 5 1 7 User Modes 5 1 7 1 Freezer Mode 18O C 0O F For general frozen food storage To use Freezer mode Open the drawer Press and hold the LOCK button for 3 seconds to unlock th...

Page 25: ...partment is at a suitable temperature this will take between 1 and 6 hours 5 1 7 5 Wine Mode 7 to 15O C 45 to 59O F The Wine mode provides an ideal controlled environment for the long and short term storage of both red and white wines To use Wine mode Open the drawer Press and hold the LOCK button for 3 seconds to unlock the control panel Press the MODE SELECT button within 15 seconds Scroll to WI...

Page 26: ...er rate than the normal freezer setting Activating Fast Freeze drops the freezer temperature down to its coldest temperature for a 24 hour time period The user may wish to use this when freezing meat or when they are making frozen desserts It is also good to use when arriving home from the supermarket and adding fresh food into the freezer The Temperature adjustment light will scroll back and fort...

Page 27: ...e high pressure high temperature gas has been condensed to a liquid the liquid refrigerant flows through the capillary tube entering the evaporator mounted horizontally in the floor of the cabinet The liquid refrigerant then boils off due to the low suction pressure applied to the evaporator from the compressor This heat laden vapour is drawn back to the compressor by way of the suction line to st...

Page 28: ...support circuitry to switch the various outputs Also built as part of the power control module is the inverter circuitry that runs the VC compressor The power control module monitors high and low side sensors and controls the compressor the evaporator and condenser fans and the defrost function 7 7 Cabinet Module This is the hub for feed back from the soft touch display module and compartment draw...

Page 29: ...as the name suggests is both a filter and a drier Whenever a system is opened it is essential that the filter drier is replaced ALWAYS ensure that replacement filter driers are kept well sealed and airtight prior to being fitted to a system PLEASE NOTE When filter driers are replaced on systems being serviced it is important that the filter drier is either cut from the system or that the desiccant...

Page 30: ...ion Tray This tray is not removable for cleaning and has part of the compressor discharge circuit running through it to assist in the evaporation of the water from the defrosting of the evaporator For cleaning refer to Section 12 4 ...

Page 31: ...temperature sensors and drawer reed switch 8 1 1 Electronic Functional Schematic Outputs 8 1 2 Power Control Module Cabinet Module Display Module User Interface Inputs Compressor Defrost Heater Auxiliary Heater Condenser Fan Evaporator Fan Fault Alarm Beeper Interior Light Speaker Upper Temperature Sensor Lower Temperature Sensor 230 115 volts AC Drawer Sensor Safety Extra Low Voltage Compartment ...

Page 32: ...iable storage and access The power control module contains a special type of memory device call an EEPROM The information on the fridge operation faults and diagnostic information is stored in this memory They include the temperature setting the history of the temperatures for approximately 18 hours defrost history the last 12 defrosts and fault history This will help the service person find and r...

Page 33: ...ture simply press the temperature COLDER or WARMER buttons to achieve the required setting 8 1 6 Defrost Heater Located as part of the fin on tube evaporator the defrost element is clipped onto the evaporator The defrost element is rated at 200 watts and is used to defrost the ice accumulated on the evaporator The defrosts are adapted to the usage and environment and are controlled by the power co...

Page 34: ...arthed in this location 8 1 8 Condensor Fan Located in front of the wire and tube condenser coil the fan has a diameter of 110mm 4 and is powered by 12 volts DC The hub of the fan should be facing the serviceman when fitted correctly Note It is important that the condenser remains free of any air restriction caused by lint dust or any other obstruction over the condenser itself 8 1 9 Evaporator Fa...

Page 35: ...1 Speaker This is located on the end of the display module and is used as sound recognition between the user and the capacitive touch switches that make up the user interface 8 1 12 Wiring Harness Air Bell Located in the evaporator sump of the cabinet this is the plug termination area for the defrost element evaporator fan motor sensors and auxiliary heater The air bell cover prevents water from e...

Page 36: ...r coil outlet is used to measure the coil outlet temperature 4 The compartment temperature sensor This sensor is located on the back wall and in the centre of the compartment at the top It senses the cold air movement from the evaporator within the compartment 5 The filter drier sensor This is used to measure the temperature of the refrigerant entering the filter drier This information is used to ...

Page 37: ...ached its cut out temperature at which point the compressor will switch off and the drawer goes into the warm up cycle 9 2 Built In Electronic Protections Within The Module Inverter 9 2 1 Compressor Start Up In the event of any anomaly occurring during compressor starting the control will wait 30 seconds before repeating the start up If the compressor doesn t start after 3 trials the control will ...

Page 38: ...ent at all from the compressor then disconnect the product from the power supply and remove the terminal cover from the compressor and check the motor winding resistance The resistance between any of the 3 pins on the compressor should be approximately 8 44 ohms If the resistance is not this value then the compressor is faulty Sealed System Checks The VC compressor will not start if there is a res...

Page 39: ...8 44 ohms UW 8 44 ohms VW 8 44 ohms Note The Compressor is a DC Variable Speed Compressor Connection to AC will damage it As the VC compressor operates as a 3 phase motor it is important that the phases connecting it are in the correct order for the compressor to run in the correct direction A transposed phase will cause the compressor to run backwards preventing any oil from being pumped into the...

Page 40: ...ms a binary code Each LED has a value and by adding the values of the illuminated LEDs a total value is obtained Example In the illustration above the LEDs illuminated have a value of 8 2 1 so the fault code is 11 10 1 2 Fault Codes The faults and their respective codes are as shown below Display Code 0 No faults present Display Code 1 Compressor Can t Start Reason The compressor has failed to sta...

Page 41: ... temperature sensor refer to Section 8 1 14 If faulty replace Display Code 8 Evaporator Inlet Sensor Hot Reason Faulty evaporator inlet temperature sensor the resistance is out of normal range resistance less than 660 Ohms Action Check resistance of the evaporator inlet temperature sensor refer to Section 8 1 14 If faulty replace Display Code 9 Evaporator Outlet Sensor Cold Reason Faulty evaporato...

Page 42: ...dule If still faulty replace the display module Display Code 105 Communications Fault Reason There is a communications fault between the cabinet module the display module user interface and the power control module It could be in any of the modules or in the wiring harness Action 1 Replace the display module user interface Wait 30 seconds after re applying power then retest If fault still exists 2...

Page 43: ...ast fault 10 1 4 Diagnostic Mode LEDs When in diagnostic mode the Special Options mode and beeper icons will be flashing to indicate that diagnostic mode has been entered Other LEDs will also be illuminated to indicate which section of diagnostic mode is being displayed For example if the Freezer and Bottle Chill LEDs are illuminated the defrost sensor temperature is being displayed in the tempera...

Page 44: ...mperature readings are only sensor temperature air temperatures and these will change rapidly with the increase in air temperature as soon as the drawer is opened NOTE Temperatures are displayed in degrees Celsius To convert to degrees Fahrenheit refer to the conversion chart in Section 10 1 6 10 1 4 2 Lower Sensor Temperature 1 2 To read the Lower Sensor Temperature not currently used in this mod...

Page 45: ...OCK button then within 1 second press the FUNCTION SELECT button Hold for 3 seconds 4 Press the WARMER button three times 5 The Freezer and Wine LEDs will be illuminated The current Evaporator Outlet sensor temperature is displayed in a binary code form in the temperature indicator LEDs 6 To return to normal operation press and hold the LOCK button then within 1 second press the FUNCTION SELECT bu...

Page 46: ...on six times 5 The Chill LED will be illuminated The current Input Status is displayed in a code form in the temperature indicator LEDs The Input Status only uses the second LED from the right on the temperature scale If the LED is on it indicates that the drawer is closed while if it is off it indicates that the drawer is open This status can be used to check that the reed switch is operating cor...

Page 47: ...e indicator LEDs refer to Section 10 1 1 6 To return to normal operation press and hold the LOCK button then within 1 second press the FUNCTION SELECT button Hold for 3 seconds Note The last fault is cleared from the memory after the next defrost 10 1 5 Sensor Temperature Conversion If the red Freezer LED plus one other LED is on refer to Section 10 1 4 this indicates that a sensor temperature is ...

Page 48: ...18O C 0O F 10 1 6 Temperature Conversion Chart As all temperatures displayed in diagnostics are in degrees Celsius the following chart may be used to convert these readings into degrees Fahrenheit to the nearest degree Fahrenheit O C 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 O F 61 59 57 55 54 52 50 48 46 45 43 41 39 37 36 O C 1 0 5 0 0 5 1 2 3 4 5 6 7 8 9 10 11 O F 34 33 32 31 30 28 27 25 23 21 19 18 ...

Page 49: ...wer will abort the defrost and the appliance will return to normal operation when the power supply is resumed Note There will be a delay of 5 minutes before the element starts to heat after going into this mode This is known as evaporator warm up time The defrost element then turns on and will remain on until any of the sensors defrost evaporator inlet or evaporator outlet have reached 8 O C 46O F...

Page 50: ... the defrost sensor fails to reach 8O C 46O F within 40 minutes the defrost will be terminated If this occurs again during the next defrost fault code 2 will be displayed Compressor Defrost Element Defrost target time 24 minutes Defrost Element Compressor Compartment Fan Turns Off Turns On Maximum defrost time is 40 minutes Turns Off Turns On Turns On Normal Run Warm up Time Defrost Time Drip Time...

Page 51: ... customer to disable various functions of the drawer To Enter Special Options Mode 1 Open the drawer 2 Press the LOCK button for 3 seconds to unlock the control panel 3 Within 15 seconds press and hold the LOCK button then within 1 second press the MODE SELECT button and hold for 3 seconds until the Special Options mode icon is displayed When the cabinet is in Special Options Mode The interior lig...

Page 52: ...iet operation To turn the control panel beeps off or on 1 Open the drawer 2 Press the LOCK button for 3 seconds to unlock the control panel 3 Within 15 seconds press and hold the LOCK button then within 1 second press the COLDER button and hold for 3 seconds until the beep icon turns off or on as required ...

Page 53: ...840653 53 11 WIRING DIAGRAMS Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω ...

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Page 55: ... part of the electrical circuit is serviced or disturbed in the course of carrying out service adjustments or procedures it is essential that an insulation and earth continuity test be carried out using a two scale megger This is to be done with the appliance disconnected from power Insulation At least 1 megohm Earth Continuity No greater than 0 5 ohm NOTE Electronic printed circuit boards can be ...

Page 56: ...us the gasket The drawer gasket is a replaceable part of the drawer It is held in place against the drawer liner by means of a moulding that locks the gasket in place once pushed into it There are no screws or retainers to remove or fit To Remove the Gasket Pull on any section of the gasket to pull it away from the moulding To Replace the Gasket Having removed the old gasket lay the new gasket aro...

Page 57: ...g harness plug Replace in reverse order 12 3 3 Removal Of Drawer Tray Open the drawer Remove the bins from the drawer Slide inwards the two retaining clips at the rear of the drawer tray Lift the drawer tray out Refit in reverse order 12 3 4 Removal Of Decorative Front Panel Open the drawer slightly Loosen the screw located in the centre behind the bottom edge of the drawer front Pull the panel ou...

Page 58: ...terface is supplied as a complete assembly with the printed circuit board and glass user interface as one unit Disconnect the refrigerator from the power supply Remove the decorative front panel refer to Section 12 3 4 Remove the left hand top end cap holding the display module user interface assembly to the top edge of the drawer Slide the assembly 12mm to the right to clear the right hand top en...

Page 59: ... them forward Unscrew the four trim brackets from the cabinetry Remove the aluminium tray and bins from the product Slide the product forward out of the cabinetry to reveal the gasket seal when the door is closed Slide the grey covers at the front of the drawer rails back to expose the door adjustment screws The covers are clipped to the drawer so it helps to pull these at the bottom and top Using...

Page 60: ...at the gasket seals to the cabinet Secure the drawer by extending the centre locking screws Completion Reverse the preparation instructions to reinstall the product 12 3 10 Removal Of Anti Racking Bar Remove the drawer front panel refer to Section 12 3 8 With a screwdriver spring out the clip on the anti racking bar lock Slide the lock inwards Slide the lock to the rear and remove Anti racking bar...

Page 61: ... Removal Of Drawer Slide Remove the anti racking bar refer to Section 12 3 10 Remove the top front over extension lever pivot screw and remove the over extension lever Lift and remove the slide bracket rail assembly to disengage from the front keyhole slot and withdraw the rail assembly forward Over extension lever Lift to disengage ...

Page 62: ...ide off the front stud of the bracket To remove the slide from the bracket with the slide fully extended depress the clip and lift the slide off To disassemble the slide open the slide assembly find the clip and prise the clip outwards pushing the front of the slide forward Refit in reverse order Press clip Push clip Pull slide apart ...

Page 63: ... in reverse order 12 3 13 Removal Of Humidity Tray Slide Press the tab and lift upwards and pull forwards Refit in reverse order 12 3 14 Removal Of Drawer Harness Remove the drawer front panel refer to Section 12 3 8 Remove the three clips holding the harness to the bottom of the drawer slide rail Remove the harness from the rail 1 Press tab 2 Lift rail upwards and slide forwards Clips ...

Page 64: ...tab on the harness rear wall cover and pull the cover forward Unplug and remove the complete harness Refit in reverse order When replacing the harness the tape mark on the new harness must align with the window on the guide This ensures that the harness is correctly located in the guide 1 Push 2 Lift 3 Slide Window in guide Tape on harness ...

Page 65: ...Of Power Control Module Located in the centre front of the drawer Remove the front chassis cover refer to Section 12 3 6 Depress the clip on the top edge of the power control module and pull the module forwards slightly Remove the three edge connectors from the front of the module Slide the module further forward and remove the three edge connectors from the side of the module The module can now b...

Page 66: ...ve the drawer slides refer to Section 12 3 11 Remover the humidity tray slide refer to Section 12 3 13 Remove the rear slide screws on each side Disconnect the main chassis harness from the duct cover At the top corner edge of the duct push down to unclip each side and pull forward Refit in reverse order ...

Page 67: ...he new sensor is done by cutting the wire off the new sensor about 50mm from the sensor and stripping the wire back about 10mm Cut the old sensor wiring off close to the sensor and strip the old wiring back about 10mm Slide the heat shrink sleaving over each wire and solder the new sensor to the old wiring Heat the heat shrink sleaving making sure both connecting wires are not shorting but are ins...

Page 68: ...nsor is done by cutting the wire off the new sensor about 50mm from the sensor and stripping the wire back about 10mm Cut the old sensor wiring off close to the sensor and strip the old wiring back about 10mm Slide the heat shrink sleaving over each wire and solder the new sensor to the old wiring Heat the heat shrink sleaving making sure both connecting wires are not shorting but are insulated wi...

Page 69: ...ng apart Refit in reverse order Note The fan is supported in the housing by a rubber band type suspension It is important that the fan sits central to the housing and that there is a loop in the fan motor wiring harness between the motor and the housing wiring post This loop should be on a horizontal plane to the fan motor Failure to correctly fit the fan will result in fatigue failure of the wiri...

Page 70: ...e type with a grill and cover Having determined that the evaporator needs replacing Recover the refrigerant Remove the evaporator fan motor refer to Section 12 3 26 Remove the cable ties from the evaporator sensors Lift the evaporator upwards to clear the bottom of the divider partition and pull the bottom edge of the evaporator forward Remove the cable ties from the thermal fuses Clean both sucti...

Page 71: ... compressor base mount to the body of the cabinet can be removed This enables the compressor to be lifted clear of the cabinet Refitting of the replacement compressor is done upside down once the compressor has been mounted on its base mount Refit the overload and plug to the compressor pins Refitting the compressor base mount to the base of the cabinet is done by holding the screw fastening side ...

Page 72: ...ctor the connections should be made one at a time For example first cut the wire in pin 1 of the old connector and insert it into pin 1 on of the new connector Push the pin fully home to lock the wire in place and then move on to pin 2 Note that the connectors contain a wall between the cavities to code or polarize the connector This is especially important in the case of the 4 and 6 way connector...

Page 73: ... names of these connectors the 02 refers to it being a 2 way connector and the AB01 for example refers to the coding of the connector Stocko is the manufacturer of these connectors PIN 1 881591 STOCKO 9290 04 EF02 000 960 Compressor cable PIN 1 New Edge connector series with internal coding note the wall Note that to minimize the number of spare parts that need to be carried these coded connectors...

Page 74: ...formance and operation of the refrigeration system using the Cassiopeia Smart Tool or a laptop computer minimum 486 running Windows 95 with the PC Smart Tool Diagnostic program loaded An interface MK2 downloading pen is needed Refer to your Technical Representative The difference between the MK1 and MK2 pens is the sensitivity of the pen The part number for the MK2 pen is 425930 A MK2 pen has a re...

Page 75: ...f to totally seal the circuit Step 3 Connect a nitrogen bottle to the in line pressure gauge by means of a hose with a Schrader valve depressing key in the hose coupling Step 4 Open the nitrogen bottle fully with the regulator backed off Step 5 Increase the regulator pressure in the circuit being tested to 150 psi Step 6 Close the nitrogen bottle valve and back off the pressure regulator Step 7 Di...

Page 76: ...o follow these steps will led to the system slugging oil as being transported any other way will allow oil in the crankcase to enter suction lines and it takes some time for this oil to return to the crankcase While the drawer can be serviced upside down to gain access to the compressor components the order in which the product is rotated is important With the drawer front closed and tapped shut t...

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