Zanussi Z1921/8 FFA Service manual

SERVICE MANUAL
REFRIGERATION
© ELECTROLUX HOME PRODUCTS S.p.A.
Spares Operations Italy
Corso Lino Zanussi, 30
I - 33080 PORCIA / PN (ITALY)
Publication no.
599 36 17-69
031119
ITZ/SERVICE/AA
Fax +39 0434 394096
PARTIAL NO FROST REFRIGERATOR with electronic timer
PARTIAL
NO FROST
REFRIGERATORS
With electronic
timer
2/30
CONTENTS
1. INTRODUCTION ..................................................................................................................................................5
2. REFRIGERATOR CIRCUIT .................................................................................................................................9
3. ELECTRIC WIRING .......................................................................................................................................... 10
4. FUNCTIONAL DIAGRAM ................................................................................................................................. 12
5. OPERATION ..................................................................................................................................................... 13
a. Normal............................................................................................................................................................ 13
b. Normal with first switching on or power failure .............................................................................................. 14
c. Defrosting ....................................................................................................................................................... 15
d. Flow chart for the defrosting management .................................................................................................... 16
e. SUPER function ............................................................................................................................................. 17
f. Malfunctioning of temperature sensor............................................................................................................. 18
6. ACCESSIBILITY FREEZER COMPARTMENT................................................................................................ 19
a. Battery evaporator and fan ............................................................................................................................ 19
7. ACCESSIBILITY TO CONTROL PANEL ......................................................................................................... 20
a. Power and display board ............................................................................................................................... 24
8. TROUBLESHOOTING ...................................................................................................................................... 27
a. Excessive ice formation on the battery: ......................................................................................................... 27
b. Failed defrosting:............................................................................................................................................ 27
c. Manual defrosting procedure ......................................................................................................................... 28
d. ON and SUPER LEDs flashing ...................................................................................................................... 29
9. TECHNICAL FEATURES ................................................................................................................................. 30
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1. INTRODUCTION
This manual describes the PARTIAL NO FROST refrigerators with electronic timer produced in the Susegana
factory called ZS.
These models differ from the previous ones (see SM 599321723) since they do not feature the electromechanic
timer because an electronic timer has been incorporated in the control and power board ERF1050-01.X (X
indicates a variant of the board).
It is a NO FROST (KBIN295 IT) appliance with the following PNCs:
PNC
92577170000
92577170100
92577170101
92577170200
92577170201
92577170300
92577170301
92577170400
92577170600
92577170700
92577170701
92577170900
Date
20031212
20040116
20040716
20031205
20040716
20040305
20040716
20040305
20040305
20040227
20040910
20040409
Model
JKG8498
SN81840-4I
SN81840-4I
329.059 6/40199
329.059 6/40412
SN71840-4I
SN71840-4I
ERF2831
ZI921/8FF
FI22/10NFA
FI22/10NFA
ZI921/8FF
Brand
Juno-Electrolux
AEG
AEG
Privileg
Privileg
AEG
AEG
Electrolux
Zanussi
Rex-Electrolux
Rex-Electrolux
Zanussi
The controls of the appliance are inserted inside the middle crossbar.
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The appliance consists of the following compartments:
ƒ
ƒ
freezer;
cooler;
The evaporating circuit consists of:
ƒ
ƒ
battery evaporator (freezer compartment);
tube evaporator (cooler compartment).
Key:
A = cooler compartment;
B = freezer compartment.
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Unlike the NO FROST refrigerators, in the PARTIAL NO FROST type the cooler and freezer compartments are
separated physically.
The battery evaporator cools only the freezer compartment, while the tube evaporator cools only the cooler
compartment.
The cold produced by the battery evaporator in the freezer compartment, is distributed by the fan placed behind
the screen C.
AIR FLOW
In case of door opening the fan stops.
To simulate the door closed, press the button of the freezer door.
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The temperature measurement of the cooler compartment is performed by 1 sensor:
ƒ
cooler temperature sensor (placed on the cooler cell).
The defrosting of the battery evaporator is controlled by the electronic board through the detection of the cooler
and freezer door openings:
ƒ
cooler door button (placed on the left upper part of the control panel)
ƒ
freezer door button (placed on the right lower part of the control panel).
Key:
A = cooler door button;
B = freezer door button;
C = control panel;
D = cooler temperature sensor.
The sensor D features the foamed cable inside the cabinet, therefore it is not replaceable.
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2. REFRIGERATOR CIRCUIT
Key:
1.
2.
3.
4.
5.
6.
7.
8.
compressor;
condenser;
anti-condensation coil;
dehydrator filter;
capillary;
battery evaporator (freezer compartment);
tube evaporator (cooler compartment);
exchanger.
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3. ELECTRIC WIRING
(check the specific diagram for each model!)
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Key:
3.
5.
9.
13.
15.
16.
24.
26.
27.
28.
41.
compressor;
motor protector;
defrosting heater;
lamp;
cooler door switch;
freezer door switch;
fan;
safety thermal switch (+40°C);
defrosting cut-out switch (+10°C);
running capacitor (only for the models which feature it);
electronic board.
a. yellow-green;
b. brown;
c. blue;
d. white;
e. black;
f. grey;
g. red;
h. orange.
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4. FUNCTIONAL DIAGRAM
(check the specific diagram for each model!)
Key:
3.
5.
9.
13.
15.
16.
24.
26.
27.
28.
41.
compressor;
motor protector;
defrosting heater;
lamp;
cooler door switch;
freezer door switch;
fan;
safety thermal switch (+40°C);
defrosting cut-out switch (+10°C);
running capacitor (only for the models which feature it);
electronic board.
a. yellow-green;
b. brown;
c. blue;
d. white;
e. black;
f. grey;
g. red;
h. orange.
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5. OPERATION
a. Normal
Warning: the electronic board is powered with a 220-240V 50Hz voltage even if the thermostat
knob is on (OFF) position. Therefore, disconnect the appliance from the electric power before
operating with the electronic board.
When the thermostat knob is on (OFF) position it means that:
ƒ
ƒ
ƒ
the compressor is off;
all Leds are off;
the electronic board is powered (220-240V 50Hz ! ! !).
Rotating the thermostat knob clockwise the green LED ON lights.
In NOFROST freezers, the humidity inside the freezer compartment accumulates on the evaporator battery
thanks to the air circulation, thus preventing the formation of frost on food.
During normal operation time the electronic board powers the compressor (3) and the fan (24) circuits.
The fan is activated or deactivated with a 2 minute delay compared to the compressor.
The operation time which corresponds to the interval between the following defrosting lasts about 14 hours with
normal opening of the door (it can last up to 71 hours if the door is never opened).
The arrows in the picture indicate the current path.
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b. Normal with first switching on or power failure
In case of fault when the appliance is switched on for the first time or in case of a power failure, one of the two
conditions described below occurs:
1. If the internal temperature is higher or the same as the thermostat cut-in temperature (CUT-IN),
when the power is restored, the electronic board activates the compressor and the fan till the set
temperature is reached and after 5 hours the electronic board activates the defrosting procedure
(after the compressor cut-out).
2. If the internal temperature is lower than the thermostat cut-in temperature (CUT-IN), when the
power is restored, the compressor functions in thermostatic conditions and after 5 hours the
electronic board activates the defrosting procedure (after the compressor cut-out).
The electronic board activates, in any case, the defrosting procedure 5 hours after the first switching on and after
a power failure.
Warning:
if the thermostat knob is turned anti-clockwise till the zero position (OFF), all
counters will be reset and once the thermostat knob has been rotated clockwise at
ON position, the compressor will function in thermostatic conditions.
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c. Defrosting
All the humidity in the compartment accumulates on the evaporator, which is the coldest part of the
compartment; periodically, about every 14 hours with normal door opening (up to 71 hours if the doors never
open!), it is then necessary to defrost the ice on the battery.
The defrosting starts after the compressor cut-out or if the compressor is on after 2,5 hours max.
The electronic board disconnects the circuit which powers the compressor (3) and the fan (24) and, after
controlling the presence of the defrosting heater, it powers the circuit of the defrosting heater (9) for a minimum
time of about 20 minutes. If the defrosting heater is interrupted or its connector is detached, the ON and SUPER
LEDs flash and the defrosting heater lasts 1 hour.
Important: If the defrosting heater is interrupted or its connector is detached, the ON and SUPER LEDs flash
and the defrosting phase lasts 1 hour.
Please refer also to Service Bulletin 599376174 since the failure signaling could be wrong due to a “bug” in the
software of the electronic board.
The heat generated by the defrosting heater does not affect the freezer compartment temperature or the food
packages temperature, because the thermal energy is consumed in the defrosting process of the evaporator ice.
After 20 minutes, the board detects the defrosting signal every minute to identify the defrosting switch cut-out
(27).
At the defrosting switch cut-out, the electronic board switches the compressor on (3) with a 5 minute delay.
After another 2 minute delay, when the air is already cold, the fan switches on too (24).
If for any reason, the defrosting cut-out switch (27) does not switch on and the battery temperature rises up to 40
°C, the defrosting heater (9) will be switched off by the safety thermal switch (26).
If 1 hour after the starting of the defrosting, the thermal switches did not cut out, the electronic board switches
the defrosting heater off and continues its operation.
The arrows in the picture indicate the current path.
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d. Flow chart for the defrosting management
POWER ON
Defrosting after 5 hours (after
the compressor cut-out or if the
compressor is ON after 2,5
hours max.)
YES
Is cooler or
freezer door
open?
see note #
NO
Defrosting after 14 hours (after the
compressor cut-out or if compressor
is ON after 2,5 hours max.)
Defrosting after 30 hours (after the
compressor cut-out or if the
compressor is ON after 2,5 hours
max.)
YES
YES
Cooler or freezer
door open?
see note #
NO
Is the time
less than 14
hours?
NO
Defrosting after 71 hours (after the
compressor cut-out or if compressor
is ON after 2,5 hours max.)
Defrosting (after the compressor
cut-out or if compressor is ON after
2,5 hours max.)
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NOTE #:
When the cooler or freezer door is open it means that one of the two doors is opened for more than 1 minute. At
every defrosting the time is cancelled.
e. SUPER function
The SUPER function is activated by pushing the SUPER button therefore:
ƒ
ƒ
The yellow LED corresponding to the SUPER function is on;
The compressor functions in thermostatic conditions and not continuously (as the thermostat knob were
in max. position) for a duration of about 52 hours, and then it deactivates automatically.
If the button is pressed again, the SUPER function is deactivated:
ƒ
ƒ
The corresponding yellow LED is switched off;
The compressor functions in thermostatic conditions.
The defrosting can occur with the SUPER function on.
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f. Malfunctioning of temperature sensor
If during the normal operation a failure of the NTC temperature sensor occurs (the signal coming from the sensor
is out of range), then:
ƒ
ƒ
The appliance functions with a pre-definite cycle where the compressor is powered for 30 minutes and
remains off for 45 minutes alternatively;
The defrosting procedure is activated every about 14 hours.
When the sensor operates again normally the above two mentioned conditions are cancelled.
NTC sensor characteristics:
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6. ACCESSIBILITY FREEZER COMPARTMENT
a. Battery evaporator and fan
To access the battery evaporator and the fan perform the following operations:
a) Remove the freezer drawers;
b) Remove the fixing screws of the evaporator shield;
remove the isolating panel;
c) components:
A)
B)
C)
D)
E)
F)
Battery evaporator;
Fan;
Thermal switches connectors +10 / +40 °C;
Defrosting heater connector;
Fan connector.
Defrosting heater.
In case of replacement of the fan it is necessary to ensure that the fan does NOT function with
the suction.
Note:
The thermal switches (+10 / +40°C) are connected together therefore they are not available as single spare
parts.
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7. ACCESSIBILITY TO CONTROL PANEL
To access the control panel and its components (power/display board, cooler/freezer switches and electric
connectors) perform the following operations:
a) components:
A)
B)
C)
D)
E)
F)
Battery evaporator;
Fan;
Thermal switches connectors +10 / +40 °C;
Defrosting heater connector;
Fan connector.
Defrosting heater.
c) Remove the hinge cover of the opposite side of
where the hinge is placed by using a cutting
screwdriver as indicated in picture;
b) Remove the hinge cover of the opposite side of
where the hinge is placed by using a cutting
screwdriver as indicated in picture;
d) Remove the hinge cover of the opposite side of
where the hinge is placed by using a cutting
screwdriver as indicated in picture;
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e) Remove the hinge cover of the opposite side of
where the hinge is placed by using a cutting
screwdriver as indicated in picture;
f) Remove the hinge cover of the opposite side of
where the hinge is placed by using a cutting
screwdriver as indicated in picture;
g) Remove the fixing screws of the control panel;
h) Remove the control panel from the intermediate
crossbar;
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a) While remounting the control panel be careful with
the wiring because it could interfere with the board
connectors;
b) Remove the wiring as indicated in picture;
c) Put the control panel close to the intermediate
crossbar and keep the wiring aside;
d) Put the control panel close to the intermediate
crossbar and keep the wiring aside;
IMPORTANT: to avoid the liquid infiltrations there are some adhesive gaskets ( A and B ) and a
polyester boss inside the control panel.
In case of replacement of the components of the control panel it is obligatory to put the gaskets
and the boss at the same place.
The adhesive gasket A must be applied only on the cooler door button.
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g) components:
A)
B)
C)
D)
E)
F)
G)
Electronic board;
Connector J1 electronic board supply and compressor control;
Connector J2 components supply (fan, defrosting heater and lamp);
Connector J3/J6 temperature sensor;
Connector J7 cooler and freezer door switch;
SUPER button;
Electronic thermostat knob.
IMPORTANT: the electronic board features a protection that ensure that the compressor does
not switch on before than 5 minutes from the last switching off !
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a. Power and display board
- View of the electronic board (welding side):
Optional components:
- A reed element
1.
2.
3.
4.
compressor
free
line
neutral
1.
2.
3.
4.
5.
lamp
neutral
neutral
defrosting heater
fan
1. NTC
2. NTC
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1. NTC
2. free
3. NTC
1.
2.
3.
4.
freezer door switch
freezer door switch
freezer door switch
freezer door switch
To identify the functions of the electronic boards, please refer to the following table (for the part nos. see the
spare part lists of the specific model):
Electronic board
Thermal
Buzzer
ERF1050-01.F
B
NO
Thermal
type
B
Pos. min
Cut-in
Cut-out
[°C]
[°C]
+11.5
+8
Green
LED
YES
Pos. int
Cut-in
Cut-out
[°C]
[°C]
+8
+5
Yellow
LED
YES
Red
LED
NO
Reed
element
NO
SUPER
button
YES
Pos. max
Cut-in
Cut-out
[°C]
[°C]
+4.5
+3
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8. TROUBLESHOOTING
WARNING !
Switch off the power to the appliance before operating.
a. Excessive ice formation on the battery:
If the rubber valve remains open, the humid air outside the freezer compartment is ducted inside and it
accumulates too much ice on the battery. The valve remains open if there are foreign bodies or if it looses
elasticity; therefore, in the first case the foreign bodies must be removed, while in the latter the rubber valve must
be replaced.
b. Failed defrosting:
In case of failed defrosting, the possible causes are:
Sequence
n°
1
POSSIBLE
CAUSES
The
defrosting
heater
is
interrupted
2
One
or
both
switches of the
thermal protectors
are open
HOW TO CONTROL
SOLUTION
Detach the power plug of the
appliance, remove the connector of the
heater and verify with the tester the
correct resistance value to the
connector clamps
Frost the battery, then detach the
power plug of the appliance, remove
the connector of the thermal switches
and verify with the tester the correct
resistance value to the connector
clamps
If the resistance value does not
correspond to the technical data,
replace the heater
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If the resistance value does not
correspond to 0 (zero Ohm) replace
the thermal switches
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c. Manual defrosting procedure
To execute the testing and the service, a manual defrosting procedure has been introduced that has to be
carried out with cold internal temperatures (this is to avoid the possible opening of the thermal protector of the
defrosting heater).
To start the manual procedure, ensure that:
ƒ
the electronic board is powered with thermostat knob ON, position 5 (or anyway in a position between
90° and 270°);
ƒ
the cooler door switch must be pressed (door closed).
Perform the 3 following operations:
1. turn the thermostat knob to OFF position;
2. press the cooler door switch for 4 times (let pass at least 1 second between every opening/closure);
3. turn the thermostat knob to ON, position 5 (or anyway to a position between 90° and 270°);
At this point the electronic board verifies the thermal cut-outs and all LEDs flash for 5 seconds; then if there
aren’t any faults, the manual defrosting phase starts. If a fault occurs, the LEDs continue to flash.
WARNING: after placing the thermostat knob in OFF position (operation 1), there are 15 seconds to perform the
other 2 operations (operation 2-3) in the correct sequence.
In case of error or incorrect execution of the operations, before executing once again the manual defrosting
procedure, it is necessary to reset the standard functions switching off the power to the appliance (detach the
power cable).
The manual defrosting phase consists of:
ƒ
ƒ
ƒ
defrosting heater ON;
green ON/OFF LED on;
compressor and fan OFF;
In this case the electronic board performs the defrosting phase as a standard function and then continues to
operate normally.
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Available time
ON
Thermostat knob
OFF
open
Cooler door
closed
ON
Defrosting phase
OFF
ON
Green LED
Yellow LED
OFF
Key:
T = 15 seconds;
t = 5 seconds (to check thermal protections);
F = standard function.
d. ON and SUPER LEDs flashing
The ON and SUPER LEDs flash and the defrosting phase lasts 1 hour if the defrosting heater is interrupted or its
connector is detached.
Please refer also to Service Bulletin 599376174 since the failure signaling could be wrong due to a “bug” in the
software of the electronic board.
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9. TECHNICAL FEATURES
1) fan:
Type
Voltage
[V – Hz]
220 - 50
F64-10..
Power
[W]
3,1
Speed
[rpm]
2000
2) Power and display board:
Software version
B100
Board version
ERF1050-01.F
3) Defrosting heater:
Voltage
[V]
240
Resistance
[Ohm]
510
Power
[W]
113
4) Thermal switches:
Type of thermal protector
DEFROSTING
SAFETY
Cut-in temperature
Opening
Closing
+ 10 °C
- 1 °C
+ 40 °C
+ 30 °C
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