Zanussi ZERC 2620 Service manual

SERVICE MANUAL
REFRIGERATION
© ELECTROLUX HOME PRODUCTS S.p.A.
Spares Operations Italy
Corso Lino Zanussi, 30
I - 33080 PORCIA / PN (ITALY)
Fax +39 0434 394096
Publication no.
599 37 75-07
060824
ITZ/SERVICE/AA
TOTAL
NO FROST
FIFTY
Sliding Door
FACTORY: ZS
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CONTENTS
1. INTRODUCTION ..................................................................................................................................................5
2. AIR CIRCULATION..............................................................................................................................................8
3. REFRIGERATION CIRCUIT ................................................................................................................................9
4. ELECTRIC WIRING .......................................................................................................................................... 10
5. COMPONENTS ................................................................................................................................................. 12
5.1. Cooler compartment ................................................................................................................................... 12
5.1.a. Control panel............................................................................................................................................ 13
5.1.b. Electronic boards ..................................................................................................................................... 14
5.1.c. Power board ERF2050............................................................................................................................. 15
5.1.d. Display board ERF2000........................................................................................................................... 17
5.1.e. Air flow regulator (damper) ...................................................................................................................... 18
5.1.f. Cooler air temperature sensor .................................................................................................................. 19
5.2. Freezer compartment.................................................................................................................................. 20
5.2.a. Cold module ............................................................................................................................................. 21
5.2.b. Cold module fan....................................................................................................................................... 21
5.2.c. Defrosting heater...................................................................................................................................... 22
5.2.d. Thermal switches ..................................................................................................................................... 22
5.2.e. Freezer door switch ................................................................................................................................. 22
5.2.f. Freezer air temperature sensor ................................................................................................................ 23
5.2.g. Connection box ........................................................................................................................................ 24
6. OPERATION ..................................................................................................................................................... 25
6.1. Normal......................................................................................................................................................... 25
6.2. Defrosting.................................................................................................................................................... 26
6.3. SUPER Function (rapid freezing)................................................................................................................ 27
6.4. SHOPPING Function (rapid cooling) .......................................................................................................... 27
6.5. Cooler compartment switching off............................................................................................................... 27
6.6. Malfunctioning of cooler temperature sensor.............................................................................................. 28
6.7. Malfunctioning of freezer temperature sensor ............................................................................................ 29
7. ALARMS ........................................................................................................................................................... 30
7.1. Freezer compartment temperature alarm ................................................................................................... 30
8. ACCESSIBILITY TO COOLER COMPARTMENT ........................................................................................... 31
8.1. Air flow regulator (damper) ......................................................................................................................... 31
9. ACCESSIBILITY TO FREEZER COMPARTMENT.......................................................................................... 33
9.1. Battery evaporator ...................................................................................................................................... 33
10. TROUBLESHOOTING .................................................................................................................................... 36
10.1. Excessive ice formation on the battery : ................................................................................................... 36
10.2. Failed defrosting: ...................................................................................................................................... 36
11. SERVICE MODE ............................................................................................................................................. 37
11.1. Starting SERVICE MODE ......................................................................................................................... 37
11.2. Exiting SERVICE MODE........................................................................................................................... 37
11.3. Functions of the SERVICE MODE............................................................................................................ 37
12. DISPLAY SYMBOLS ...................................................................................................................................... 39
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1. INTRODUCTION
This manual describes the TOTAL NO FROST refrigerators with Sliding Door system produced in the Susegana
factory called ZS.
These models feature:
-
Total No Frost (freezer: no frost; cooler: no frost)
Built-in
Single-compressor
Electronic control (electronic board ERF2050)
LCD display (liquid crystal digit)
They are appliances (KBIN 260 IT SD) with the following PNCs:
PNC
92569770000
92569770100
92569770200
MODEL
ERF2620
ERF2620
ZI918/9FFA
BRAND
Electrolux
Electrolux
Zanussi
The controls of the appliance are inserted in the higher part of the cooler compartment.
The power control board is ERF2050.
The user interface board is ERF2000 (LCD display)
The appliance is a single-compressor one, but it is possible to switch off only the cooler compartment through
the temperature regulation knob (position 0).
The temperature regulation is the following:
ƒ
from +8 to +2 °C for the cooler
ƒ
from -15 to -24 °C for the freezer
The appliance has the following functions:
ƒ
ƒ
ƒ
rapid freezing
rapid cooling
freezer temperature alarm
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The appliance consists of the following compartments:
ƒ
ƒ
freezer;
cooler;
The evaporating system consists of:
ƒ
battery cold module (freezer compartment);
A
Key:
A = control panel
B = cooler compartment
C = cold module
D = freezer compartment
B
C
D
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The temperature detection of the cooler compartment is carried out by 1 sensor:
ƒ
cooler temperature sensor (located inside the air vent grid)
The temperature detection of the freezer compartment is carried out by 1 sensor:
ƒ
freezer temperature sensor (located inside the freezer cell)
The defrosting of the battery evaporator is controlled by the electronic board through the temperature detection
of the sensors and the detection of the door opening.
A
Key:
A = cooler temperature sensor
B = freezer temperature sensor
B
The temperature sensors A and B feature the foamed cable inside the cabinet, therefore they are not
replaceable.
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2. AIR CIRCULATION
Unlike in the PARTIAL NO FROST refrigerator, in the TOTAL type the cooler and the freezer communicate each
other, therefore the battery evaporator cools both compartments.
The cold produced by the battery evaporator in the freezer compartment is distributed by the F fan placed
behind the cold module.
Cooler compartment air flow: the cold air is pushed by the fan into the foamed duct and exits from the air flow
regulator (damper) E located in the rear part of the diffuser-lamp holder. The air returns in the freezer
compartment by means of some foamed ducts entering the air vent grids G.
Freezer compartment air flow: the cold air is pushed into the compartment through the air screen and returns
into the cold module through the front air vent grid.
E
G
F
In case of opening of the freezer or cooler door, the fan stops.
To simulate the door closet use a magnet and put it next to the reed element placed on the
intermediate crosspiece or to the reed element placed on the electronic board.
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3. REFRIGERATION CIRCUIT
Key:
1.
2.
3.
4.
5.
6.
7.
compressor;
condenser;
anti-condensation coil;
dehydrator filter;
capillary;
battery evaporator (freezer compartment);
exchanger.
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4. ELECTRIC WIRING
( Check the specific diagram for each model ! )
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Key:
3.
5.
9.
13.
16.
24.
41.
52.
56.
57.
compressor
motor protector
defrosting heater
lamp
freezer door switch
battery evaporator fan
electronic board ERF 2050
air flow regulator (damper)
cooler air temperature sensor
freezer air temperature sensor
a. yellow-green;
b. brown;
c. blue;
d. white;
e. black;
f. grey;
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5. COMPONENTS
5.1. Cooler compartment
B
A
D
C
Key:
A.
B.
C.
D.
control panel
reed element for cooler door switch
cooler air temperature sensor
air flow regulator (damper)
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5.1.a. Control panel
Key:
A.
B.
C.
D.
E.
F.
ON/OFF button
Freezer temperature regulation knob
Temperature display button
Temperature and function display
Function activation button (freezer compartment temperature alarm reset)
Cooler temperature regulation knob
1.
2.
3.
4.
5.
6.
cooler symbol
freezer symbol
temperature indicator (sign – or +)
temperature indicator
SUPER function (rapid freezing)
SHOPPING function (rapid cooling)
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5.1.b. Electronic boards
The electronic board of the appliance consists of:
1. power board ERF2050
2. display board ERF2000
The two electronic boards are connected by means of a flat cable with a connector; therefore, the two boards
are available singularly as spare part.
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5.1.c. Power board ERF2050
- View of the electronic board (side of components):
1.
2.
3.
4.
5.
6.
7.
8.
9.
earth contact;
free;
line;
compressor;
neutral;
neutral;
lamp;
neutral;
defrosting heater;
1. fan;
2. fan.
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1.
2.
3.
4.
5.
6.
7.
8.
free;
free;
free;
free;
damper;
damper;
damper;
damper.
1. free;
2. free;
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1.
2.
3.
4.
5.
6.
cooler sensor;
cooler sensor;
free;
free;
freezer sensor;
freezer sensor;
1.
2.
3.
4.
free;
free.
free;
free;
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1.
2.
3.
4.
free;
free.
freezer door switch;
freezer door switch;
5.1.d. Display board ERF2000
Key:
SW1
SW2
SW3
SW4
LCD
POT1
POT2
NTC1
= function activation button (freezer temperature alarm reset);
= ON/OFF button;
= temperature display button;
= reed element;
= liquid crystal display;
= freezer temperature regulation;
= cooler temperature regulation;
= room temperature sensor (not used);
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5.1.e. Air flow regulator (damper)
The temperature regulation of the cooler compartment occurs by means of the passage or not of cold air from
the damper, which can have only 2 fixed positions, opened or closed.
The air flow regulator (damper) 1 is located inside the lamp holder diffuser 2.
1
2
The damper consists of a door and a stepping motor and it is connected to the electric wiring by means of a 4pole connector.
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5.1.f. Cooler air temperature sensor
The cooler air temperature sensor is located inside the air vent grid.
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5.2. Freezer compartment
A
B
D
C
Key:
A.
B.
C.
D.
freezer door switch magnetic sensor
freezer door switch reed element
freezer temperature sensor (foamed inside the cell)
cold module
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5.2.a. Cold module
3
2
1
Key:
1 = cut-out defrosting and safety switches
2 = cold module fan
3 = cold module defrosting heater
Note: The cut-out defrosting and safety switches ( +8 / +40 °C ) are connected together, therefore they are not
available as single spare parts.
5.2.b. Cold module fan
The fan is located behind the cold module.
The air is intaken by the fan, therefore, in case of its replacement, ensure that the air is forced towards the cell
bottom.
The fan has the following characteristics:
-
power 240 V
voltage 3,1 W
speed 2000 rpm
The fan stops in case of opening of the freezer or cooler door.
To simulate the door closed, use a magnet and put it next to the magnetic sensor placed on the
intermediate crosspiece or the magnetic sensor placed on the electronic board.
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5.2.c. Defrosting heater
The defrosting heater is used to defrost the ice that has accumulated on the battery evaporator.
The balancing heater has the following values:
-
power 274 W
voltage 240 V
resistance 210 Ohm
5.2.d. Thermal switches
The thermal cut-outs are positioned in direct contact with the battery evaporator.
They switch off the defrosting heater respectively at:
ƒ
+8 °C cut-out defrosting switch (cable colour: black - blue)
ƒ
+40 °C cut-out safety switch (cable colour: black - white)
TYPE OF THERMAL
OVERLOAD CUT-OUT
DEFROSTING
SAFETY
CUT-IN TEMPERATURE
OPENING
CLOSING
+ 8 °C
- 1 °C
+ 40 °C
+ 30 °C
Note: The cut-out defrosting and safety switch ( +8 / +40 °C ) are connected together, therefore they are not
available as single spare parts.
5.2.e. Freezer door switch
The control of the freezer door opening is carried out by a magnetic switch located inside the intermediate
crosspiece.
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5.2.f. Freezer air temperature sensor
The freezer air temperature sensor is foamed inside the cell (see S figure).
S
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5.2.g. Connection box
The connectors are in the box located inside the freezer:
1. fan (white cables)
2. thermal switches and defrosting heater (cables: brown and blue).
1
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6. OPERATION
6.1. Normal
Warning: unplug the appliance before operating.
In case of first switching on with a freezer compartment temperature higher then 10 °C, the appliance operates
with a test cycle (for the factory) for a maximum time of about 1,5 hours. In this period do not check the correct
functioning of the appliance, since the loads are activated only for internal check (compressor, fan, defrosting
heater, damper).
When the appliance is (OFF) then:
ƒ
ƒ
ƒ
the compressor is off
the fan is off
the is display off
Pushing the ON/OFF button, the LCD display switches on with the following displaying:
ƒ
ƒ
ƒ
sign +
red display background
freezer compartment temperature alarm (buzzer active)
Push the function activation button to deactivate the buzzer.
Regulate the compartment knobs so as to set the following temperatures:
ƒ
about +5 °C in the cooler
ƒ
about -18 °C in the freezer
In NO FROST refrigerators, 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 and the fan circuit. The fan and
compressor operation is independent (the fan is on only when the compressor is on).
The fan is 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 72 hours if the doors are never opened!).
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6.2. 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 72 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 immediately disconnects the circuit which powers the compressor after 2 minutes the fan,
waits 3 minutes and then it powers the circuit of the defrosting heater for a minimum time of about 20 minutes.
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 electronic board checks the state of the thermal switch every minute to detect the cut-out.
When the defrosting switch cuts-out, and anyway after 20 minutes, the electronic board switches the compressor
on with a 5 minute delay.
After 3 minute delay, when the air is already cold, the fan switches on too.
If for any reason, the defrosting cut-out switch does not switch on and the battery temperature rises up to 40 °C,
the defrosting heater will be switched off by the safety thermal switch.
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.
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6.3. SUPER Function (rapid freezing)
The SUPER function (rapid freezing) is activated by pushing the function button till the symbol
therefore:
ƒ
ƒ
appears,
the relative symbol SUPER is displayed;
the compressor operates in thermostatic conditions and not continuously (as the temperature knob was
on max. position) for a duration of about 52 hours, and then it deactivates automatically.
To deactivate the SUPER function push the function activation button till the symbol
disappears.
With the SUPER function the defrosting heater is powered.
With the SUPER function some fixed defrosting can anyway occur depending on how much time has elapsed
after the last defrosting.
6.4. SHOPPING Function (rapid cooling)
The SHOPPING function (rapid cooling) is activated by pushing the function button till the symbol
therefore:
ƒ
ƒ
appears,
the relative symbol SHOPPING is displayed;
the compressor operates in thermostatic conditions and not continuously (as the temperature knob was
on max. position) for a duration of about 6 hours, and then it deactivates automatically.
To deactivate the SHOPPING function push the function activation button till the symbol
disappears.
6.5. Cooler compartment switching off
The refrigerator compartment can be switched off by turning the temperature regulation knob to 0.
The display shows OF.
The air flow regulator (damper) is closed and the lamp remains off also if the door is open.
Note: in order to avoid bad odours inside the cooler, the damper is open and closed immediately at intervals of
about 20 minutes.
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6.6. Malfunctioning of cooler temperature sensor
If during the normal operation a failure occurs to the cooler NTC temperature sensor (the signal coming from the
sensor is out of range), pushing the function activation button:
ƒ
The display shows cooler temperature sensor faulty
ƒ
The air flow regulator (damper) has the following operation:
™ open when the compressor is on
™ closed when the compressor is off
When the sensor operates again normally, the above described conditions terminate.
Characteristics of the NTC sensor:
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6.7. Malfunctioning of freezer temperature sensor
If during the normal operation a failure occurs to the freezer NTC temperature sensor (the signal coming from
the sensor is out of range), pushing the function activation button:
ƒ
The display shows freezer temperature sensor faulty
ƒ
The appliance operates with a predefined cycle, therefore the compressor is switched on for 40 minutes
and off for 40 minutes alternatively
ƒ
The defrosting procedure is activated every about 14 hours
Characteristics of the NTC sensor:
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7. ALARMS
7.1. Freezer compartment temperature alarm
When the freezer compartment reaches -11 °C, the temperature alarm activates:
ƒ
The LCD display background is red;
ƒ
The freezer symbol flashes;
ƒ
The temperature digits flash;
ƒ
The buzzer sounds.
Push the function activation button to deactivate the buzzer.
When normal conditions are reset (after a power failure):
ƒ
The acoustic signal deactivates;
ƒ
The temperature digits flash;
ƒ
The display lighting is red.
Pushing the function activation button:
ƒ
The highest temperature reached in the freezer compartment is displayed for 5 minute;
ƒ
The display red lighting switches off.
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8. ACCESSIBILITY TO COOLER COMPARTMENT
Warning: unplug the appliance before operating.
8.1. Air flow regulator (damper)
To access the air diffuser and its components (air flow regulator and lamp holder) perform the following
operations in sequence:
a) Remove the lamp cover pushing the hook
c) Remove the 2 upper fixing screws
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b) Remove the filter support pulling it downwards
d) Remove the 2 front fixing screws
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e) View of the lamp holder
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f) The damper is fitted with 2 screws and is connected
to the electric wiring through a 4-pole connector
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9. ACCESSIBILITY TO FREEZER COMPARTMENT
Warning: unplug the appliance before operating.
9.1. Battery evaporator
To access the battery evaporator and its components (fan, defrosting heater, door switch, and thermal switches)
perform the following operations in sequence:
a)
Remove the drawers and the grids
b) Remove the 3 screw covers
c) Remove the 3 fixing screws of the evaporator
shield
d) Remove the cover of the connection box
e) Detach the 2 connectors of the fan and of the
defrosting heater
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f) Release the 3 lower hooks of the air vent grid
g) Insert a screwdriver inside the slot
h) Insert the edge of the screwdriver and turn it
towards the direction of the arrow
i) Extract the cold module
l) Thermal switch connectors
m) Thermal switches
Note:
The defrosting cut-out and safety thermal switches
(+8 / +40°C) are connected together, therefore they
are not available as single spare parts.
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n) The fan is fitted to the support which is extracted
from the cold module
In case of replacement of the fan it is necessary to ensure that the fan draws in air.
Note:
If to be able to extract the cold module the pipes are too short, it is necessary to release and turn the condenser
and the compressor as indicated in figure:
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10. TROUBLESHOOTING
WARNING !
Unplug the appliance before operating.
10.1. 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.
10.2. Failed defrosting:
In case of failed defrosting, the possible causes are:
Sequence
no.
1
POSSIBLE
CAUSES
The
defrosting
heater
is
interrupted
2
One
or
both
switches of the
thermal protectors
are open
HOW TO CONTROL
SOLUTION
Unplug 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 assembly.
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11. SERVICE MODE
11.1. Starting SERVICE MODE
To start the procedure perform the following operations:
1.
2.
3.
4.
5.
Connect the plug to the socket.
Switch on the appliance with the ON/OFF button.
Open the doors of the appliance.
Switch the appliance off with the ON/OFF button.
Within the first 10 seconds hold down the two buttons “temperature displaying” and “function activation”
simultaneously.
The confirmation of the procedure start occurs with the acoustic signalling of the buzzer which emits a long beep
and with the lighting up of the LCD display.
11.2. Exiting SERVICE MODE
The procedure terminates when one of the following conditions is satisfied:
a. The plug is detached from the socket and replugged.
b. 40 minutes have elapsed and no button has been pushed.
c. The last phase of the procedure has been reached.
11.3. Functions of the SERVICE MODE
Press the “displaying temperature” button to skip to the following phase of the procedure.
Press the “ON/OFF” button to activate/deactivate the loads (compressor, defrosting heater, lamp, fan and air
flow regulator).
List of the phases of the SERVICE MODE:
1. All the segments of the display are on.
2. All the segments of the display are off.
3. The number +0 is shown on the display and the load controlled by the ACS TH1 [compressor] is
checked.
To activate/deactivate the load press the “ON/OFF” button (the load is activated when the SUPER
is displayed).
function symbol
4. The number +1 is displayed and the load controlled by ACS TH2 [defrosting heater] is checked.
To activate/deactivate the load press the “ON/OFF” button (the load is activated when the SUPER
is displayed).
function symbol
5. The number +2 is shown on the display and the load controlled by the ACS TH3 [lamp] is checked.
To activate/deactivate the load press the “ON/OFF” button (the load is activated when the SUPER
function symbol
is displayed).
6. The number +3 is shown on the display and the load controlled by the ACS TH4 [fan] is checked.
To activate/deactivate the load press the “ON/OFF” button (the load is activated when the SUPER
function symbol
is displayed).
7. The number 00 (= damper closed) or 0F (= damper open) is shown on the display and the air flow
regulator (damper) is checked.
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To activate/deactivate the load press the “ON/OFF” button (the load is activated when the SUPER
function symbol
8.
9.
10.
11.
is displayed).
Note: when the procedure skips to the following phase pressing the button “temperature displaying”, the
load maintains its status (for example if the compressor had been activated it will remain active also in
the following phase. In this way it is possible to check the loads simultaneously.
Check of the doors. The display digits correspond to the doors: the unit digits correspond to the cooler
door, while the ten digits correspond to the freezer door. If the relative door is closed, the displayed digit
is 0 otherwise is 1.
Check of the potentiometers. Turning the knobs, the display shows the digits from 00 to 07 (from MIN to
MAX position).
Check of the counter. The display shows an increasing number at intervals of 1 second. This is a
counter used by the board for its internal management. At the same time, the display background
changes from red to blue.
Check of the temperature sensors. The display shows one of the following codes:
code
E0
E1
E2
E4
E5
description
No error
Evaporator sensor faulty
Ambient temperature sensor faulty (installed on the display board)
Ambient temperature sensor faulty (installed on the power board)
0 degree compartment sensor faulty
Note: the error regarding the cooler and freezer air sensors are already displayed during the normal
operation.
At this point all the phases necessary to check the loads have been displayed, therefore it is advisable to
interrupt the SERVICE MODE procedure unplugging and replugging the appliance.
Note: if you do not want to interrupt the SERVICE MODE, the procedure continues with some phases
dedicated exclusively to the factory, therefore they have not been considered.
Also in this case, the exit from the SERVICE MODE is carried out unplugging and replugging the
appliance.
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12. DISPLAY SYMBOLS
DISPLAY
DIGITS
DESCRIPTION
NOT FLASHING
Cooler compartment off (knob on 0)
NOT FLASHING
It indicates the cooler temperature with
normal function [from +2 to +8 °C]
NOT FLASHING
It indicates the freezer temperature with
normal function [from -15 to -24 °C]
NOT FLASHING
It indicates the cooler temperature with
SHOPPING function
NOT FLASHING
It indicates the freezer temperature with
SUPER function
FLASHING
It indicates the freezer temperature in alarm
condition
NOT FLASHING
It indicates the malfunctioning of the cooler
air temperature sensor
NOT FLASHING
It indicates the malfunctioning of the freezer
air temperature sensor
NOT FLASHING
NOT FLASHING
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It indicates incompatibility between the
electronic boards
Solution: check the spare part nos. of the
electronic boards
It
indicates
an
Eeprom
parameter
writing/reading error
Solution: replace both electronic boards
(power and display)
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