Dometic RM182B Service manual

DOMETIC
Dometic
MANUAL REFRIGERATOR
DIAGNOSTIC SERVICE
MANUAL
The Dometic C o r p o r a t i o n
2320 Industrial Parkway
Elkhart, IN 46515
219-295-5228
Corporate Office
Warranty
Department
205 E. Fenn St.
LaGrange, IN 46761
219-463-2191
Technical Services
509 S. Poplar St.
LaGrange, IN 46761
219-463-4858
Department
OS1286 8/89
D-l
Diagnostic Service
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia
T25Manuals
/ T3 / Vanagon campers
NOTES:
www.westfaliaT3.info - a useful site for enthusiasts andD-2owners of VW Westfalia T25 / T3 / Vanagon campers
MANUAL REFRIGERATOR
DIAGNOSTIC SERVICE ‘MANUAL
Table of Contents
Page
Diagnostic Flow Charts
No Operation . . . . . . . . . . . . .
D-4-l
No 12OV AC Operation . . . . . . . . .
D-4-2
No Gas Operation (Piezo Igniter)
D-4-3
. . . .
No Gas Operation (Automatic Reigniter)
..
D-4-4
Operation and Diagnosis
......
D-6- 1
. . . . . . . . . . . .
D-8-l
Dometic M a n u a l R e f r i g e r a t o r s .
Glossary
of
Service Bulletins
Terms
.
.
.
.
.
.
.
.
.
.
.
.
D-9-l
D-3
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
MANUAL REFRIGERATOR
DIAGNOSTIC FLOW CHART
NO OPERATION
A.
1
Check Supply Voltage
I~>1C o r r e c t
1. 110 Volt Plug
2. Wire Size
as
Necessary
OK
B.
V
Check Fuse
NOT OK
Correct as Necessary
> Replace if Defective
OK
C.
\/
> Correct as Necessary
Check wiring
NOT OK
1
OK
D.
Check Switch
> Correct as Necessary
NOT OK
(Page D-6-20, Para. 66)
OK
E.
V
Check Thermostat
NOT OK
, Correct as Necessary
’ Continuity Check
D-4-l
www.westfaliaT3.info - a useful site for enthusiasts and owners
of VW Westfalia T25 / T3 / Vanagon campers
MANUAL REFRIGERATOR
DIAGNOSTIC FLOW CHART
NO 120 VOLT AC OPERATION
A.
1.
2.
3.
4.
Check AC Power
Refrigerator Plugged in ~=I i Correct as Necessary
Breaker
Coach Plug
OK
B.
w
Check Selector Switch
NOT OK
Correct as Necessary
(Page D-6-20, Para. 66)
OK
c .
V
Check Thermostat
NOT OK
D.
IIf
Correct as Necessary
Continuity Check
OK
Check 120 Volt Heater
NOT OK
D-4-2
Correct as Necessary
B Ohm’s Reading
Bulletin #28
(Page D-9-l 4, D-9-l 5)
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
MANUAL REFRIGERATOR
DIAGNOSTIC FLOW CHART
NO GAS OPERATION - Models Equipped with Piezo igniter
9
.
Check Gas Supply
OK
B.
v
Check Switch
Correct as Necessary
(Page D-6-20, Para 66)
>
NOT OK
I
OK
.C.
Check Thermostat
NOT OK
Correct as Necessary
=> Continuity Check
OK
V
D.
Check Gas Pressure
NOT OK
Correct as Necessary
(Page D-6-13, Para. 37)
>
OK
>
Check Flue & Burner
NOT OK
I
Correct as Necessary
No Obstructions
OK
F.
Check Piezo Resistance
Correct as Necessary
(Page D-6-l 8, Para. 58)
>
NOT OK
I
V
G.
OK
r
Para Replace Electrod
> (Page D-6-18, Para. 58)
Check Piezo Electrode
NOT OK
I
OK
,H.
V
Check Spark Gap
of Electrode to Burner
NOT OK
D-4-3
>
Correct as Necessary
(Page D-6-19, Para. 62)
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
MANUAL REFRIGERATOR
DIAGNOSTIC FLOW CHART
NO GAS OPERATION - Models Equipped with Automatic Reigniter
A.
Check Gas Pressure
NOT OK
> Correct as Necessary
(Page D-6-13, Para 37)
I
OK
V
B.
Check Gas Supply
>
Correct as Necessary
(Page D-6-14, Para. 40)
NOT OK
I
C.
I
v
OK
Check 12 Volt D.C.
Supply
> Correct as Necessary
NOT OK
I
I
OK
Check Switch
NOT OK
I
B
Correct as Necessary
(Page D-6-20, Para. 66)
OK
_E.
Check Thermostat
NOT OK
> Correct as Necessary
Check for Continuity
OK
F.
V
Clean Assembly &
> Orifice as Necessary
Check Flue & Burner
NOT OK
I
,G.
I
OK
V
Check Electrode
>
Replace Electrode
(Page D-6-19, Para. 62)
NOT OK
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
NOTES:
D-5
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
OPERATION & DIAGNOSIS
OF
DOMETIC
MANUAL REFRIGERATORS
D-6-1owners of VW Westfalia T25 / T3 / Vanagon campers
www.westfaliaT3.info - a useful site for enthusiasts and
(1)
This is Dometic’s Manual Refrigeration Diagnosis and Troubleshooting program. In this program
we will discuss the way an absorption cooling unit operates, and the diagnostic procedures
used to troubleshoot the complete refrigerator system.
(2)
Before we begin extensive troubleshooting
procedures on the cooling unit, let’s take a few
minutes to see how it operates.
THE ABSORPTION SYSTEM
(3)
The sealed combustion unit contains a
mixture of ammonia, water and a rust
inhibiting agent. After this solution is
introduced into the coils, this unit is
pressurized with hydrogen gas. When
this system is in operation, the ammonia vaporizes in the hydrogen atmosphere and absorbs heat from inside
the refrigerator.
EVAPORATOR
GAS
TEMPERATURE
EXCHANGER
Lil I
ABSORBER
VESSEL
BOILER
.
www.westfaliaT3.info - a useful site for enthusiasts andD-6-2
owners of VW Westfalia T25 / T3 / Vanagon campers
(4)
\ PUMP
The cooling unit parts that accomplish this
‘cooling’ or heat extraction process, include the:
Boiler or Generator
/ BOILER
l------------WATER
SEPARATOR
-l
I
(5)
Condenser
I
I
I
I
GAS
TEMPERATUR
EXCHANGER
- - - - - - - - - - - -
_-.I
1
(6)
Evaporator
D-6-3
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
(7)
Absorber
ABSORBER
THE ABSORPTION SYSTEM
CONDENSER
EVAPORATOR
Because the self-contained cooling unit
does not utilize an electric compressor
or pump, the cooling coils can be operated from a variety of heat sources. LP
gas, 120 volts AC and 12 volts DC
heating elements are the most commonly used heat sources for recreational vehicle applications.
TEMPERATURE
EXCHANGER
TEMPERATURE
EXCHANGER
(9)
_
THREE REQUIREMENTS
FOR PROPER OPERATION
Before this cooling system can properly
extract heat from the cabinet of the
refrigerator, three requirements for proper refrigerator operation must be met.
These are precise heat, specified ventilation and proper leveling.
1. Level
2. Air Flow (Ventilation)
3. Heat
D-6-4
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
c---_-------____---------__----_-__-7
(10)
We will now take a closer look at how the
cooling unit functions in normal operation.
When proper heat is supplied to the boiler,
ammonia vapor is produced and rises in the
siphon pump, carrying with it a weak liquid
ammonia solution. As seen from this drawing,
the siphon pump, or pump tube, is an internal
arrangement within the boiler section. The boiler
section utilizes the ammonia-water liquid solution in the absorber and as it is heated, turns
the solution into a strong ammonia vapor, which
is needed to operate the system. This strong
ammonia vapor rises from the pump tube to the
condenser coil.
Any deviation from the listed amount of
heat to the absorption system will alter the
ammonia to water ratio, which, in turn, will
decrease the cooling unit’s overall efficiency.
The weak ammonia solution which remains
behind is diverted to the top of the absorber
coils to perform a function that we will discuss
in further detail later in the program.
I
I
I
WATER
1
ENSER
i
I------------------------~
PUMP
/
PI
(11)
The air that passes through the condenser fins,
from the venting system, removes heat from the
ammonia vapor, causing it to condense into a
strong liquid ammonia solution. As a liquid, it
then flows to the low temperature evaporator, or
freezer companment, where it comes into
contact with a hydrogen atmosphere. When this
occurs, the ammonia begins to evaporate which
draws heat from inside the freezer section, to
the rear of the cooling unit.
COLD INTERIOR
(12)
This heat is then dissipated out through the
upper vent, which allows the refrigerators
interior temperature to properly maintain food
storage requirements. Not all of the liquid
ammonia evaporates in the freezer. What is left
continues to evaporate as it flows to the high
temperature evaporator, or food storage compartment.
D-6-5
www.westfaliaT3.info - a useful site for enthusiasts and
owners of VW Westfalia T25 / T3 / Vanagon campers
I--
U 3)
As this process continues, the ammonia and
hydrogen vapors become intermixed and flow
downward into the absorber vessel. As the
ammonia vapor comes in close contact to the
liquid ammonia solution in the absorber vessel,
the ammonia is absorbed into the liquid
solution, allowing the hydrogen vapor to rise up
through the absorber coils. After this absorption
process, the vapor consists of mostly hydrogen
with some traces of ammonia.
I
1
I
I
I
I
I
I
-------
Ll_____i
(14)
To remove the remaining amounts of ammonia
vapor still present in the hydrogen, a
continuous flow of weak ammonia solution is
fed, by gravity, to the top of the absorber coil
from the boiler. As this weak ammonia solution
flows downward through the absorber, it
absorbs the ammonia vapor from the mixture,
allowing the hydrogen vapor to rise through the
absorber coil and return to the evaporator. With
the hydrogen returned to the evaporator and
the ammonia remixed into solution in the
absorber vessel, the cooling process can
continue.
I --- __-----(15)
Now that we have a basic understanding of
proper cooling unit flow and operation, let’s
take a step-by-step look at the three requirements for proper cooling unit operation. Please
note it is essential that these three requirements
be diagnosed before attempting to diagnose
the cooling unit. A problem with leveling, heat
input or ventilation may lead you to think that
the cooling unit is faulty, when actually it is not.
This causes an increased expense to you, the
customer, and valuable shop time is wasted
because of incorrect diagnosis, By following
and checking the three unit requirements, costly
diagnostic errors can be eliminated.
I
__A
THREE REQUIREMENTS
FOR PROPER OPERATION
1. Level
2. Air Flow (Ventilation)
3. Heat
www.westfaliaT3.info - a useful site for enthusiasts andD-6-6
owners of VW Westfalia T25 / T3 / Vanagon campers
(16)
THREE REQUIREMENTS
FOR PROPER OPERATION
1. Level
Since the absorption system utilizes no
mechanical pumps or compressors to circulate
the refrigerant within the system, proper leveling
is required to provide correct refrigerant flow in
the gravity-feed system. Without proper leveling,
refrigerant within the cooling coils will collect
and stagnate at certain areas. When this
happens the cooling process will stop.
(17)
On the older style cooling units equipped with
square boiler box covers, this condition can
cause permanent cooling unit failure. As we can
see from this drawing, square boiler box
cooling units utilize an exposed siphon pump
tube which will become excessively superheated in an out-of-level condition. This can
allow the rust inhibiting agent to chemically
break down and permanently block or restrict
the normal refrigerant flow through the pump.
Shaking, tipping or so called ‘burping the
refrigerator will not loosen or dislodge the
blockage. The only recommended service
procedure is to replace the cooling unit. To
prevent this occurrence, proper leveling is of
utmost importance when the RV is parked for
any length of time.
REFRIGERATOR IS TO BE LEVEL
(18)
LEVELS
To level these units, the spirit or bubble level
should be placed in the approximate front and
center of the floor of the freezer compartment.
The coach should then be positioned so that at
least 3/4 of the bubble is within the required
mark while the refrigerator is in operation.
REMEMBER: Failure to property level a square
boiler box can result in a lack of cooling or
permanent damage to the coding unit. W h e n
the vehicle is moving, leveling is not critical as
the rolling and pitching movement of the RV will
keep the solution in motion, preventing the
solution from accumulating in the piping.
- m
-_C==Z
_
-5
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
D-6-7
(19)
In recent years Dometic has engineered a new
type of cooling unit that utilizes an improved
siphon pump tube design which drastically
reduces the possibility of permanent damage to
the coils if operated in an out-of-level condition,
or too much heat is generated at the boiler
section. As we can see from this drawing, the
siphon pump tube is enclosed in the design
and is surrounded by a weak ammonia solution,
which will protect the pump tube from abnormally over-heating. This type of unit; however,
does not eliminate the need for proper leveling.
The unit still requires gravitational flow to
provide the proper cooling process, and if
leveling is outside the necessary limits, cooling
will dramatically slow down or stop completely.
The cooling coils are not normally damaged in
this fashion and once proper leveling is maintained, the cooling process will resume.
\ PUMP
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
(20)
Spirit or bubble levels are no longer being
supplied with the new style refrigerators as the
RV or vehicle only needs to be leveled so it is
comfortable to live in, with no noticeable sloping
of the floor or walls. For diagnosis, the new
style cooling units that incorporate the
protection boiler system, can be differentiated
from the older style coils by the shape and
design of the outer boiler box cover on the rear
of the cooling unit. These units will incorporate
a circular metal cover,
. . .
while the older style utilizes a square
shaped enclosure. We will discuss diagnosis
and troubleshooting of these units in more
detail later in the program.
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
(22)
The coach vent system must be able to provide
a way to direct the hot air, produced by the
action of the cooling unit, out away from the
installation of the refrigerator.
THREE REQUIREMENTS
FOR PROPER OPERATION
1. Level
2. Air Flow (Ventilation)
-------- -----
(23)
In a good installation there should be as little
open space as possible surrounding the sides
and top of the refrigerator to achieve proper air
flow. All potential dead air pockets should be
blocked or baffled to insure that heat from the
cooling unit won’t be trapped in these spaces
and reduce efficiency. In addition, the cooling
unit should be at least one inch from the
nearest surface made of combustible materials.
Please follow the installation manual for proper
dimensions and clearances.
RVIA requires that the refrigerator be
installed in such a manner as to provide
complete separation of the combustion system
and the interior atmosphere of the recreational
vehicle. This regulation requires all seams and
joints in the enclosure be sealed. The undercounter installation is different. The addition of
a metal chute the width of the enclosure, that
extends from the upper side vent, will help
eliminate the possibility of dead air pockets. It
helps direct the hot air out the exhaust vent.
The best method for venting the absorption
refrigerator is with a lower side vent and a roof
vent. Using proper Dometic vents will give you
sufficient intake and exhaust areas for ventilation
1
I
I
0" CLEARANCE
1" FROM
AIR FLOW
_.
,/‘,/, .i.,l I,,,, ,. n
/
I
I
- - - - - - - - - - - -
(24)
Heat application to the boiler section of the
cooling unit must be within the designed BTU’s.
Never oversize the heating element on AC or
DC power source. Always use the proper size
orifice for gas modes. As explained earlier, any
deviation will cause a potential cooling unit
failure.
I
I
I
J
THREE REQUIREMENTS
FOR PROPER OPERATION
1. Level
2. Air Flow (Ventilation)
3. Heat
www.westfaliaT3.info - a useful site for enthusiasts and
owners of VW Westfalia T25 / T3 / Vanagon campers
D-6-9
THE ABSORPTION SYSTEM
(25)
Three things must be remembered
when diagnosing a cooling unit:
First, circulation within the cooling unit is totally gravitational. This
means proper leveling is important.
Second, heat - created to boil
the ammonia - now has to be dissipated into the surrounding air. Heat
from the absorber and condenser must
also be dissipated so as to cool the
ammonia sufficiently.
Third, proper heat application at
the boiler section.
CONDENSER
EVAPORATOF
TEMPERATURE
EXCHANGER
BOILER
(26)
When diagnosing a cooling unit, remember this
is the only part we cannot field check with test
equipment, yet it is the simplest and quickest
part to diagnose.
DIAGNOSING
THE
COOLING UNIT
(27)
After the unit has been operating for
approximately one hour, carefully touch the unit
at the boiler box and the absorber area. These
areas should be approximately the same
of the ambient
temperature,
regardless
temperature. Equal heat between the boiler and
the absorber indicates the fluid circulation within
the unit is good.
TEMPERATURE
b
GOOD CIRCULATION
www.westfaliaT3.info - a useful site for enthusiasts andD-6-10
owners of VW Westfalia T25 / T3 / Vanagon campers
(28)
One of the faults with a cooling unit is
a blockage. This can happen when the
unit is operated off-ievel, or if too much
heat has been applied to the boiler
area. To the touch, this unit will be
extremely hot at the boiler with little
warmth at the absorber. In other words,
no circulation.
i_______________________________--________
T
G-- BOILER
(29)
This type of fault means a lost charge.
It is known as a ‘leaker’. To the touch,
this unit will be warm at the boiler and
extremely hot at the absorber. In this
condition we are still boiling ammonia
but have no hydrogen for evaporation.
HOT GAS ONLY
(30)
The following section of the program
examines the Dometic manual refrigerator’s gas and electrical systems.
Dometic refrigerators are designed for
both piezo and automatic ignition. Both
systems will be covered in this presentation.
WARM
BOILER
.__i
D-6-1 1
www.westfaliaT3.info - a useful site for enthusiasts and
owners of VW Westfalia T25 / T3 / Vanagon campers
UNDERSTANDING
THE
GAS SYSTEM
(31)
Let’s look at the current Dometic refrigerators
and see how the gas flows.
SHUT-OFF
VALVE
(32)
Gas flows from the gas line to the shut-off valve
and to the connection piece.
I
=cYz=zc
GAS LINE
CONNECTION
PIECE
(33)
into the combination gas and electric thermostat
(34)
COMBINATION
GAS & ELECTRIC
THERMOSTAT
W
SAFETY VALVE/
through the safety valve thermocouple
(35)
PRESSURE
TEST
HOUSING
v
”
test housing
D-6-12
www.westfaliaT3.info - a useful site for enthusiasts and
owners of VW Westfalia T25 / T3 / Vanagon campers
(36)
and onto the orifice and burner assembly.
Remember that except for the connection piece,
all fittings are O-ring sealed. Whenever the
system is separated the O-rings must be
replaced.
ORIFICE & BURNER
ASSEMBLY
(37)
To diagnose the gas system, connect a
manometer to the test point. With the
thermostat on maximum you must have 11
inches water column pressure at this point. If
you have 11 inches pressure, your problem
Is to the right of the test point. If you do not
have 11 inches water column pressure, the
problem Is to the left.
_f===? DIAL SHAFT
(38)
Let’s take a closer look at the gas thermostat.
In this drawing we will review how a thermostat
functions. When the thermostat is working
properly, the manometer will read line pressure
when set at maximum and the refrigerator is
trying to cool. From this drawing you can see
the gas flow when the refrigerator is trying to
cool. The gas flows through the thermostat at
line pressure without restriction. The valve is
open at this time.
VALVE
= DIAL SHAFT
q._=/
--c
(39)
The valve is now closed and the gas must flow
through the by-pass screw; the gas is now
diverted through the by-pass screw, which
regulates the size of the low flame. This
condition can only exist when the refrigerator is
cold or the thermostat is set to minimum or off.
If the sensing tube has lost its pressure, even
with the thermostat set on maximum, you will
have only low flame.
i&‘-T
SCREW
w
-
,-
-
CLOSED VALVE
D-6-13owners of VW Westfalia T25 / T3 / Vanagon campers
www.westfaliaT3.info - a useful site for enthusiasts and
(40)
The most efficient way to diagnose the gas
system would be to first connect the gas
manometer to the pressure test point. With the
thermostat set at maximum you must have 11
to 12 inches water column pressure for the
refrigerator to operate properly. If your
manometer reads higher than 11 to 12 inches
water column pressure, the tank regulator is
adjusted to high, readjust it. Make sure the
gas system has at least 50% of the coach’s LP
appliances on at the time the system is being
adjusted. If the manometer reads 11 inches, the
problem of no cooling lies in the burner
assembly, flue pipe or venting.
(41)
If you have less than 11 inches water column
pressure, the next step would be to remove the
by-pass screw.
NOTE:
The by-pass screw
reduces the pressure and
volume of gas to the burner.
(42)
Shut off gas supply at the back of the refrigerator. Remove the by-pass screw from the top of
the thermostat,
Use a by-pass screw that does not have the
small O-ring at the bottom. Reinstall this bypass screw into the thermostat.
www.westfaliaT3.info - a useful site for enthusiasts andD-6-14
owners of VW Westfalia T25 / T3 / Vanagon campers
Turn on the main gas supply and take a
reading. If the manometer now reads 11 inches,
the thermostat is defective and must be
replaced.
(45)
If the by-pass screw test shows no change in
gas pressure, the problem lies with the gas
supply to the refrigerator. Shut off the gas
supply, remove the by-pass screw, replace it
with one that has an O-ring and turn on gas
supply. Remember to check for a gas leak. At
this time we will take a look at the rest of the
gas system.
(46)
The safety valve, or flame failure
device,
consists of a brass alloy valve housing and
cap, an electro-magnet, and a thermocouple,
which generates 14 to 30 millivolts when heat is
applied to the tip. It is used to energize the
electro-magnet in the safety valve. The purpose
of this device is to insure that the flow of gas is
shut off in the event flame is lost at the burner.
If this should occur, the thermocouple cools,
the magnet loses it magnetic field and the
valve closes. Most failures of this device are
related to the magnet, not the thermocouple.
Should this happen, the complete safety valve
should be replaced.
safety
D-6-15
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
(47)
Once the gas has been allowed to pass
through the safety valve, it flows to the gas jet
and burner. These have been specifically
designed to eliminate most of the normal maintenance required due to the corrosive contaminants in the gas, as well as soot and rust
which fall from the flue pipe. The jet has an
orifice made of an industrial ruby which has
been laser-beam drilled. Each model of
Dometic refrigerator uses a different size orifice
in order to maintain the required amount of
heat at the siphon pump. To clean the jet and
burner, soak them in an alcohol base solvent
and allow to air dry. DO NOT use a pin or
needle. This will distort or shatter the orifice.
(48)
If you determine that disassembly is required,
be aware there are two model designs for
manual refrigerators. The design pictured here
will be discussed first.
(49)
Shut off the main gas supply, then disconnect
at the back of the refrigerator. Remove the
cover over the thermostat and burner protection
cover at the right,
(50)
Now disconnect the 12 volts at the terminal
block and unplug the 120 volt cord. Remove
the two mounting screws on the left and pull
the metal locking arm out from under the
burner housing.
D-6-1owners
6
www.westfaliaT3.info - a useful site for enthusiasts and
of VW Westfalia T25 / T3 / Vanagon campers
(51)
The control assembly will now drop down and
can be pulled outward for service.
(52)
Pictured here is the other model design. Make
sure the main gas supply has been shut off
and disconnect the gas supply line at the
refrigerator.
I
(53)
Remove 3 screws on the burner cover plate.
The sheet metal assembly should now slide out
from the back of the refrigerator.
Remove the 2 screws from the plastic cover.
Also the 2 screws on the left and 2 screws on
the right of the metal bracket.
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
There are 3 screws in the burner area that
must also be removed. Please note - these are
machine screws, not sheet metal type. It is
important for them to be reinstalled in this area
only.
(56)
The control assernbly will now drop down and
Warfi ._,
fnr crwvir~
can be pulled out..,.,
1-1 II”“.
On the present line of manual refrigerators we
use one of two methods of igniting the burner
flame. Shown on the right is the piezo system;
on the left is the igniter reigniter.
(58)
The piezo lighter is a self-contained assembly
which generalty -does not need maintenance.
When the button is ‘pushed, a spring loaded
striker creates a spark. If there is no resistance
when pressing the button, the piezo igniter is
defective and must be replaced. If the piezo
snaps or has resistance when the button is
pushed, but there is no spark, the problem lies
in the electrode or electrode wire.
D-6-16
www.westfaliaT3.info - a useful site for enthusiasts and
owners of VW Westfalia T25 / T3 / Vanagon campers
The igniter reigniter, used on certain Dometic
model refrigerators, operates on 12 volt current.
On gas operation the igniter senses the resistance through the flame between the electrode
and burner. When there is no flame at the
burner, the resistance is high and the igniter
begins sparking to light the burner. As soon as
the flame is lit, the resistance between the
electrode and burner drops and the igniter
stops sparking. The resistance is monitored by
the igniter, and, if for any reason the flame
goes out, the igniter begins sparking until the
burner is lit. This insures that the flame will
always be lit when desired. Each time the
igniter reigniter system sparks, a light will
illuminate on the lower left front corner of the
refrigerator.
If the electrode does not spark first, make sure
the igniter is receiving 12 volts. If the igniter is
receiving 12 volts and produces no spark, it
must be checked for operation.
(61)
Turn the refrigerator off and remove the wire
between the electrode and igniter. Now turn the
refrigerator to the gas mode. If no internal
clicking sound is heard the igniter is defective.
It is important to remove the high voltage wire
that goes to the electrode from the igniter when
you are checking the igniter for operation. The
high voltage wire and the electrode can be
shorted to ground causing the igniter reigniter
to think that the flame is lit, resulting in no
spark on gas operation.
SPARK GAP
(62)
The distance between the tip of the electrode
and the burner, known as the spark gap,
should be 3/16 of an inch. A greater distance
will create a slow spark causing the light to
blink. A lesser distance will create a fast spark
that may not light the burner.
Burner
D-6-19
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
w
THE
ELECTRICAL
SYSTEM
The Electrical System
The electrical system consists of a combination
switch assembly, heating element and
thermostat. The quickest method of diagnosing
the electrical system would be testing for
continuity of components.
Following the wiring diagram, the component
that does not show continuity would be
suspect.
The selector switch should be checked for
continuity in the following manner. Remove all
wires from the assembly. Continuity should
exist between terminals 1 and 1 A and 2 and 2A
for the DC mode. When the switch is put in
the gas mode, you should have continuity
between 3 and 3A if the unit has an igniter
reigniter.
For the AC mode you should have
continuity between 4L and 4A and 5N and 5A.
If you find lack of continuity in any mode when
making these checks, the switch is defective
and should be replaced.
SWITCH ASSEMBLY
DC Mode
DC Mode
Gas
Mode
Gas
Mode
A/C Mode
A/C Mode
D-6-20
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
(67)
IDometicI
Before an appliance can be sold to a recreational vehicle manufacturer it must be tested
and approved by a nationally recognized
testing laboratory for the specific end use
All Dometic refrigerators used in
intended.
recreational vehicles have received this certification.
If you require additional service assistance on
the basic requirements for the cooling unit
operation or the manual refrigeration, please
refer to the diagnostic manual. For additional
technical service assistance, contact the
Technical Service Department at (219) 4634858.
(69)
You are an essential part of a team that contributes greatly to the successful future of the
RV industry, your dealership and Dometic.
Thank you for participating in the training
program.
D-6-21
www.westfaliaT3.info - a useful site for enthusiasts and
owners of VW Westfalia T25 / T3 / Vanagon campers
NOTES:
www.westfaliaT3.info - a useful site for enthusiasts and D-7
owners of VW Westfalia T25 / T3 / Vanagon campers
Glossary of Terms
MANUAL REFRIGERATION
1.
ABSORBER: Section of the cooling unit where the hydrogen and ammonia vapor are intermixed
in the absorber. Ammonia vapor returns to solution and the hydrogen returns to the
evaporator.
2.
BOILER: Section of the cooling unit where heat is applied. This is where the ammonia is
partially separated from the water.
3.
BY-PASS SCREW: Small brass screw located on any Dometic gas thermostat that regulates gas
flow in the low flame mode. There are three common sizes of this screw: S-17-350 BTU, S14-325 BTU, S-l l-300 BTU.
4.
F
5.
CONDENSER:
6.
COOLING UNIT:
Self-contained, hermetically sealed set of steel coils where the refrigeration
process takes place. The chemicals involved in the cooling process include hydrogen,
ammonia, water and a rust inhibiting agent.
7.
CUT-OFF VALVE (Shut-Off Valve):
Valve where the incoming propane supply is attached.
This valve is direct-coupled to the selector switch by means of a steel clip. When the selector
switch is turned to the electric mode, the cut-off valve is automatically closed. When this
same switch is turned to the LP gas mode, the electric circuit is also automatically
interrupted.
8.
A process that causes a liquid to turn into a vapor. Whenever evaporation
EVAPORATION:
takes place, heat is removed.
9.
EVAPORATOR:
Section of the cooling unit where the cooling effect is produced. Liquid
ammonia evaporating in a hydrogen atmosphere takes place in the evaporator.
10.
HEATING ELEMENTS:
the cooling unit.
11.
The igniter-reigniter, used on certain Dometic model refrigerators,
IGNITER-REIGNITER:
operates on 12 volt current. On gas operation the igniter senses the resistance through the
flame between the electrode and burner. When there is no flame at the burner, the resistance
is high and the igniter begins sparking to light the burner. As soon as the flame is lit, the
resistance between the electrode and burner drops and the igniter stops sparking. The
resistance is monitored by the igniter, and if for any reason the flame goes out, the igniter
begins sparking until the burner is lit. This insures that the flame will always be lit when
desired. Each time the igniter-reigniter system sparks, a light will illuminate on the lower
left front corner of the refrigerator.
12.
L.P. GAS PRESSURE:
For the refrigerator to operate properly on LP gas, the gas pressure
should be set at 11” water column pressure. NOTE: use the test port at the rear of the
refrigerator to take this reading.
o
u n d GAS/ELECTRIC
o n
c uTHERMOSTAT:
r r e n t
Dometic
m a n u a l
refrigerators, this device is held in place with "0"" ring seals in the gas line and replaces
separate electric and LP gas thermostat controls. On the LP gas mode, full line pressure is
directed through the thermostat to the burner until the thermostat senses that the
refrigerator cabinet has reached proper cooling temperature. At that rime an internal valve
closes and redirects the gas flow through the by-pass screw. This reduces the amount of LP
gas going to the burner assembly. The gas flow remains in this “by-pass” mode until the
thermostat senses that the refrigerator cabinet needs more cooling. Again, the thermostat
directs the LP gas flow through the thermostat at full line pressure until the cabinet
temperature is sufficient. On the electric mode the internal mechanism breaks contact
(continuity) when adequate cabinet temperature has been reached.
Section of the cooling unit that cools the ammonia vapor into ammonia liquid.
Elements that operate off either AC or DC voltage that create heat to
D-8-1
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
(Glossary of Terms . . continued)
13.
ORIFICE (JET):
A small brass fitting that is mounted on the gas line just prior to the burner.
This device incorporates a very small opening to greatly reduce gas flow to the burner. The
orifice is cleaned by using an alcohol based solvent and allowing to air dry.
14.
PIEZO LIGHTER: Self-contained lighter assembly that is used to generate a spark to light the
refrigerator on LP gas. This unit contains a quantity of quartz crystals that when pushed or
snapped, produce a spark. There are no serviceable parts on this device.
15.
SAFETY DEVICE: An assembly of parts (safety valve, magnet and thermocouple) that shuts off
the supply of LP gas to the burner assembly if the flame goes out for any reason. This is to
ensure that a concentration of unburned gas does not accumulate in the refrigerator vent
area.
16.
SELECTOR SWITCH: This is also a circuit interrupter on the 12 volt DC, 120 volt AC and gas
sides of operation on the refrigerator. When the customer selects either DC, AC or GAS
operation, the selector switch directs electricity first to the thermostat and on to the heating
element, or igniter-reigniter. When this switch is turned off, the AC or DC circuit is
interrupted.
17.
SPIRAL BAFFLE: Spiral metal device that is hung in the flue tube assembly of the cooling unit.
The baffle causes the heat supplied by the gas burner to stay at the boiler assembly a longer
period of time. This allows the absorption system to work as efficiently on LP gas as other
heat sources.
18.
WATER COLUMN: The pressure rating given to LP gas line pressure. Usually this pressure can
be varied by adjusting the regulator on the LP supply tank. A manometer is the device used
to test LP gas pressure.
D-8-2
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
TYPES OF BLOCKAGE
To understand the absorption principle we have set up several refrigerators to inspect and diagnose.
Carefully touch the absorber and boiler sections of each unit and record your findings. Proceed with
caution as some of these units could be extremely HOT.
Listed below are three types of units you will be testing:
LI
GOOD COOLING UNIT
Carefully touch the unit at the boiler box and the absorber area. These areas
should be approximately the same temperature, regardless of the ambient
temperature. The equal heat between the boiler and the absorber indicates the
fluid circulation within the unit is good.
q
BLOCKAGE
One of the faults with a cooling unit is blockage. This can happen when the unit
is operated off-level, or if too much heat has been applied to the boiler area. To
the touch this unit will be extremely hot at the boiler with little warmth at the
absorber. In other words, NO CIRCULATION.
LI
LEAKER
This type of fault means the unit has lost its charge - it’s known as a “leaker”. To
the touch this unit will be warm at the boiler and extremely hot at the absorber.
In this condition we are still boiling ammonia but have no hydrogen for
evaporation.
D-9-l
www.westfaliaT3.info - a useful site for enthusiasts and
owners of VW Westfalia T25 / T3 / Vanagon campers
q]piGiGq
CHANGING THE
HINGE POSITION
Refrigerator
Bulletin R54/7A
March 1987
I
2600,2602,2800,2802, 3600,3601,3800 & 3801
MODELS:
WHEN CHANGING THE HINGE POSITION:
Insure that the door latch assembly operates
properly after changing the hinge position from
left to right, or vice-versa, with the following
checks:
R7A54/
If the door(s) open when the latch assembly
is in the locked position, adjust the hinge/door
assembly. Follow the outlined steps to complete
this procedure:
1.
A. The refrigerator door(s) opens and closes
easily.
B. The door gasket seals smoothly and completely
on all sides.
C. Slide the latch left to the locked position
The latch
and try to open the door(s).
assembly should keep the door(s) from opening.
NOTE:
_
2.
Open the door and remove the two (2)
front decoration screws located underneath
the upper hinge assemblies.
Remove the front decoration by lifting
the decoration upward.
A hard pull will release the door
latch assembly and the door(s) will
(If an
This is not a fault.
open.
adjustment is required, repeat the
above p r o c e d u r e t o d e t e r m i n e t h e
effectiveness of the repair.)
FIG. 2
SMOOTH FIT,
PROPER SEAL
SMOOTH FIT,
PROPER SEAL
3.
4.
Loosen the screws that hold the upper
hinge in place.
Reorient the door so the catch retainer
on the door will engage with the latch
assembly.
(Usually lowering the door
will accomplish this.)
MOVABLE
FlG. 3
FIG. 1
www.westfaliaT3.info - a useful site for enthusiasts and
owners of VW Westfalia T25 / T3 / Vanagon campers
D-9-2
(Bulletin R54/7A continued)
5.
6.
7.
8.
Hold the door in its new p o s i t i o n a n d
carefully retighten t h e h i n g e s c r e w s ,
being careful not to change the hinge
position.
Close the door and again determine if
the latch is now operational.
If more adjustment of the door position
is necessary, the center hinge screws
may be loosened to reorient the door in
the proper position.
Again retighten t h e h i n g e screws to
allow the latch to operate properly.
SPECIAL HINTS TO ADJUST DOOR
1.
If there is a large distance between the lower door
catch retainer and the latch, adjusting t h e h i n g e
position still may not allow the latch to operate properly.
LATCH
FIG. 5
EXCESSIVE
GAP
2.
3.
Remove the upper, and if necessary, the center hinge
This allows you to remove the refrigerator
pin(s).
door(s).
P l a c e a m e t a l , 1/4" f l a t w a s h e r ( a v a i l a b l e a t a n y
hardware store) over the lower hinge pin and reinstall
This will raise the door to engage the
the door(s).
latch assembly. (On very rare occasions two [2] washers
may be required.)
If the latch assembly still will not engage, the base can
be repositioned to reorient the door as follows:
1.
2.
3.
Turn the refrigerator on its side to gain access to the
four (4) base screws. Loosen all four (4) screws slightly.
Reposition the base so that the door catch retainer
engages with the latch.
Retighten the base screws w h i l e holding the base in
its new position.
FIG. 7
By following the above listed procedures you will be able
to correct any door latching problems incurred when
reversing the hinge position on your Dometic refrigerator.
I f y o u h a v e a n y q u e s t i o n s c o n c e r n i n g this procedure,
contact our Technical Services Department at:
DOMETIC SALES CORPORATION
509 South Poplar St.
LaGrange, IN 46761
BASE SCREWS
www.westfaliaT3.info - a useful site for enthusiasts and
D-9-3owners of VW Westfalia T25 / T3 / Vanagon campers
PROCEDURE FOR
CHANGING COOLING UNIT
Refrigerator
Bulletin R55/7A
April 1 9 8 7
The following categories have been established
predicated on similarity of design and procedure
for replacement of cooling units. Most Dometic
r e f r i g e r a t o r s a r e c o v e r e d in one (1) of these
categories.
SPECIAL NOTE: After the cooling unit has been
installed, t h e i n i t i a l start-up time can be
shortened by tilting the refrigerator from side
to side and then from front to back before the
refrigerator is turned on.
6
\,
WOOD BLOCK
DPnTCPtth
FIG. Al
2
TILT SIDE-TO-SIDE
Run the refrigerator on a bench for 12 hours
after the cooling unit has been installed (all
food should be removed for testing).
FIG. A2
\ I
FC140 Cooling Unit cannot be replaced
A. C a t e g o r y #l
RM46
RM360
RM460
RM46 1
RM660
RM661
RM663
RM2500
RM2300 R M 3 5 0 0
RM2400
REMOVAL OF COOLING UNIT
1.
2.
3.
4.
5.
6.
Remove heater(s) from boiler case (FIG. Al).
Disconnect burner from chimney (FIG. A2).
Remove evaporator screws inside refrigerator
and remove cooling flange (FIG. A3).
Remove screws holding clamp for capillary
tube. Pull capillary gently out of plug (FIG.
A3).
Remove screws holding unit from rear (FIG.
Al).
Apply leverage as shown and pull out (FIG.
Al).
FIG. A3
www.westfaliaT3.info - a useful site for enthusiasts and
D-9-4 owners of VW Westfalia T25 / T3 / Vanagon campers
(Bulletin R55/7A c o n t i n u e d )
INSTALL REPLACEMENT COOLING UNIT:
1. Trim the Styrofoam portion of the cooling
2.
3.
4.
5.
6.
7.
unit if it does not go freely into the
refrigerator.
Apply sealing permagum (sealing tape) on
mounting plate (A; FIG. A4).
Apply thermal mastic on the evaporator coil
(B; FIG. A4).
Tighten screws securely to obtain proper
contact between the evaporator coil and
evaporator flange; otherwise improper cabinet
performance may result.
Install the heating element completely back
into the pocket and plug in.
Reconnect burner assembly to chimney.
Reinstall capillary tube into proper position
(FIG. A3).
4. Remove evaporator screws (FIG. B4).
5. Remove screws holding unit from rear (FIG.
Bl).
6. Cut tape holding plate (FIG. B1).
7. Apply leverage as shown and pull unit out
(FIG. B ).
5
6
G
WOOD BLOCK
-PROTECTION
FIG. B3
FIG. A4
B. Category #2
RM100
RM760
RM76 1
RM763
RM1300
RM1301
RM1303
RM2600
RM2800
RM3600
RM3800
FIG. 84
REMOVAL OF COOLING UNIT:
1. Remove screw holding clamp for capillary
tube.
Pull capillary tube out gently and
place aside (FIG. Bl).
a. RM3600, RM3800 (FIG. B4)
2. Remove heater(s) from boiler case (FIG. Bl).
3. Disconnect burner from chimney (FIG. B2
and B3).
a. RM2600,
RM2800, RM3600, RM3800
(FIG. B3).
INSTALL REPLACEMENT COOLING UNIT:
1. Trim the Styrofoam portion of the cooling
u n i t i f it does not go freely into the
refrigerator.
www.westfaliaT3.info - a useful site for enthusiastsD-9-5
and owners of VW Westfalia T25 / T3 / Vanagon campers
(Bulletin R55/7A) c o n t i n u e d )
2. Apply sealing permagum (sealing tape) on
mounting plate (A; FIG. B5).
3. Apply thermal mastic on the evaporator coil
(B; FIG. B5).
4. T i g h t e n s c r e w s s e c u r e l y t o o b t a i n p r o p e r
contact between the evaporator coil and
evaporator flange; otherwise improper cabinet
performance may result.
5. Install the heater element completely back
into pocket and plug in.
6. Reinstall capillary tube into proper position.
a. RMl00, RM2600 & RM2800 will clamp to
cooling flange. (FIG. B4)
b. RM760, RM761 & RM763 will extend into
retainer tube approximately 31” (FIG. Bl)
RM1300, RM1301 ` RM1303 will extend
C.
into retainer tube approximately 36”
(FIG. Bl)
d. RM3600 & RM3800 have internal thermostat
with capillary tube clamped to cooling
flange (FIG. B4)
7. Reconnect the burner assembly to chimney.
3. Remove screws holding unit from rear (FIG.
Cl).
4. Disconnect green grounding wire (FIG. Cl).
5. Pull out on cooling flange to remove fr
evaporator coil (FIG. Cl).
6. Pull thermostat capillary tube out gently and
move so that cooling unit will clear (FIG. Cl).
7. Remove cooling unit by hinging out on right
side (FIG. Cl).
SEALING PERMAGUM
INSTALL REPLACEMENT COOLING UNIT:
1. Trim the Styrofoam portion of the cooling
2.
3.
4.
5.
FIG. B5
6.
7.
C . C a t e g o r y #3
RC150
RC160
unit if it does not go freely into the
refrigerator.
Apply sealing permagum (sealing tape) on
window insulation (A; FIG. C2).
Apply thermal mastic on the evaporator coil
(B; FIG. C2).
Tighten screws securely to obtain proper
seal; otherwise improper cabinet performance
may result.
Install the heat elements completely back
into the pocket and attach to terminal block
(FIG. Cl).
Reconnect burner assembly to chimney (FIG.
Cl).
Reinstall capillary tube into proper position
(FIG. Cl).
SEALING PE
(Sealing
(A)
REMOVAL OF COOLING UNIT:
1. Remove screw and disconnect burner from
chimney (FIG. Cl).
2. Disconnect heater wires from terminal block
(FIG. Cl).
Remove heaters from boiler case (FIG. Cl).
a.
D-9-6
FIG. C2
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
(Bulletin R55/7A c o n t i n u e d )
D . C a t e g o r y #4
RM190
RM2190
3. Apply sealing permagum (sealing tape) on
window insulation (A; FIG. D3).
4. Tighten screws securely to obtain proper seal.
5. Install the heating elements completely back
into the pocket.
6. Reinstall capillary tube into proper position.
7. Reconnect burner assembly to chimney and
replace cover.
RM2 192
REMOVAL OF COOLING UNIT:
1. Remove cover and flue tube, then disconnect
burner from chimney (FIG. D1).
2. Remove heater(s) from boiler case (FIG. Dl).
3. Remove screws and take out evaporator fins
and shelf (FIG. D2).
4. Release holding clamp for thermostat capillary
tube and pull tube out gently (FIG. D2).
5. Remove one (1) screw and bend two (2) tabs
and then pull cooling unit out (FIG. Dl).
“\
A)
SEALING
PERMAGUM
(Sealing Tape)
5
FIG. D3
E . C a t e g o r y #5
RM211
FIG. D1
REMOVAL OF COOLING UNIT:
1. Remove cover and disconnect burner from
chimney (FIG. El).
2. Remove heater from boiler case (FIG. El).
3. Remove three (3) screws holding unit from
rear (FIG. E 1).
4. Pull cooling unit part way out and then
disconnect thermostat capillary tube and pull
out (1; FIG. E2).
5. Complete removal of cooling unit.
6. Remove evaporator fins and shelf (2; FIG. E2).
INSTALL REPLACEMENT COOLING UNIT:
INSTALL REPLACEMENT COOLING UNIT:
1. Trim the Styrofoam portion of the cooling
unit if it does not go freely into the
refrigerator.
2. Apply thermal mastic on the evaporator coil
(B; FIG. D3).
1. Apply thermal mastic on the evaporator coil
(B; FIG. E2).
2. Install evaporator fins and shelf (FIG. E2).
3. Apply sealing permagum (sealing tape) on
window insulation (A; FIG. E2).
4. Reinstall capillary tube into proper position
(FIG. E2).
5. T i g h t e n s c r e w s s e c u r e l y t o o b t a i n p r o p e r
sealing.
6. Reconnect burner assembly to chimney and
replace cover (FIG. El).
7. Install the heating elements completely back
into the pocket (FIG. El).
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
D-9-7
(Bulletin R55/7A c o n t i n u e d )
3
(A)
SEALING
PERMAGUM
(Sealing Tape)
FIG. E2
FIG. El
F. C a t e g o r y #6
RM75
3
RM76
RM77
REMOVAL OF COOLING UNIT:
1.
2.
3.
3.
5.
6.
Remove burner protection cover and remove
burner from chimney (FIG. Fl).
Remove heaters from boiler case (FIG. Fl).
Remove evaporator screws (FIG. F2).
Remove two (2) screws holding clamp for
thermostat capillary tube.
Pull capillary
tube out gently (FIG. F2).
Remove ten (10) screws holding unit from
rear (FIG. Fl).
Pull out on cooling unit and remove.
INSTALL REPLACEMENT COOLING UNIT:
1. Trim the Styrofoam portion of the cooling
unit if it does not go freely into the
refrigerator.
_3 . Thermal mastic is not used on these units.
3. Apply sealing permagum (sealing tape) on
mounting plate (FIG. F3).
5
2
5
FIG. F1
-1
www.westfaliaT3.info - a useful site for enthusiasts and
D-9-8 owners of VW Westfalia T25 / T3 / Vanagon campers
(Bulletin R55/7A c o n t i n u e d
4. Tighten screws securely to obtain proper seal.
5. Install heating elements completely back into
the pocket and plug in (FIG. Fl).
6. Reconnect burner assembly to chimney (FIG.
Fl ).
7. Reinstall capillary tube into proper position
(FIG. F2).
5. Tighten screws securely to obtain proper seal.
6. Install the heating elements completely back
into the pocket.
7. Reconnect burner assembly to chimney and
replace cover.
FIG. F3
6
FIG. G1
/
G.
l
THERMAL MASTIC IS NOT USED
C a t e g o r y #7
RM182
REMOVAL OF COOLING UNIT:
1.
2.
3.
4.
5.
6.
Remove six (6) screws from burner cover
(FIG. Gl).
Disconnect burner from chimney (4 screws)
(FIG. Gl).
Remove heaters from boiler case (FIG. G1).
Carefully pull out thermostat capillary tube
(FIG. G1).
Remove two (2) evaporator screws and take
out ice tray support (FIG. G2).
Remove eight (8) screws holding unit from
rear (FIG. G1).
Remove two (2)
gasket (FIG. Gl).
screws
holding
gas
FIG. G2
line
(A)
INSTALL REPLACEMENT COOLING UNIT:
1. Trim the Styrofoam portion of the cooling
unit if it does not go freely into the
refrigerator.
2. Apply thermal mastic on the evaporator coil
(B; FIG. G3).
3. Apply sealing permagum (sealing tape) (A;
FIG. G3).
4. Reinstall thermostat capillary tube.
SEALING PERMAGUM
(Sealing Tape)
FIG.
D-9-9
G3
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
Before You Change
That Cooling Unit
REFRlGERATOR
BULLETIN R61/7A
DEC. 1987
PART I. PROPER DIAGNOSIS
Cooling units are sometimes diagnosed as being
defective when the actual problem is something
else. Cooling units are expensive to replace, so
it is important to make the correct diagnosis. By
using the proper test procedures, you can eliminate
all other possibilities before condemning the
cooling unit.
For a simple method to check gaskets, close
the door on a dollar bill, then pull the dollar
bill out. If no resistance is felt, the gasket
is not sealing properly. This should be done
on all four sides of the door.
Any time the cooling unit is a possible suspect,
use the following step-by-step procedure before
replacing it.
A.
PRELIMINARY CHECKS
1.
Check for an ammonia smell around the
cooling unit and inside the refrigerator.
This could indicate a possible refrigerant
leak.
Check for any deposits of yellow
powder on the tubing which will sometimes
form around the area of a leak. NOTE: A
yellow deposit in the area of the fill valve
could be due to splashing of refrigerant
during manufacture, and would not indicate
a leak.
2.
Determine if the refrigerator works on one
heat source but not another by testing it in
the alternate modes. Also, ask the customer
if he gets better cooling results from one
energy source than another. If this is true,
it indicates the problem is NOT in the cooling
unit.
3.
Make sure the refrigerator is level. Sometimes
the vehicle is level but the refrigerator is
not, due to improper installation.
Place a
level on the bottom of the freezer compartment and check side-to-side and front-to-back
Use a mirror, if
levels (see FIG. Al).
necessary to read the level.
4.
Carefully check door gaskets for proper
A leaking gasket can allow enough
seal.
warm air inside the refrigerator to overcome
most of the cooling being produced.
\
CHECK LEVEL
BOTH WAY.
FIG. Al
5.
Check the venting system to insure that
ample air flow is provided at the back of
the refrigerator.
A. Check for, and remove, any restrictions
in the vents, such as filters installed by
the customer, bird nests in the roof
vent, or smashed louvers in the wall
vents (see FIG. A2).
B. M a k e s u r e t h e c o r r e c t r o o f v e n t h a s
Larger models such as
been installed.
RM100, 760, 761, 1300, 1303, 2600, 2800,
2802, 3600, 3800, 3802 and 4801, require
a 5” X 24” opening for the roof vent
Smaller models will also use the 5” J
24” roof opening. To check this, measure
the actual opening in the roof - DO
See
NOT measure the roof vent itself.
FIG. A2.
www.westfaliaT3.info - a useful site for enthusiasts D-9-l
and0 owners of VW Westfalia T25 / T3 / Vanagon campers
(Bulletin
c o n t i n u e d )
Also, make sure the distance from
the bottom of the refrigerator to the
roof v e n t i s a t l e a s t t h e m i n i m u m
dimension given
in the
Installation
Instructions for each model.
See FIG.
A2.
FIG. A2
D. Check the open space above the refrigerator. If this space is 1 1/2 inches or
more it must be blocked off to prevent
hot air from being trapped above the
refrigerator. See FIG. A2.
If venting is suspected as a problem, run the
performance test described below with the refrigerator installed, then run the same test with
the refrigerator removed. If there is a definite
improvement in performance, a venting problem
is indicated. Also, see Section B. PERFORMANCE
TEST, Item 9.
MIN. 5
SPECIAL VENTING FOR DIRECT-VENT MODELS
RM182, 215, 2192
These models are designed to be
small vans and are usually placed
that is not open to the outside of
This means that air from within
must be used to cool the condenser.
FOR MINIMUM
DIMENSION.
SEE INSTALLATION
INSTRUCTIONS
MAXIMUM OPEN
SPACE 1 1/2 IN.
(See 5D)
installed in
in a cabinet
the vehicle.
the vehicle
Customers with this type of installation must be
made aware that the vehicle interior must be
If the vehicle is
kept from getting too hot.
left parked in the sun, with all doors and windows
closed, the inside temperature can quickly exceed
100 degrees, and the cooling process will slow
down or stop completely.
REAR VIEW OF REFRIGERATOR
CHECK FOR RESTRICTIONS
IN AIR DUCTS OR VENTS
(See 5A)
C.
Some smaller models may be installed
with two side wall vents instead of
using a roof vent.
For this type of
installation make sure the top of the
upper vent is the correct distance above
See FIG. A3.
the refrigerator.
The
minimum dimension for this measurement
is listed in the Installation Instructions
for each model.
Arrows indicate direction
Alternative
+,,fi
SIDE VIEW OF REFFERATOR
FIG. A3
upper
positions
ventilator
CHECK MINIMUM
HEIGHT (See
Installation
Instructions)
Arrows indicate direction
of air flow over Cooling Unit
L
Lower
Ventilator
www.westfaliaT3.info - a useful site for enthusiasts and
D-9-1 1owners of VW Westfalia T25 / T3 / Vanagon campers
[Bulletin R61/7A continued)
B.
1.
3
3.
4.
PERFORMANCE TEST
First perform a l l t h e p r e l i m i n a r y checks
described previously.
Remove all food from the refrigerator and
place all controls in the OFF position.
Place an accurate thermometer in an ice
cube tray, half filled with water, and place
the tray in the center of the lower food
storage compartment.
N O T E : I f a remotereading
thermometer
is
used (allowing
temperature readings w i t h o u t o p e n i n g t h e
door) the tray of water is not required.
Make sure the AC heating element is the
correct wattage for the model being tested,
and that the resistance reading is correct.
(See “ C h e c k i n g R e s i s t a n c e o f a H e a t i n g
Element” below.)
Connect 120 volt AC power directly to
the heating element leads (make sure the
leads are not connected to the refrigerator
circuit), then check the voltage at the
element with a volt meter.
Reading must
show at least 115 volts.
CHECKING RESISTANCE OF A HEATING ELEMENT
A simple test to check a heating element is to
measure the resistance through the element
with an ohmmeter.
The correct resistance, in
ohms, c a n b e c a l c u l a t e d i f t h e w a t t a g e a n d
voltage ratings are known.
(These ratings are
stamped on all Dometic heating elements.)
5.
FIG. Bl
(TEMPERATURE
TEST AREA)
CONDENSER
i3OBR
ENCLOSURE
(TEMPERAT U RE
TEST AREA)
Under normal operation the temperature at
the absorber coils (A) and the boiler (B)
If the
should be approximately the same.
temperature at the absorber coils (A) is
much hotter it indicates loss of refrigerant
and the cooling unit must be replaced. If
the temperature at the boiler (B) is very hot
and the absorber coils (A) are cool it indicates
that the refrigerant is not circulating properly.
This could indicate:
A.
Liquid trapped in the evaporator sections,
caused by out-of-level operation for a
period of time. Resetting the refrigerator
to a level position will not necessarily
correct the problem as liquid can remain
trapped even after level is corrected.
Shut off the heat source and let the
system cool down, then re-start it and
observe the temperatures at A and B
If the same
again after several hours.
condition exists it could indicate:
B.
A permanent blockage within the boiler
pump tube, caused by too much heat
applied to the burner (oversized orifice
or heating element) or prolonged operation
of the unit when out-of-level or with
restricted ventilation.
This type of
blockage consists of hard deposits inside
the boiler pump tube. This condition is
not repairable and the cooling unit must
be replaced.
Use this Formula:
Volts + (Watts + Volts) = Ohms
Example:
Heating element rated 135 Watts at 110 Volts.
110 f (13.5 f 110) or,
110 + 1.23 = 89.4 ohms
The ohm reading should be within 10% of this
figure, or between 80.46 and 98.34 ohms.
Use
the lowest setting on the ohmmeter which will
give an accurate reading.
When testing a 12 volt heating element, a
very accurate ohmmeter must be used because
of the very low readings that will be found.
For example, a 200 watt element will have a
reading of .72 ohms (less than 1 ohm).
A f t e r t w o h o u r s o f o p e r a t i o n , c h e c k the
temperature on the back of the cooling unit
with your hand, at the locations shown.
www.westfaliaT3.info - a useful site for enthusiasts andD-9-12
owners of VW Westfalia T25 / T3 / Vanagon campers
(Bulletin R61/7A c o n t i n u e d )
NOTE:
The cooling units currently being used
are specially designed to prevent overheating of
the boiler tube even when operated out-of-level.
This special design can be identified by the
round insulation box around the boiler, rather
than the square-cornered box used on older units.
Q
FIG. B2
Older Style
Boiler Enclosure
7.
8.
If the previously mentioned test was performed
90”. and the
in air temperatures above
temperature in the refrigerator is above the
acceptable ranges, it may indicate a restricted
air flow. To make sure there is no problem
with the venting system repeat the performance test with the refrigerator removed
from its installed location and placed on
the floor, or in your service shop.
If the
second test indicates satisfactory performance,
re-check the venting and installation.
3
Current Style
Boiler Enclosure
Blockage symptoms on the newer cooling units
almost always, indicate t r a p p e d l i q u i d i n t h e
evaporator, which can be corrected by proper
leveling and allowing the cooling unit to cool
off before restarting.
6.
= ONE LASTCHECK =
If the temperatures are satisfactory in Step
5, continue operating the unit, with power
directly to the heating element, for a total
of 10-12 h o u r s .
The doors must be kept
closed for this entire period.
If the temperature is within the previously
mentioned guidelines the problem is not in
the cooling unit.
See Section I I . O T H E R
C A U S E S for additional items that could be
causing a loss of cooling.
If the temperature in the food compartment
is higher t h a n t h e a c c e p t a b l e l i m i t , the
cooling unit is probably defective.
If you
are still in question as to the performance
of the cooling unit, please contact our Technical Service Department (219) 463-4858. See
the n e x t p a r a g r a p h b e f o r e c h a n g i n g t h e
cooling unit.
9. The importance of adequate air flow across
the cooling unit cannot be emphasized too
much.
A minor restriction in the venting
system will not create a problem on cooler
days - the available air flow w i l l still provide
adequate cooling due to the lower temperature.
However, on a hot day (90” or more) even
a minor restriction will cause overheating of
the cooling unit and the cooling process will
slow down or stop.
PART II.
OTHER CAUSES FOR
LOSS OF COOLING
If the previously mentioned performance test
shows that the refrigerator is working satisfactorily, and the customer still experiences loss of
cooling, the following items need to be considered:
1.
Make sure the customer is using the refrigerator properly. The cooling capacity of the
absorption refrigerator is usually much lower
than the refrigerator the customer has in his
home, so the customer should be advised to
follow the instructions for proper use in his
Owner’s Manual.
A.
Start the refrigerator the day before it
is to be filled with food.
B. When the refrigerator is being filled
when preparing for a trip, the food
should be pre-cooled, and frozen foods
s h o u l d b e p r e - f r o z e n , before placing
Ice making
them in the refrigerator.
should be avoided until the refrigerator
has cooled the lower compartment to the
desired temperature.
C. Air circulation within the food compartment is important for proper cooling.
DO NOT place paper on the shelves or
over-fill the compartment with large
cartons, etc.
D. Do not put hot food in the refrigerator.
Allow it to cool in room air first.
D-9-13
www.westfaliaT3.info - a useful site for enthusiasts and
owners of VW Westfalia T25 / T3 / Vanagon campers
B]1DOmeticl
REFRIGERATOR TECHNICAL DATA
l
RAK1 00
RAK1302
RC15
RC65G
RC65K
RC150
RC150A
RC1 50TEG
RC 150TEG
RC152
RC160E
RC 160E
RC1 6 0 T E G
RC 1 60TEG
M52
l
M70
l
l
l
l
9286111001
9286179008
2922000000
N/A
N/A
2922302001
2922471020
2942312022
Kerosene
Kerosene
------ - 50 (0061667002)
Kerosene
- - - - - - - - - - - - - - (2928787031)
2922441015
2942312022
-------(2928787031)
2942312121
(2928787031)
N/A
________
N/A
________
9283171008
51
9283191006
4 3 (2002660161)
9283521004
5 2 (2002660187)
9283571009
5 2 (2002660187)
9283599000
51
928352 1004
5 2 (2002660187)
9283521004
5 2 (2002660187)
RM67D
9283521004
RM75,76,77,76D
D 9285134004
l RM100
9286109005
l RM100
RM182
2929302004
RM182B
2929302053
RM182B
I
RM190
9281 152000
l RM211
t 9282740010
l RM2llB
19282743005
RM215
19282761000
52 (2002660187)
5 3 (2002660195)
5 8 (2002660211)
RM45,46,47
RM45,46,47
RM46E
RM46E
l RM60,66
l RM60,66
RM66E
RM66E
RM66F
RM66F
* RM67
l RM67
RM67D
l
(2002660179)
l
l
l
l
(2002660179)
2 4 (2928787049)
2 4 (2928787506)
I
F (2902540059)
1 4 (2901860010)
1 4 (2901860010)
t J (2902540075)
Models that use brass heating elements approximately 3/4’ in diameter.
www.westfaliaT3.info - a useful site for enthusiasts andD-9-14
owners of VW Westfalia T25 / T3 / Vanagon campers
(Bulletin 828
l
.
continued)
RM3601
RM3604
2934803996
53
(2007419191)
215/12
295/120
0173757022
0173754045
2.5
48
17.9
___
RM3604
RM3800
2934901097
58 (2007419217)
215112
325/120
0173757022
0173742081
2.7
44
17.9
___
Models that use brass heating elements approximately 3/4’ in diameter.
www.westfaliaT3.info - a useful site for enthusiasts and
owners of VW Westfalia T25 / T3 / Vanagon campers
D-9-15
(Bulletin #28 c o n t i n u e d )
l
Models that use brass heating elements approximately 3/4’ in diameter.
NOTE: The formula for calculating amps & OHMS:
Watts + Volts (120/12) = AMPS
Volts (120) + Amps = OHMS
D-9-16
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
Ell[ Dometic
1
BULLETIN # 4 5
MAY 1983
Replacement of cooling units in RM760.
Cooling unit 531A will replace 530A in production and service.
When installing 331A as replacement for 530A three new holes should be drilled in the cooling
flange.
0
J
0
c
0
0
0
0
0
0
New holes +
1 3/16” (29 mm)
down.
0
0
0
0
~
Furthermore the hole for the air channel (no longer necessary) in the burner box should be covered
by a piece of aluminium tape (No combustible material must be used).
Cover this hole
www.westfaliaT3.info - a useful site for enthusiasts andD-9-17
owners of VW Westfalia T25 / T3 / Vanagon campers
Kl: Dometic
REFRIGERATOR BULLETIN
REVISED AUGUST, 1984 #38
CROSS REFERENCE OF REFRIGERATORS MANUFACTURED BY
A.B. ELECTROLUX AND DOMETlCARE PROCEDURE CHANGES
SUBJECT: Dometicare Procedure
An out of warranty cooling unit purchased from Dometic for installation on
an Instamatic, Magic Chef, Hadco or GE refrigerator does not qualify for our
three year Dometicare cooling unit coverage.
We will warrant cooling units purchased from Dometic for installation on
other than Dometic refrigerators for two (2) years providing the installation is
within our established installation specifications.
We will offer our three year Dometicare coverage on the following cooling
units purchased from Dometic for out of warranty Dometic refrigerators only,
for $35.00.
RC 150
RM
RM
RM
RM
182
19a
211
2118
RM
RM
RM
RM
RM
215
235
36C
36E
360
RM
RM
RM
RM
RM
361
46
46E
460
461
RM
RM
RM
RM
RM
66
66E
66F
660
661
RM
RM
RM
RM
RM
663
76
77
760
761
RM 763
RM 100
RM 13C0
RM 1303
RA 100
RAK 100
RAK 1302
RA 1300
RA 1302
RC 65
All Dometic cooling units for Dometic refrigerators manufactured prior to
these models will no longer qualify for our Dometjcare coverage.
CROSS REFERENCE OF REFRIGERATORS MANUFACTURED BY
A.B. ELECTROLUX
HADCO
HR-2 same
HR-3 same
HR.4 s a m e
HR-6 same
HR-7 same
DOMETIC
GE
TG3z08 s a m e a s R M 3 6
TG4-S-06 s a m e a s R M 65
TGS-S-06 s a m e a s R M 6 0
DOMETIC
as RM 24
as RM 36C
a s R M 460
as RM 660
as RM 760
MAGIC CHEF
MKM
MKM-110
MKM-150
R-82, 83, 84,85,86
R-87
R-88
same
same
same
same
same
same
DOM ETIC
as M-28
as M-40
as M-52
as RM 75
as RM 77
as RM 760
DOMETIC
INSTAMATIC
same as RX1 211
IM-2
same as Rhl 36E
IM-3
same as Rhl 46E
IM-4
s a m e a s 66E
IM-6
same as R!d 77
IM-7
IM-10 same as RLI 1 0 0
D-9-1 8owners of VW Westfalia T25 / T3 / Vanagon campers
www.westfaliaT3.info - a useful site for enthusiasts and
HEATING ELEMENTS 360-460-660-760
Previous literature covering the following models, lists the wattage of 110 volt
heading elements as follows:
RM360
RM460
RM660
RM760
- 120
- 135
- 175
- 250
watts
watts
watts
watts
The ratings that are actually stamped on the replacement heating elements are
as follows:
RM360
RM460
RM660
RM760
-
135
150
190
275
watts
watts
watts
watts
These elements are identical and are covered under the same part numbers.
The difference being that the newer elements have been rated at 115 volt input
rather than 110 volt input.
The American Gas Association now requires that every refrigerator be
supplied with a spare parts list included inside the cabinet. They are also
requiring that all literature packaged inside the cabinet, from this point on, rate
electrical input at 120 volt A.C. Therefore, the new spare parts list supplied with
the refrigerator will list the wattage, at 120 volt input, as follows:
R M 360-150 watts
RM460 - 160 watts
RM660 - 210 watts
RM760 - 295 watts
Once again, these elements are identical to the previous elements and are
covered under the same part numbers which are as follows:
RM360 - 173734-01 I3
RM460 - 173736-0118
R M 660-173738-0114
R M 760-173740-0110
Should a customer be concerned that the wattage stamped on the heating
element does not correspond to that shown in his spare parts list, the above
information should be passed on to him.
D-9-19
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers
THE ABSORPTION SYSTEM
WATER SEPARATOR
VAPOR PIPE
A
- \i’EAK A~I~IOSIA SOLUTION
B
c
D
E
F
-
STROSG AXIhIOSIA SOLUTION
LIQUID A~I>lO~IA
X313lOSIA VAPOR
HYDROGEN GAS
HYDROGES 5; A~IllO~;IA V A P O R
D-9-20
www.westfaliaT3.info - a useful site for enthusiasts and owners of VW Westfalia T25 / T3 / Vanagon campers