Danfoss 4-Pin Controller Testing

Danfoss 4-Pin Controller Testing
Danfoss controller Repairs TEST PAGE B
TEST PAGE B
Contents
CONTENTS
Thisdocumentcontainstestinginstructionswhichare
Section A Check the battery
specific to the controller shown below. If the seven tests
Section B Check the fuse
throughout this document do not resolve a problem with
Section C Check the thermostat
your fridge, the remove and send instructionsatthe
Section D Check the fan
end of this document will help you send your Danfoss
controller to Cold Technology to be repaired.
Section E Check the compressor plug
Section F Compressor resistance test
Section G Supply Voltage test
Section H Conclusion - Remove & Send
Very Important Note!
This type of controller may not be repairable. An exchange unit may
not be available. If the fault in your controller is due to the failure of an
electronic component that we cannot source then we cannot repair
your controller and therefore, cannot provide you with an exchange unit,
however, most controllers of this type can be exchanged.
Danfoss controller Repairs TEST PAGE B
SECTION A
Check the battery
This procedure should only be used for the type of controller shown on the contents page of this document.
The most common cause of the poor operation of a 12 volt or 24 volt fridge is insufficient state of charge of the car,
boat or house batteries supplying power to the fridge. In simpler terms, your batteries are flat. When the state of
charge of the batteries supplying power to the fridge drops to approximately 20%, the Danfoss controller will turn the
compressor off automatically. This means that the fridge will not operate, even though most lights, radios and other
electrical equipment in the boat, vehicle or house will still operate. In these conditions the fridge is the only device that
is not operating and it is often falsely assumed that the fridge is faulty when in fact the problem lies in the batteries or
charging system. The following procedure will help you check the state of charge of the batteries.
If you do not understand this procedure seek help from a qualified electrician or technician!
1
2 Turn on some lights or electrical equipment that share the power supply to the fridge. This will place some load on the battery.
Most installations have a meter somewhere in the boat, vehicle or house to indicate the state of charge of the batteries. This may be labelled as a voltmeter or a battery condition meter. With the load suggested in step 1, the meter in a 12 volt system should show 11.5 volts or higher. With the load suggested in step 1, the batteries in a 24 volt system should show 23 volts or higher.
3
If the battery state is lower than recommended in step 2, the batteries should be charged until they meet the recommendation. If the fridge operates after the batteries have been charged, you have probably diagnosed a low battery problem. You do not need to continue with the instructions in this document and your Danfoss controller probably does not need to be repaired. The batteries, charging system or charging method should be investigated. If the battery state meets the recommendations in step 2 but the fridge still does not operate, go to the next procedure.
Note: There are many combinations and capacities of batteries as well as charging methods used in D.C. Electrical
systems. There are also many opinions regarding suitable state of charge of batteries. The recommendations in step
2 refer only to the minimum battery state of charge necessary to test a refrigerator and do not indicate the state of
charge necessary for good battery system maintenance.
Danfoss controller Repairs TEST PAGE B
SECTION B
Check the fuse
This procedure should only be used for the type of controller shown on the contents page of this document.
If you do not understand this procedure seek help from a qualified electrician or technician!
BEWARE a short circuit between two terminals of a battery can result in a fatal explosion of
the battery
1
2
Turn off or isolate any charging sources such as wind generators, mains battery chargers or solar panels.
with the procedure. Adjust the fridge thermostat to the off position.
Solar panels can simply be covered to block the sun.
Disconnect the fridge from the battery/power supply by turning off the battery isolator switch which is usually near the batteries in the boat, vehicle or house. If there is no battery isolator switch in the installation, continue If you are unsure of the battery or electrical configuration seek help from a qualified electrician or technician!
3
Locate the plastic fuse cover
on the Danfoss controller - lever
off with a screw
driver.
4
Loosen the fuse by moving from side to side and pulling outward.
5
Grip the sides
& pull outwards
to remove the
fuse completely
from the holder.
6
The fuse can be inspected visually or tested with an ohm/multi meter or simply replaced with another fuse of and the holder. With the fuse firmly inserted for the final time, push it firmly into place.
the same rating. Remove and re-insert the fuse several times to create a good connection between the fuse 7 While listening for any sound from the compressor, reconnect the fridge to the battery/power supply by turning on the battery isolator switch and turn on the fridge and adjust the fridge thermostat to the coldest setting.
Wait at least 1 minute to see if the compressor will run.
8
If the compressor runs you have probably diagnosed a faulty or dirty fuse. You do not need to continue with the instructions in this document and your Danfoss controller probably does not need to be repaired. Replace the plastic cover on the fuse holder. If the compressor does not run, go to the next procedure.
9
Danfoss controller Repairs TEST PAGE B
SECTION C
Check the thermostat
This procedure should only be used for the type of controller shown on the contents page of this document.
A thermostat is commonly used with Danfoss compressors to stop and start the compressor thereby controlling the temperature in the fridge/freezer compartment. The thermostat should be connected between terminal (C) and terminal (T) on the Danfoss controller. When the temperature in the fridge/freezer rises the switch contacts of the thermostat close and create a circuit between terminal (C) and terminal (T). In this condition the controller will run the compressor to cool the fridge/freezer
When the temperature in the fridge/freezer drops, the switch contacts in the thermostat open, removing the circuit between terminal (C) and terminal (T). In this condition the controller will stop the compressor.
The following procedure will temporarily eliminate the thermostat.
The fridge should not be run for more than a few minutes in this configuration.
If you do not understand this proceedure seek help from a qualified electrician or technician!
BEWARE a short circuit between two terminals of a battery can result in a fatal explosion of
the battery.
1
2
Turn off or isolate any charging sources such as wind generators, mains battery chargers or solar panels.
Solar panels can simply be covered to block the sun.
Disconnect the fridge from the battery/power supply by turning off the battery isolator switch and remove the fuse
as shown in Section B steps 3,4 & 5. If there is no battery isolator switch, remove the fuse as shown in Section B steps 3,4 & 5.
If you are unsure of the battery or electrical configuration seek help from a qualified electrician
or technician!
3
.
Locate the
terminal
marked (T) on
the Danfoss
controller .
4
Mark any wires connected to this terminal (T) so that you can replace them in the correct position after the test.
Danfoss controller Repairs TEST PAGE B
5
6
Disconnect any wires connected to the terminals marked (T) and (C) on the Danfoss controller. Use insulation tape to protect the wires once they are disconnected from the terminals marked (T) and (C) on the Danfoss
controller so it cannot contact other wires,electrical components or metal.
Fire could result if this wire is not insulated correctly. Always grip the
crimped terminal, not the wire.
You may need to have a technician or auto electrician assemble a wire with
a female spade terminal each end for this step. Connect one end of the wire
to the terminal marked (C) on the Danfoss controller. Connect the other end
of the wire to the terminal marked (T) on the Danfoss controller.
7
While listening for any sound from the compressor, reconnect the fridge to the battery/power supply by turning compressor. Wait at least 1 minute to see if the compressor will run.
8
If the compressor runs you have probably diagnosed a faulty thermostat and the thermostat will need to be does not need to be repaired.
9
If the compressor does not run, disconnect the fridge from the battery/power supply by turning off the battery on the isolator switch and/or re-inserting the fuse removed in step 2 and try to detect noise or vibration from the replaced. You do not need to continue with the instructions in this document and your Danfoss controller probably isolator switch and remove the fuse as shown in Section B steps 3,4 & 5. If there is no battery isolator switch, remove the fuse as in Section B steps 3,4 & 5. Remove the temporary wire link that you connected in step 6, reconnect any wires you removed in step 5 to the terminal marked (T) so that the wiring is back as it was before the test and go to the next procedure.
Danfoss controller Repairs TEST PAGE B
SECTION D
Check the fan
This proceedure should only be used for the type of controller shown on the contents page of this document.
In some installations an electric fan may be used to cool the condensor of the refrigeration system. The fan may be
connected between the terminal marked (F) on the Danfoss controller and the terminal marked (C) on the Danfoss
controller. The Danfoss controller will turn the fan on when the compressor is running. If a fan connected to the Danfoss controller is defective it may cause the controller to shut down.
The following proceedure will temporarily eliminate the fan.
The fridge should not be run for more than a few minutes in this configuration.
If you do not understand this proceedure seek help from a qualified electrician or technician!
BEWARE a short circuit between two terminals of a battery can result in a fatal explosion of the battery.
1
2
Turn off or isolate any charging sources such as wind generators, mains battery chargers or solar panels.
steps 3,4 & 5.
Solar panels can simply be covered to block the sun.
Disconnect the fridge from the battery/power supply by turning off the battery isolator switch. Remove the fuse as
shown in Section B steps 3,4 & 5. If there is no battery isolator switch, remove the fuse as shown in Section B, If you are unsure of the battery or electrical configuration seek help from a qualified electrician
or technician.
3
4
Locate the terminal marked (F) on the Danfoss controller.
Mark any wires connected to this terminal (F) so that you can replace
them in the correct position. Remove the wire from the terminal marked
(F) on the Danfoss controller. Use insulation tape to protect the wire
once it is disconnected from the terminal so it cannot contact other
wires,electrical components or metal as shown in Section C, Step 5.
Fire could result if this wire is not insulated correctly.
Danfoss controller Repairs TEST PAGE B
5
While listening for any sound from the compressor, reconnect the fridge to the battery/power supply by turning on
the isolator switch and/or re-inserting the fuse you removed in step 2. Adjust the fridge thermostat to the coldest setting and try to detect noise or vibration from the compressor. After you turn on the fridge wait at least 1 minute to see if the compressor will run.
6
If the compressor runs you have probably diagnosed a faulty fan and the fan may need to be replaced. You do not
be repaired.
7
If the compressor still does not run, disconnect the fridge from the battery/power supply by turning off the battery
remove the fuse as shown in Section B steps 3,4 & 5. Reconnect any wires you removed in step 4 to the terminal marked (F) on the Danfoss controller so that the wiring is back as it was before the test and go to the next procedure.
need to continue with the instructions in this document and your Danfoss controller probably does not need to isolator switch and remove the fuse as shown in Section B steps 3,4 & 5. If there is no battery isolator switch, SECTION E
Check the compressor plug
This proceedure should only be used for the type of controller shown on the contents page of this document.
If you do not understand this proceedure seek help from a qualified electrician or technician!
BEWARE a short circuit between two terminals of a battery can result in a fatal explosion of
the battery.
1
2
Turn off or isolate any charging sources such as wind generators, mains battery chargers or solar panels.
Solar panels can simply be covered to block the sun.
Disconnect the fridge from the battery/power supply by turning off the battery isolator switch and remove the fuse
as shown in Section B steps 3,4 & 5. If there is no battery isolator switch, remove the fuse as shown in Section B, steps 3,4 & 5.
If you are unsure of the battery or electrical configuration seek help from a qualified electrician
or technician.
3
Locate the power lead that connects the Danfoss controller to the compressor.
4
Remove the metal
clip and plastic cover
from the compressor
plug. You may need
to lever it off with a
screwdriver.
Danfoss controller Repairs TEST PAGE B
5
Take note of the orientation of the plug
on the compressor so
you can replace it correctly.
6
Carefully remove the plug from the compressor. It may be nessecary to use a small screwdriver to lever the plug from the compressor, if so try to move each side of the plug alternately by only 1 or 2 millimetres each time. WARNING: If you do not take sufficient care the plug
may be damaged or broken.
7
Inspect the plug and the four matching pins on the compressor for corrosion and clean them with an abrasive cleaning pad or coarse
weave cloth if necessary. WARNING: DO NOT USE SANDPAPER
OR EMERY PAPER.
8
9
Replace the plug in the same orientation as you noted in step 5. Do not replace the cover and clip at this time.
While listening for any sound from the compressor, reconnect the fridge to the battery/power supply by turning on the battery isolator switch and/or re-insert the fuse removed in step 2. Adjust the fridge thermostat to the coldest setting and try to detect noise or vibration from the compressor. Wait at least 1 minute to see if the compressor will run.
10
If the compressor runs, you have probably diagnosed a dirty plug connection and resolved the problem. Turn off the fridge and replace the cover and clip. You do not need to continue with the instructions in this document and your Danfoss controller probably does not need to be repaired. 11
If the compressor still does not run go to the next proceedure.
Danfoss controller Repairs TEST PAGE B
9
SECTION F
Compressor resistance test
This proceedure should only be used for the type of controller shown on the contents page of this document.
Inside the Danfoss compressor are three coils that are switched by the Danfoss controller to make the compressor
run.These coils and the points where they connect to the outside plug some times become loose or disconnected.
The proceedure described below allows you to test the condition of the connections and the coils inside the
compressor. Experience with electrical meters is preferred as it is quite impossible to include instructions for all the
meters that could be used for this test.
If you do not understand this proceedure seek help from a qualified electrician or technician!
BEWARE a short circuit between two terminals of a battery can result in a fatal explosion of
the battery.
1
2
Turn off or isolate any charging sources such as wind generators, mains battery chargers or solar panels.
Solar panels can simply be covered to block the sun.
Disconnect the Danfoss controller from the battery/power supply by turning off the battery isolator switch and
remove the fuse as shown in Section B steps 3,4 & 5. If there is no battery isolator switch, remove the fuse as
shown in Section B steps 3,4 & 5.
If you are unsure of the battery or electrical configuration seek help from a qualified electrician
or technician!
3
5
Locate the power lead
that connects the Danfoss
controller to the
compressor (as in the
compressor plug test).
Take note of the
orientation of the plug
onthecompressorso
you can replace
it correctly.
4
Remove the metal
clip and plastic cover
from the compressor
plug (as in the
compressor plug test).
Danfoss controller Repairs TEST PAGE B
6
10
Carefully remove the plug from the compressor. It may be
nessecary to use a small screwdriver to lever the plug from the
compressor, if so try to move each side of the plug alternately
by only 1 or 2 millimetres each time.
WARNING: If you do not take sufficient care the plug
may be damaged or broken.
7
2
4
9
For 12
1
Identify the
positions of
the four pins.
8
On your meter select the lowest range
capable of measuring 5 ohms. Place one
meter probe on pin 3. Place the second
meter probe on pin 1, then pin 4, then
pin 2, recording the values for each.
3
volt Danfoss compressors the measured resistances between the pins should be as follows
Betweenpins 3and1 should be 0.2 ohms
Betweenpins3and4 should be 0.2 ohms
Betweenpins3and2 should be 2.7 ohms
For
24 volt Danfoss compressors the measured resistances between the pins should be as follows
Betweenpins3and1 should be 0.7 ohms
Betweenpins 3and4 should be 0.7 ohms
Betweenpins3and2 should be 2.7ohms
These are the coil resistances recommended by Danfoss but I have seen compressors that varied from these
recommended values by 10% that still operated.
10
The results of this test will be the basis of a major and perhaps costly decision in resolving your refrigeration
problem, so take some time, check your results and perhaps get some one with more electrical experience to
repeat the procedure and verify your results.
11
If the values you measured vary from the values recommended in step 9 by more than 10%, the windings or
connections inside the compressor are probably damaged and will need the services of a refrigeration
technician to test and probably replace the compressor.
12
If the values you measured meet the specifications, replace the plug on the compressor making sure the plug
is oriented the same way as it was before you removed it. Reconnect the fridge to the battery/power supply
by turning on the isolator switch and/or re-insert the fuse removed in step 2 and go to the next procedure.
Danfoss controller Repairs TEST PAGE B
11
SECTION G
Suppy voltage test
This proceedure should only be used for the type of controller shown on the contents page of this document.
If you do not understand this proceedure seek help from a qualified electrician or technician
BEWARE a short circuit between two terminals of a battery can result in a fatal explosion of
the battery.
1
2
Locate the terminal marked + and the terminal marked - on the controller.
3
Turn the fridge off.Then using a d.c. voltmeter or a multi
meter place one of the meter probes in the terminal marked +
on the Danfoss controller and place the second meter probe
in the terminal marked - on the Danfoss controller and read
the voltage.
Power and thermostat wiring can vary in individual installations so there is no ”best” way to carry out this test. However, if possible, it is advantageous to initiate a compressor start attempt. This may be accomplished by turning the thermostat that controls the fridge/freezer temperature fully to the warm or off position, wait approximately 3 minutes, then while watching the volt/multimeter, turn the thermostat fully to cold. Alternately in some installations turning the power supply off and then back on will initiate a start attempt. If the compressor rattles or squeals this is an indication that the compressor is trying to start. It is important to note the voltage at the + and - terminals on the Danfoss controller during these start attempts.
4
If the voltage measured at the + and - terminals on the Danfoss controller drops below 11 volts for a 12 volt system
be investigated and the Danfoss compressor/controller may not be at fault. You do not need to continue with the instructions in this document and your Danfoss controller probably does not need to be repaired.
or below 22 volts for a 24 volt system, the batteries and/or electrical system supplying power to the fridge should If the voltage measured at the + and -terminals is consistent and stays above the recommended values and you have
performed all the tests on this site but the compressor still does not run, the Danfoss controller is probably defective.
If you do not understand this proceedure seek help from a qualified electrician or technician Note: When the Danfoss compressor attempts to start, it uses a large amount of electrical power for a short
time (less than a second) During this time a loose or dirty connection in the power supply or a poor b
attery can cause the voltage at the Danfoss controller terminals to drop so that the compressor won`t start.
Some voltage/multi meters don`t update their readings quickly enough to indicate this short drop in supply
voltage even though it causes the compressor controller to turn off.
Danfoss controller Repairs TEST PAGE B
12
SECTION H
Conclusion - REMOVE, PACK AND SEND
If you have carried out all the procedures in this document and the values recorded during the compressor resistance
test and the supply voltage test were within the recommended values then the Danfoss controller is probably defective.
Cold technology can provide an exchange controller which has been cleaned, repaired, recoated and tested under
various temperature, supply voltage and load conditions. The following information is a guide to help you remove the
Danfoss controller from your installation and send it to us. It is important that you follow the instructions below
very carefully.
1
Turn off or isolate any charging sources such as wind generators, mains battery chargers or solar panels.
Solar panels can simply be covered to block the sun.
BEWARE a short circuit between two terminals of a battery can result in a fatal explosion of
the battery.
2
Disconnect the fridge from the battery/power supply by turning off the battery isolator switch and remove the fuse
steps 3,4 & 5.
as shown in Section B steps 3, 4 & 5. If there is no battery isolator switch, remove the fuse as shown in Section B, If you are unsure of the battery or electrical configuration or do not understand this procedure seek
help from a qualified electrician or technician.
3
Attach a piece of tape to each wire connected to the Danfoss controller and write on the tape which terminal the
when you reinstall the repaired Danfoss controller.
4
When you have marked the wires, remove one wire and use insulation tape to protect the wire once it is
wire is connected to as in Section C step 4. This will allow you to reconnect the wires to the correct terminals disconnected from the Danfoss controller so it cannot contact other wires, electrical components or metal as in Section C step 5. Fire
5
6
7
Repeat step 3, removing and insulating one wire at a time until all the wires are disconnected from the Danfoss controller. Fire
could result if this wire is not insulated correctly.
could result if these wires are not insulated correctly.
Locate the power lead that connects the Danfoss controller to the compressor. See Section F step 3.
Remove the clip and plastic cover from the compressor plug. See Section F step 4.
Danfoss controller Repairs TEST PAGE B
8
9
13
Take note of the orientation of the plug on the compressor so you can replace it correctly. See Section F step 5.
Carefully remove the plug from the compressor. It may be necessary to use a small screwdriver to lever the plug from the compressor, if so try to move each side of the plug alternately by only 1 or 2 millimetres each time. See Section F step 6.
WARNING: If you do not take sufficient care the plug may be damaged or broken.
If you are not confident in carrying out this procedure seek assistance from a qualified electrician or technician!
10
Remove any screws or bolts that hold the Danfoss controller in place. TIGHTEN THE SCREWS
TRANSPORT.
IN ALL THE TERMINALS ON THE DANFOSS CONTROLLER SO THAT THEY ARE NOT LOST IN
IMPORTANT - READ BEFORE SENDING
Please include YOUR NAME and EMAIL address which we will use to:
1. Advise you when your controller arrives.
2. Provide your invoice.
3. AFTER RECEIPT OF PAYMENT, notify you that your controller has been shipped.
For pricing see the pricing page in the services menu on the Cold Technology website.
SENDING INSTRUCTIONS
Now that you have uninstalled the Danfoss controller, Pack it and send it to:
COLD TECHNOLOGY
UNIT 15/398 THE BOULEVARDE
KIRRAWEE 2232
SYDNEY, AUSTRALIA
Very Important Note!
This type of controller may not be repairable. An exchange unit may
not be available. If the fault in your controller is due to the failure of an
electronic component that we cannot source then we cannot repair
your controller and therefore, cannot provide you with an exchange unit,
however, most controllers of this type can be exchanged.
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