Dometic EA 3080 User manual

Pub. Nr.: 599363870 – REV.:A
Service Manual
Models:
EA 3080 WA 3080
EA 3120 WA 3120
EA 3140 WA 3140

2
Table of Contents:
1. The appliance .................................................................................... 3
1.1. Specifications .................................................................................... 3
1.2. Important notes.................................................................................. 3
1.3. Spare parts ........................................................................................ 4
1.3.1. Cabinet .............................................................................................. 4
1.3.2. Aggregate and electrical circuit.......................................................... 4
1.3.3. Door................................................................................................... 5
1.4. Wiring diagram .................................................................................. 6
2. Installation and repair operations....................................................... 7
2.1. Tools.................................................................................................. 7
2.2. Cabinet, door ..................................................................................... 8
2.2.1. Adjusting right and left-hand swing door............................................ 8
2.2.2. Replacing legs .................................................................................10
2.2.3. Replacing hinge...............................................................................11
2.2.4. Replacing lock .................................................................................12
2.2.5. Replacing door panel.......................................................................13
2.3. Electrical component (Fuzzy logic solution).....................................15
2.3.1. Replacing lighting device and bulb ..................................................15
2.3.2. Replacing bulb without dismounting lighting device.........................17
2.3.3. Replacing heating element (Cylinder heating element) ...................18
2.3.4. Replacing temperature sensor.........................................................20
2.3.5. Temperature controller (Thermo fuse) .............................................21
2.4. Cooling aggregate ...........................................................................22
2.4.1. Replacing cooling aggregate ...........................................................22
3. Devices of different composition......................................................26
3.1. Model with ”half-moon” shaped heating element (as of May 2003) .26
3.1.1 Spare parts (Aggregate and electrical circuit)..................................26
3.1.2. Replacing heating element (”Half-moon” shaped) ...........................27
3.2. Model with electromechanical thermostat........................................29
3.2.1. Spare parts (Aggregate and electrical circuit)..................................29
3.2.2. Wiring diagram ................................................................................29
3.2.3. Replacing thermostat.......................................................................31
3.2.4. Replacing timer................................................................................33
3.3. Appliance with semi-automatic defrosting........................................34

3
1. The appliance
1.1.Specifications
The appliance is a 21, 31 and 41 litre upright refrigerator, operating with a wet
absorption cooling system.
At ambient temperatures between +16°C and +32°C, the cooling compartment
temperature can be adjusted between 0°C and +6°C using the thermostat.
It is suitable for ice making using the ice tray placed on the cooling flange.
Defrosting of the appliance is either automatic, where the appliance is switched off for
2 hours every 24 hour by the installed control, or it is semi-automatic and can be
initiated by pressing the defrost switch. Restart is done automatically in both cases.
1.2. Important Notes
- Do not repair or clean the appliance with the power supply cord plugged in!
- The appliance may only be operated by adults!
- All instructions in the operating manual must be followed when operating
the appliance!
- Any repair or service of the appliance that involves disassembling electrical
parts may be carried out by authorized service technicians only!
- Certain parts of the aggregate remain hot for a while after shutdown;
service must be carried out with caution!
- After any repair that involves disrupting the electrical circuit or the
replacement of aggregate, an electrical insulation resistance test must be
carried out at all times! (see 2.3.3.)
- Only appliances with compliance qualifications may be connected to the
mains!
- It is recommended to wear protective gloves for operations with possible
hand injuries!

4
1.3. Spare parts
1.3.1. Cabinet
1. Foamed cabinet
2. A,B,C Leg
3. Hinge
4. Door hinge top
5. Door hinge bottom
6. Door hinge hole cover
8. Cooling flange
10. Thermostat switch
11. Thermostat switch pad
12. Socket and switch casing
13. Bulb
15. Shelf
19. Door stop
20. Ice tray
21. Ice tray pad
30. Door stop plate
52. Sensor cover
53. 4°C temperature indicator
502. Lock cover
1.3.2. Aggregate and electrical circuit
200. Cooling aggregate +
(335.) Thermostat
201. Foam pad I.
202. Foam pad II.
203. Boiler-insulation
205. Drain water evaporizer
300. Various power outlets
306. Electrical cover
310. Heater element
323. Wire clamp
333. Temperature sensor
334. Circuit board mounted
Figure 2
Figure 1

5
1.3.3. Door
101. Foamed door
103. Door panel
104. Lock bar
106. Lock
110. Door shelf
111. Bottle holder rail
Attention!
Any functional parts that need to be replaced during repair may only be
replaced by parts identical to the originals and which were chosen based
on the list of spare parts!
Figure 3

6
1.4.Wiring diagram
Wiring diagram without temperature controller
Wiring diagram with temperature controller (as of April 2002)
Figure 5
Figure 4

7
2. Installation and repair operations
2.1.Tools
Recommended tools:
-Universal pliers 160-mm, 2 pc.
-magnetic screwdriver handle
-Pz 1 fitting-strip
-Pz 2 fitting-strip
-Phillips screwdriver Ph 1
-Standard screwdriver 120 * 5
-Standard screwdriver 100 * 4
-14-mm wrench
Figure 6

8
2.2.Cabinet, door
2.2.1. Adjusting right and left-hand swing door
- Unscrew top door mount screws. (Figure 7)
- Unscrew door mount hole cover screws. (Figure 8)
- Open door.
- Pull top door mount by tilting door. (Figure 9)
- Set aside door mount, unhinge door from
bottom door mount pin.
- Pull door mount hole cover. Help with
standard screwdriver when pulling.
(Figure 10,11)
Figure 7 Figure 8
Figure 9
Figure 10 Figure 11

9
- Place cabinet on its back carefully so that the hinge is not damaged.
- Dismount two front outer legs carefully so that the inner leg does not fall
out of the outer leg socket. (Figure 12,13,14) (The screws of the leg
secure the door mount and the door stop.)
Pull bottom door mount and door stop. Help with gently pulling the elements
crosswise. (Figure 15,16,17)
Push top door mount in place of the door stop, door stop in place of the bottom
door mount by turning it lengthwise 180°.
- Screw legs in place. (Figure 18)
- Stand cabinet on its legs.
- Reinsert door mount plate on to door mount pin of bottom door mount.
- Place door on bottom door mount. (Figure 19)
Figure 12 Figure 14
Figure 15 Figure 16 Figure 17
Figure 18 Fi
g
ure 19
Figure 13

10
- Place the replaced bottom door mount into left top door mount bore of
door. Push door mount into left-hand-side opening and secure with 2
screws. (Figure 20,21)
- Push door mount hole cover into upper right-hand-side opening, then
secure with a screw. (Figure 22)
Make sure of unhindered opening and appropriate secure sealing of the door. If
needed, make corrections after loosening the screws that secure the door. Re-
fasten the screws.
- When only replacing the door, dismounting of the door mount hole cover and
door stop or the switching of the door mounts is not necessary.
2.2.2. Replacing the legs
- Place unit on its back carefully so that the hinge is not damaged.
- Dismount outer legs by unscrewing 2-2 screws. (Figure 23)
- Take out inner legs from outer legs. (Figure 24)
- Mount inner legs by securing front legs using bores closer to door and
securing back legs using bores closer to back panel. (Figure 25)
Screw remaining screws into appropriate bores, fasten.
The front screws play a part in securing the door mount and the door stop.
Figure 20
Figure 22
Figure 21

11
- Set aside the outer legs (possible re-mounting).
- Place the refrigerator on its legs and check the door opening (the door
mount might have been repositioned due to loosening the door mount locking).
2.2.3. Replacing hinge
- Turn cabinet onto door using appropriate protection support.
- In case of curved door use support on both sides to avoid oscillation
(cardboard support). (Figure 26)
- Unscrew the screw that secures hinge, while keeping the end of hinge from
folding down.( Figure 27,28)
- Lastly, remove screw next to boiler insulation.( Figure 29)
(mounting ease)
- Lift up hinge, then put replacement part in place. (Figure 30)
Figure 26 Figure 27 Figure 28
Figure 23 Figure 24 Figure 25
Fi
g
ure 29 Figure 30

12
- Fasten screws starting with the screw next to boiler insulation, while
holding the unfastened end of hinge with your hand.
- Tighten screws. While fastening, check the leveling of hinge and plate.
Adjust as necessary.
2.2.4. Replacing lock
- Open door.
- Pull down rosette using 2 standard screwdrivers. (Figure 31)
- Pop up lock cover.
- With the bolt in locked position, pull the rim of lock cover onto the bolt
using a standard screwdriver to keep it from snapping back. (Figure 32)
- Snap off lock cover lid using 2 standard screwdrivers. (Figure 33)
- Unscrew securing screws. (Figure 34)
- Pull out lock. (Figure 35)
- Reassembly is done in reverse order.
- Rosette and lock cover lid should be snapped in place applying slight
pressure.
When popping the lock cover lid open, the bolt must be in locked position.
Figure 31 Figure 32 Figure 33
Figure 35
Figure 34

13
2.2.5. Replacing door panel
- Replacement of the door panel should be done with the door detached and
the lock dismounted (see 2.2.1, 2.2.4).
- Remove door shelves. They can be removed by lifting the shelves. (Figure
36,37)
- Place door – with door lining down – on protective support.
- Unscrew screws that secure locking-panel. (Figure 38)
- Lift locking-panel from its nest. (Figure 39)
Figure 36 Figure 37
Figure 38 Figure 39

14
- Pull out door panel. (Figure 40,41)
- Adjust foil lining.
- Place the the door panel up to the handle lath into groove on one side of
door. (Figure 42)
- Slightly bend door panel. (Figure 43)
- Snap door panel into place in groove on other side of door.
- Push door panel until cylindrical bores on the plate and on the door are
concentric. (Figure 44,45)
Figure 42 Figure 43
Figure 44 Figure 45
Figure 40 Figure 41

15
- Insert locking-panel, secure with screws.
- Reinstall lock (see 2.2.4)
- Reinstall door (see 2.2.1)
2.3. Electrical component (Fuzzy logic solution)
2.3.1. Replacing lighting device and bulb
- Remove screws securing lighting device. (Figure 46)
- Detach blocking tab on reflector from the lighting device by pressing the
reflector plate. At the same time, push the light shield off of the casing.
(Figure 47,48)
- Unscrew bulb. (Figure 49)
- Snap the lighting device open by detaching the tab behind the threaded
part of the casing with a screwdriver. (Figure 50)
- Disconnecting electrical wires, removing defective lighting device.
- Reconnecting electrical wires in new casing. Prior to wiring, wires must be
threaded in the appropriate bore of the reflector holder. (Figure 51)
- Placement of the socket in the casing so that its securing rib fits in the
groove of casing. Screws securing the wires must stand outwards from
lighting device. (Figure 52)
Figure 46 Figure 47 Figure 48
Figure 49 Figure 50

16
- Insert control switch while holding socket in place with your finger. (Figure
53)
- Screw in bulb while constantly holding down the socket. (Figure 54)
The bulb holds the socket elements in place, then the reflector mount can
be popped open. When snapping shut, the blocking tab should be slightly
pressed with a screwdriver. (Figure 55)
- After snapping shut, fitting should be tested.
- Replacing light shield. Make sure that the groove fits correctly on the light
shield.
While pushing aside the blocking tab of the reflector plate with a
screwdriver, the casing can be pushed in place. (Figure 56)
- Prior to installing the lighting device, the securing screws must be
reinserted into the lighting device so that the tips of the screws overhang
by 1-2 mm. These help positioning.
Figure 52Figure 51
Figure 53 Figure 54 Figure 55

17
- Install lighting device, with attention to the placement of electrical wires.
(Figure 57)
- Fastening securing screws. Make sure it fits correctly. The must be no gap
between the lighting device and the inner compartment.
2.3.2. Replacing bulb without dismounting the lighting device
- By pushing the reflector plate unhinge blocking tab on reflector from the
light shield. At the same time, push the light shield off of the casing with a
screwdriver. (Figure 58)
- Unscrew defective bulb and replace with a new one; pay attention to
appropriate back-up power. Bulb needs to be tightened to an extent that
loose connection does not cause contact failure. (Figure 59)
- Replacing the light shield. Make sure the groove fits correctly on the light
shield. (Figure 60)
The light shield can be slid in place by slightly pressing the blocking tab
with a screwdriver.
Figure 56 Figure 57
Figure 58 Figure 59 Figure 60

18
2.3.3. Replacing heating element (cylindrical heating element) :
- Remove screws of electrical cover. (Figure 61)
- Remove electrical cover. (Figure 62)
- Pop out locking tabs of the base with a screwdriver, lift off printed circuit
board. (Figure 63)
- Push off flat socket of heating element from flat connector with a
screwdriver (x3 connector).(Figure 64)
- Push off flat socket of the heating element’s protective grounding with a
screwdriver while the protective tab is pressed. (Figure 65)
- Spread the the temperature controller connection of the heating element.
(Figure 66)
- Unscrew and remove the wire clamp. (Figure 67)
Fi
g
ure 61 Fi
g
ure 62 Figure 63
Fi
g
ure 64 Figure 65
Figure 67
Figure 66

19
- Unscrew securing screw of boiler-insulation. (Figure 68)
- Turn metal casing of boiler-insulation so that the joint rim becomes visible.
- While slightly pressing the metal casing of the boiler-insulation, detach the
rims. (Figure 69)
- Turn out insulation – metal casing and rock wool together – from under the
boiler. (Figure 70)
- Loosen screw securing the element, pull out heating element upwards. If
the heating element is jammed in the heating tube, then push it out from
below with a screwdriver. (Figure 71,72,73)
- Installing the new heating element is done in reverse order. The
heating element must be securely fixed.
- Attention ! The capacity of a heating element with ”fuzzy logic” control is
different from those with electromechanical control!
- The boiler-insulation can be reinserted by turning it in. The rims must be
snapped together by slightly pressing the metal casing.
- Turn in boiler-insulation so that the securing bore is in the correct position.
- Attach boiler-insulation to back panel with securing screw.
- Adjust wires.
- Connect electrical connections at the appropriate points.
- Snap it back into printed circuit board. When replacing, make sure that the
driving shaft jointing fits in the potentiometer’s bore.
- Secure wire clamp.
- Reinsert electrical cover, secure with screws.
- Place refrigerator in upright position. Check that that thermostat switch
turns freely in the entire control range.
- Check electrical insulation resistance (with 1000-V electrical insulation
resistance metering device.)
The insulation resistance RINS > 2Mohm
Other composition: see section 3
Figure 68 Figure 69 Figure 70
Figure 71 Figure 72 Figure 73

20
2.3.4 Replacing temperature sensor
- Remove electrical cover. (See 2.3.3)
- Push off flat sockets of temperature sensor from the flat connectors of
printed circuit board. (Sensor)
- Open refrigerator door, remove plugs from two bores of sensor cover in the
inner compartment, set aside. (Figure 74)
- Unscrew screws of sensor cover, lift out sensor from cover. (Figure 75,76)
- Pull out sensor wire towards inner compartment carefully, so that the flat
sockets do not get jammed in the lead rubber gasket. (Figure 77,78)
- Thread back new sensor wire.
Practical way to do it:
From the back panel side insert a 4x100 standard screwdriver through
the lead bore. Slightly push the flat connector of sensor insulation socket
onto the edge of the screwdriver, secure with insulating tape. Fold back the
end of wire with insulation socket by 180°. Using the screwdriver, pull the
wire through the bore, then using that pull through the other end of the wire
as well.
When pulling through, pay attention to the position of the lead rubber
gasket. If it falls out, it must be put back in the bore by all means. (Figure
79,80)
Figure 77 Figure 78
Figure 74 Figure 75 Figure 76