Fisher & Paykel E169T User manual

ELECTRONIC COMPACT SERIES
REFRIGERATOR FREEZER
Models
E169T, E249T,
E240B
517795

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MANUAL 517795 - AUGUST 2004 REPRINT:
The specifications and servicing procedures outlined in this manual are subject to
change without notice.
The latest version is indicated by the reprint date and replaces any earlier editions.
Fisher & Paykel Australia Pty Ltd
A.C.N. 003 335 171
19 Enterprise Street
P O Box 798
Cleveland, Queensland 4163
Telephone: [phone]
Facsimile: 07 3826 9164
Fisher & Paykel Appliances Ltd
78 Springs Road, East Tamaki
PO Box 58-732, Greenmount
Auckland, New Zealand
Telephone: [phone]
Facsimile: 09 272 0219
COPYRIGHT  FISHER & PAYKEL LTD 2004

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CONTENTS
1 INTRODUCTION ..................................................................................................4
1.1 Electronics..................................................................................................4
1.2 Product Specification..................................................................................4
1.2.1 Compressors......................................................................................4
1.2.2 Compressor Specification ..................................................................4
1.3 Condenser Layout ......................................................................................5
2 ELECTRONICS ....................................................................................................5
2.1 Control Module ...........................................................................................5
2.2 Light Operation...........................................................................................5
2.3 Beeper........................................................................................................5
2.4 Temperature Sensors.................................................................................5
2.5 Thermistor Sensors Resistance Table........................................................ 6
2.6 FC Fan .......................................................................................................6
2.7 Defrost Heater ............................................................................................6
2.8 Defrost Cycle..............................................................................................7
2.9 PC Heater...................................................................................................7
2.10 Temperature Controller ..............................................................................7
2.11 Fault Alarm .................................................................................................7
2.12 Compressor Starting...................................................................................7
3 FAULT CODES ....................................................................................................8
3.1 Fault Code Table ........................................................................................8
3.2 To Disable a Fault Alarm ............................................................................9
3.3 To Manually Force a Defrost ......................................................................9
4SERVICE PROCEDURES ..................................................................................10
4.1 Control Module .........................................................................................10
4.2 Compressor Overload ..............................................................................10
4.3 FC & PC Sensors .....................................................................................10
4.3.1 To Replace PC Sensor ....................................................................10
4.3.2 To Replace FC Sensor..................................................................... 10
4.4 Variable Resistor ......................................................................................11
4.4.1 To Replace Variable Resistor ..........................................................11
4.5 FC Defrost Heater ....................................................................................11
5Wiring Diagram .................................................................................................12
6FAULT FINDING.................................................................................................13
6.1 Compressor Won’t Start ...........................................................................13
6.2 Compressor Starts, Runs And Then Stops............................................... 13
6.3 Compressor Humming..............................................................................13
6.4 PC Too Cold.............................................................................................13
6.5 PC Warm..................................................................................................13
6.6 FC Too Cold .............................................................................................13
6.7 FC Warm .................................................................................................. 14
6.8 Alarm Sounds When Door Is Opened ......................................................14
6.9 Light Not Functioning................................................................................ 14

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1 INTRODUCTION
The service manual covers the implementation the compact series electronic models
E169T, E240B, E249T.
1.1 Electronics
Changes to the compacts are that an electronic module has replaced the defrost
timer and relay. A variable resistor replaces the thermostat.
With the introduction of the electronic module, some of the current functions of the
product will also change. These will be covered under the appropriate headings.
The operational components such as evaporator, condenser and cabinet do not
change.
1.2 Product Specification
1.2.1 Compressors
Product Model Compressor Part Number Refrigerant Charge
E169T 207108 85 grams R134a
E249T 207108 95 grams R134a
E240B 207109 95 grams R134a
1.2.2 Compressor Specification
Brand EMBRACO EMBRACO
Model EMY45HSC EMY60HSC
Part Number 207108 207109
Volts 220 – 240 220 – 240
Hertz 50 50
Nominal BTU 372 491
Output Watts 109 144
Input Watts 70 92
Run Current (Amps) 0.33 0.43
Start Resistance (Ohms) 39.55 15.54
Run Resistance (Ohms) 35.07 Ohms 23.56
Relay F&P Electronic F&P Electronic
Overload
Part Number 207152 207152
Description 4TM189KFBYY-53 4TM189KFBYY-53
Run Capacitor
Part Number 207160 207161
Description 3uF 400V 5uF 400V

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1.3 Condenser Layout
The new compressors have no oil cooler lines, therefore the re-routing of the
condenser is as follows:
Discharge line from the compressors runs directly to the condenser on the back
panel. From the back panel it enters the LH side condenser, through the cross rail
heater (if applicable) then into the RH condenser, then into the filter dryer. The
remaining layout remains unchanged.
2 ELECTRONICS
2.1 Control Module
The electronic control module is situated in the unit compartment. It is connected to
220-240 volt supply for switching of the compressor, defrost heaters and FC fan.
The compressor is switched through a solid state Triac and relay, and the defrost
heater through a relay. The compressor has an external overload. Sensors are
located in the PC and FC and, along with a variable resistor, which replaces the
thermostat, are used to cycle the refrigerator. The defrost timer has also been
replaced by the control module.
2.2 Light Operation
The light globe remains at 230V 15 watt and is switched using the same light switch
mechanism as for compacts. The light switch is operated by the plunger being
depressed by the dairy cover to turn the light on and off. If the P.C. door is left open
longer than 90 seconds, the alarm will sound. This will repeat every 30 seconds until
the door is closed, and will sound continuously after the door has been left open for 5
minutes. The control module measures the current drawn by the P.C. light to
determine whether the door is open or closed. If the P.C. lamp circuit is open circuit
(e.g. lamp is blown or missing) the door open alarm will not operate.
2.3 Beeper
This is a piezo electric device located in the control module to provide the user with
feedback on fault alarms. If a fault occurs, the alarm only sounds when the PC door
is opened. It turns off when the door is closed.
2.4 Temperature Sensors
These are temperature sensing devices, the resistance of which change with respect
to temperature. They have a single connector on the printed circuit board to ensure
the integrity of the resistance of the sensor is measured. Two sensors are located in
the product. The PC sensor is located in a pocket attached to the left-hand side of
the PC evaporator and senses the temperature for switching on and off the
compressor. The FC sensor, which is the defrost sensor, is located immediately
above the FC evaporator for defrost termination temperature sensing.

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2.5 Thermistor Sensors Resistance Table
Temperature (OC) Resistance
(K Ohms + 5%)
-30.0 25.17
-25.0 19.43
-20.0 15.13
-15.0 11.88
-10.0 9.392
-5.0 7.481
0.0 6.000
5.0 4.844
10.0 3.935
15.0 3.217
20.0 2.644
25.0 2.186
30.0 1.817
35.0 1.518
40.0 1.274
45.0 1.075
50.0 0.9106
2.6 FC Fan
The fan is a 240v shaded pole motor. The fan cycles with the compressor but
remains on when the door is opened.
2.7 Defrost Heater
A 230/240V, 350watt heating element positioned beneath and around the FC
evaporator is used to defrost the ice accumulated on the evaporator.
There are two thermal fuses mounted in the wiring harness of the defrost element,
having a tripping temperature of 72Oc. Once open circuit they cannot be reset.
Replacement is part of the element heater assembly.
These fuses in both leads of the element protect the refrigerator from any over
heating through failure of the element itself or a triac failure in the control module.
Both sides are protected in case polarity is reversed.
NOTE: Care should be taken if manually defrosting the evaporator if using heat
guns, that the thermal fuses are not over heated.
In normal conditions the defrost period is terminated by the control module when the
FC evaporator sensor (defrost sensor) reaches +8OC.

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2.8 Defrost Cycle
The defrost heater is controlled by the control module, which switches it via a relay.
The defrost interval can vary from between 8 hours of compressor run time to 16
hours of compressor run time, depending on the duration time of the last defrost.
When the control module switches the compressor off for a defrost, there is a 2
minute delay before the defrost heater is turned on. The defrost is terminated when
the defrost sensor reaches +8OC. At the conclusion of the defrost, there is a 4
minute delay after the defrost element has been turned off before the compressor is
turned on.
Defrost Cycle
Normal RunNormal Run
Warm up time Drip time
Compressor switches off
Defrost element
switches on
Defrost element switches off at +8oC
Compressor switches
back on
2 minute
delay
30 minutes Maximum defrost time
4 minute
delay
Defrost Cycle
2.9 PC Heater
The PC heater is located behind the cooling plate. The heater is connected directly
to the control module.
2.10 Temperature Controller
A control, consisting of a variable resistor, located in the control box is used to set the
desired temperature. The resistance range of this resistor is from 0Ω to 1KΩ. The
PC evaporator temperature range varies between -17.5OC at the lowest setting of 1,
to –28O C at the highest setting on 7. Mid setting of 4 is -23.5O C.
2.11 Fault Alarm
If the control module detects a fault, which it is unable to recover, an alarm is
sounded. The alarm only comes on when the PC door is opened. The numbers of
beeps indicate the fault code. (Refer Fault Codes, Section 3.)
If the door is closed, the alarm discontinues until the door is opened again.
2.12 Compressor Starting
The compressor is started by the control module. It is a timed start, therefore if the
compressor does not start within 1 second, the controller will cancel the start. If the
compressor draws too much current, the overload will activate and cut power to the
compressor.

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3 FAULT CODES
If a fault should develop in the temperature measurement system, defrost system,
temperature control variable resistor, or should the compressor fail to start, an audio
fault alarm will sound when to P.C. door is opened. The alarm consists of a number
of beeps emitted by the beeper located in the control module. The number of beeps
emitted indicates the fault as shown in the Fault Code Table below.
3.1 Fault Code Table
Fault 2: 2 beeps
Reason: Defrost sensor failed to reach +8oC within 30 minutes. This has
happened in the last three defrosts, therefore probably defrost
heater failure.
Action: Check connections at the control module and inline connectors.
Check defrost heater. If faulty, replace.
Fault 3: 3 beeps
Reason: The resistance of both the temperature sensors is outside the
normal range (> 45K Ohms).
Primary Action: Check the 4 way connector at the control module.
Secondary Action: Check sensor resistance.
Re-terminate the 4 way connector.
Tertiary Action: Replace the control module.
Fault 4: 4 beeps
Reason: The resistance of both the temperature sensors is outside the
normal range (< 660 Ohms).
Primary Action: Check the 4-way connector at the control module.
Secondary Action: Check sensor resistance.
Re-terminate the 4 way connector.
Tertiary Action: Replace the control module.
Fault 7: 7 beeps
Reason: The resistance of the defrost sensor is outside the normal range
(> 45K Ohms).
Primary Action: Check sensor resistance.
Check the sensor connection at the control module.
Secondary Action: Replace the sensor.
Fault 8: 8 beeps
Reason: The resistance of the defrost sensor is outside the normal range
(< 660 Ohms).
Primary Action: Check sensor resistance.
Check the sensor connection at the control module.
Secondary Action: Replace the sensor.

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Fault 9: 9 beeps
Reason: The resistance of the PC sensor is outside the normal range (>
45K Ohms).
Primary Action: Check sensor resistance.
Check the sensor connection at the control module.
Secondary Action: Replace the sensor.
Fault 10: 10 beeps
Reason: The resistance of the PC sensor is outside the normal range (<
660 Ohms).
Primary Action: Check sensor resistance.
Check the sensor connection at the control module.
Secondary Action: Replace the sensor.
Fault 11: 11 beeps
Reason: The compressor has failed to start after 5 attempts.
Primary Action: Check the integrity of the compressor.
Secondary Action: Replace the control module.
Fault 12: 12 beeps
Reason: The control (variable resistor) has an open circuit fault.
Primary Action: Check the continuity of the circuit between the variable resistor
and control module and the connections at the variable resistor
and control module.
Secondary Action: Replace the variable resistor.
3.2 To Disable a Fault Alarm
Turn the variable resistor (control knob) fully clockwise and then fully anticlockwise
within 5 seconds.
3.3 To Manually Force a Defrost
While pushing in the light switch knob, turn the variable resistor (control knob) fully
clockwise and then fully anticlockwise within 10 seconds.

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4 SERVICE PROCEDURES
Note: No work is to be carried out on the product while in a live situation. All
components can be at a 230volt potential. The product is to be turned off and
disconnected from the power source.
Electrical Safety Checks
Whenever any part of the electrical circuit is serviced or disturbed in the course of
carrying out service adjustments or repair, it is essential that insulation and earth
continuity tests are carried out using the appropriate test equipment.
4.1 Control Module
• Remove the drain pan/tray.
• Remove the two screws securing the module to the cabinet.
• Pull the module outwards.
• Remove all the connectors from the control module.
• Refit the module in reverse order making sure all wiring is secured in the module
and the wiring harness is located in the module slot.
4.2 Compressor Overload
Remove the compressor cover. Once the cover is removed, the compressor
connector from the control module needs to be removed before the overload is
removed by pulling off the compressor terminals. An Ohmmeter is used to test for
continuity of the overload.
4.3 FC & PC Sensors
The FC & PC sensor are tested at the module. The module is to be removed and the
Sensor RAST connector can be removed for testing.
4.3.1 To Replace PC Sensor
• Unplug the refrigerator from the power source.
• Remove control housing and rear duct from housing.
• Disconnect all connectors to give access to PC sensor.
• Replacement of the sensor is done by cutting the wiring to the old sensor as close
to the sensor as possible. Strip each wire back far enough (about 10mm) to allow
it to be soldered to the wiring of the new sensor. Strip each wire of the new
sensor back a similar amount and slide some heat shrink sleaving over each wire.
Solder a wire from the new sensor to a wire of the harness that was going to the
old sensor. Slide the heat shrink sleaving over the joint and heat to shrink.
Repeat with the other wires.
• Reassemble in reverse order.
• Test light operation after assembly.
4.3.2 To Replace FC Sensor
• Unplug the refrigerator from the power source.
• Remove air duct (on B models). Note: Care should be taken in removing duct so
as not to damage duct or cabinet.
• Remove rear evaporator cover, disconnect fan wiring and remove cover from
refrigerator.

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• Replacement of the sensor is done by cutting the wiring to the old sensor as close
to the sensor as possible. Strip each wire back far enough (about 10mm) to allow
it to be soldered to the wiring of the new sensor. Strip each wire of the new
sensor back a similar amount and slide some heat shrink sleaving over each wire.
Solder a wire from the new sensor to a wire of the harness that was going to the
old sensor. Slide the heat shrink sleaving over the joint and heat to shrink.
Repeat with the other wires.
• Reassemble in reverse order.
4.4 Variable Resistor
Testing of the variable resistor is carried out by using a multimeter set on Ohms.
However, it is difficult to check the full resistance range of the variable resistor,
therefore to check if the resistor is working correctly and there are not faults with the
resistor, manually force a defrost. If the product does not defrost, then further checks
must be carried out by removing the variable resistor.
If the product start the defrost, then the variable resistor has no fault.
4.4.1 To Replace Variable Resistor
• Remove control housing.
• Disconnect variable resistor from harness.
• Remove knob from resistor.
• Loosen nut on resistor and remove.
• Reassemble in reverse order.
4.5 FC Defrost Heater
• Remove air duct (B Models).
• Remove FC evaporator cover, disconnect fan.
• Disconnect heater from the connector.
• Cut heater wires below fuses.
• Remove evaporator brackets, heater clips and deflectors.
• Lift evaporator outwards and separate the evaporator to remove old heater.
• Feed new heater from underneath evaporator.
• Connect new heater and position fuses.
• Reassemble in reverse order.

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5 Wiring Diagram
ΩΩ
ΩΩ

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6 FAULT FINDING
The following faults and probable cause/s have been listed with the assumption that
all basic checks have been carried out. Example, product has power, door is closing
correctly etc.
6.1 Compressor Won’t Start
• Check continuity of overload. If no continuity replace overload.
• Check Start and Run Winding (as per specifications).
• Check Run Capacitor.
(Manual Compressor Starting Device can be used to confirm diagnostics.)
6.2 Compressor Starts, Runs And Then Stops
• Check connections at the fusite plug, overload and control module connections.
• Check supply voltage.
(Manual Compressor Starting Device can be used to confirm diagnostics.)
6.3 Compressor Humming
• Check continuity of overload. If no continuity replace overload.
• Check connections at the fusite plug, overload and control module connections.
• Check Start and Run Winding (as per specifications).
• Check Run Capacitor.
6.4 PC Too Cold
• Check resistance of variable resistor.
• Check resistance of PC sensor as per table.
• Check cooling plate for frost pattern. Full frost pattern is required. If not a full
frost pattern, check product for shortage of refrigerant or inefficient compressor.
• Check temperatures of cooling plate both intake and exit of plate. If temperature
of intake differs from exit temperature, further investigation is required.
6.5 PC Warm
• Check setting of control knob.
• Check resistance of variable resistor.
• Check resistance of PC sensor as per table.
• Check if cooling plate has normal frost pattern. If not, further investigation is
required.
6.6 FC Too Cold
• Check setting of control.
• Check if PC sensor is in correct position.
• Check resistance of PC sensor as per table.
• Check if FC Evaporator has normal frost pattern. Checking temperature of the FC
evaporator and cooling plate is recommended to rule out or confirm system or
compressor fault/s.

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6.7 FC Warm
• Check setting of control.
• Check door seal.
• Check frost pattern of FC evaporator. If fully frosted, check defrost by forcing a
defrost.
• If defrost doesn’t work, check defrost sensor and/or defrost heater and fuses.
• If defrost is working, checking temperature of the FC evaporator and cooling plate
is recommended to rule out or confirm system or compressor fault/s.
6.8 Alarm Sounds When Door Is Opened
• Count how many beeps, check fault code table for probable cause.
6.9 Light Not Functioning
• Check light globe and ensure light is fully screwed in.
• Check connections.
• Is light switch depressing correctly? Check position of plunger and/or is the dairy
cover in place.