Fisher & Paykel E210 User manual

517798
ELECTRONIC VERTICAL
FREEZERS
Models E150, E210, E308, E388

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517798 APRIL 2006 REPRINT JULY 2006
Fisher & Paykel Appliances Ltd
78 Springs Road, East Tamaki
PO Box 58-732, Greenmount
Auckland, New Zealand
Telephone: [phone]
Facsimile: 09 273 0656
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
COPYRIGHT ©FISHER & PAYKEL LTD 2006 ALL RIGHTS RESERVED
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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.

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CONTENTS
1 INTRODUCTION ...................................................................................................................5
1.1 Electronics..................................................................................................................5
1.2 Product Specification..................................................................................................5
1.2.1 Compressors/Refrigerant Charge..........................................................................5
1.2.2 Compressor Specification......................................................................................5
1.3 Condenser Layout......................................................................................................6
1.4 Suction Line Assembly...............................................................................................6
1.5 Bottom Step Evaporator.............................................................................................6
2 ELECTRONICS.....................................................................................................................6
2.1 Control Module...........................................................................................................6
2.2 Temperature Controller..............................................................................................6
2.3 Temperature Sensors.................................................................................................6
2.4 Beeper/Alarm .............................................................................................................7
2.5 Defrost Heater............................................................................................................7
2.6 FC Fan .......................................................................................................................7
2.7 Door Reed Switch ......................................................................................................7
2.8 Defrost Cycle..............................................................................................................8
2.9 Fault Alarm.................................................................................................................8
2.10 Compressor Starting ..................................................................................................8
3 FAULT CODES .....................................................................................................................8
3.1 Fault Code Table........................................................................................................8
3.2 To Disable Alarm......................................................................................................10
3.3 To Manually Force a Defrost....................................................................................10
4 SERVICE PROCEDURES...................................................................................................10
4.1 Control Module.........................................................................................................10
4.2 Compressor Overload ..............................................................................................10
4.3 FC and Defrost Sensor.............................................................................................10
4.3.1 To Replace FC Sensor........................................................................................10
4.3.2 To Replace Defrost Sensor .................................................................................11
4.4 Variable Resistor......................................................................................................11
4.5 FC Defrost Element..................................................................................................11
4.6 Reed Switch.............................................................................................................11
4.7 Fan Motor.................................................................................................................11
5 WIRING DIAGRAM .............................................................................................................13
6 FAULT FINDING .................................................................................................................15
6.1 Compressor Won’t Start...........................................................................................15
6.2 Compressor Starts, Runs and Then Stops...............................................................15
6.3 Compressor Humming .............................................................................................15
6.4 Freezer Too Cold .....................................................................................................15
6.5 Freezer Too Warm ...................................................................................................15

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1 INTRODUCTION
The service manual covers the implementation of electronic control to Vertical Freezers.
1.1 Electronics
Changes to the vertical freezers are that an electronic module has replaced the defrost timer and a
variable resistor replaces the temperature control.
With the introduction of the electronic module, some of the current functions of the product will also
now change. These will be covered under the appropriate headings.
The operational component such as the evaporator has also changed from the corrugated type
evaporator to the new Showa fin on tube type evaporator. The internal condenser and cabinet do
not change.
1.2 Product Specification
1.2.1 Compressors/Refrigerant Charge
Product Model Compressor Part Number Refrigerant Charge
E150 207119 85 grams R134a
E210 207120 105 grams R134a
E308 207120 105 grams R134a
E388 207121 115 grams R134a
VF-300EX 207200 105 grams R134a
VF-J300EX 207200 105 grams R134a
1.2.2 Compressor Specification
Brand Matsushita Matsushita Matsushita
Model DG66C11RAW5 DG73C12RAW5 DG77C14RAW5
Part Number 207119 207120 207121
Volts 220 – 240 220 – 240 220 – 240
Hertz 50 50 50
Nominal BTU 638 723 768
Output Watts 187 212 225
Run Current (Amps) 0.56 0. 62 0.71
Start Resistance (Ohms) 17.7 17.6 13.1
Run Resistance (Ohms) 15.4 14.1 11
Relay F&P Electronic F&P Electronic F&P Electronic
Overload Part Number 207130 207130 207130
Run Capacitor Part Number 814809 814809 814809
Brand Matsushita
Model EGU80HLC 100V
Part Number 207200
Volts 100V
Hertz 50 / 60
Nominal BTU -
Output Watts 205 / 240
Run Current (Amps) 1.41 / 1.52
Start Resistance (Ohms) 3.15
Run Resistance (Ohms) 3.05
Relay PTC 207203
Overload Part Number 207202
Run Capacitor Part Number 814817

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1.3 Condenser Layout
The compressors have no oil cooler lines; therefore the re-routing of the condenser is as follows:
Discharge line from the compressor runs directly to the condenser on the back panel. From the
back panel it enters the base panel, then through the left-hand side condenser, into the right-hand
side condenser, then to the filter dryer capillary. The remaining circuit layout remains unchanged.
1.4 Suction Line Assembly
The accumulator has been incorporated into the Showa evaporator assembly, therefore the
accumulator inside the insulating foam has been removed. This has, in effect, removed three
internal welds and replaced them with two external welds (above the evaporator assembly). The
suction line assembly now has exposed ends at the unit compartment and the FC compartment.
1.5 Bottom Step Evaporator
With the new electronics and thermistor temperature control, the bottom step evaporator has been
made redundant. This also has the effect of removing a further two internal welds (inside the
insulating foam) from the unit.
2 ELECTRONICS
2.1 Control Module
The electronic control module is situated in the unit compartment. It is connected to mains supply
and switches the compressor, defrost heater and FC fan motor. The compressor is switched
through a solid state Triac and relay, and the defrost heater through a relay. The compressor has
an external overload and relay fitted. The defrost and FC sensors are located above the
accumulator and on the rear duct. A variable resistor, which replaces the temperature controller, is
used to cycle the freezer. The defrost timer has also been replaced by the electronics in the
control module.
2.2 Temperature Controller
The temperature adjustment is a variable resistor located on the control module at the rear of the
cabinet. The FC evaporator temperature range varies between –12ºC at the warmest setting of 1
and -24ºC at the coldest setting of 7. Between 3 and 4 is the mid factory setting (approx is -18ºC).
2.3 Temperature Sensors
These are thermistors whose resistance changes 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 within the FC compartment. The FC sensor is located in the
centre of the duct panel above the evaporator and senses the temperature for switching the
compressor on and off. The defrost sensor is located immediately above the FC evaporator
accumulator. Its only job is to terminate the defrost (switch off the defrost element) once the
sensor reaches +8º C.

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Thermistor Sensors Resistance Table
Temperature (ºC) Resistance
(K Ω±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
2.4 Beeper/Alarm
This is a piezo electric device located in the control module to provide the user with feedback on
fault alarms. If a fault occurs or the door is left open, the alarm will sound. It will repeat the fault
alarm each time the door is opened.
2.5 Defrost Heater
A 230/240v 260 watt (E150/210), 450 watt (E308/388) defrost heater is positioned beneath and
around the evaporator and is used to defrost 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. The thermal fuses are part
of the element heater assembly.
These fuses in both leads of the element protect the refrigerator from any overheating through
failure of the defrost element itself or a failure in the control module. Both sides are protected in
case polarity is reversed.
NOTE: Care should be taken if manually defrosting the evaporator using heat guns to ensure that
the thermal fuses are not over heated.
In normal conditions the defrost period is terminated by the control module when the defrost sensor
reaches +8º C.
2.6 FC Fan
The FC fan is a Shaded Pole Motor. The fan cycles with the compressor, however turns off if the
door is opened. A further feature added into the electronic software energises the fan during the
off cycle should the compressor run time fall below 25%. This feature will aid in preventing the unit
from short cycling during low ambients.
2.7 Door Reed Switch
The door reed switch is located on the bottom cross rail and is activated by a magnet located in the
door.

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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 12 hours to 22 hours of compressor run time, depending on the
duration time of the last defrost.
When the control module switches the compressor off for the defrost, there is a 2 minute delay
(warm up time) before the defrost element is turned on. The defrost is terminated when the defrost
sensor reaches +8º C. Then there is a 4 minute delay (drip time) after the defrost element has
been switched off before the compressor is turned on and the system is back to normal run.
Defrost Cycle
Compressor switches off Defrost element switches off at 8º C
Defrost element Compressor switches
Switches off back on
2 minute 4 minute
delay delay
30 minute maximum defrost time
Normal Run Warm up Defrost Cycle Drip Time Normal Run
Time
2.9 Fault Alarm
If the control module detects a fault, which it is unable to correct, an alarm is sounded. When the
cabinet has a fault, the alarm will sound a fault code each time the door is opened. The number of
beeps indicates the fault code. If the door is closed, the alarm discontinues until the door is
opened again. To repeat the fault code, close and open the door.
2.10 Compressor Starting
The compressor is started by the control module through the PTC (relay) fitted to the compressor.
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.
3 FAULT CODES
If a fault should develop in the temperature measuring system, defrost system, temperature control
variable resistor, or should the compressor fail to start, an audio fault alarm will sound when the
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 code as shown in the Fault Code
table below.
3.1 Fault Code Table
Fault 2: 2 beeps
Reason: Defrost sensor failed to reach +8º C 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.

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Fault 3: 3 beeps
Reason: The resistance of FC sensor is outside the normal range (> 45K Ohms)
Primary Action: Check the 4-way connector at the control module.
Secondary Action:Check sensor resistance.
Reterminate the 4-way connector.
Tertiary Action: Replace control module.
Fault 4: 4 beeps
Reason: The resistance of FC sensor is outside the normal range (< 660 Ohms)
Primary Action: Check the 4-way connector at the control module.
Secondary Action:Check sensor resistance.
Reterminate the 4-way connector.
Tertiary Action: Replace control module.
Fault 7: 7 beeps
Reason: The resistance of defrost sensor is outside the normal range (> 45K Ohms)
Primary Action: Check the 4-way connector at the control module.
Secondary Action:Check sensor resistance.
Reterminate the 4-way connector.
Tertiary Action: Replace control module.
Fault 8: 8 beeps
Reason: The resistance of defrost sensor is outside the normal range (< 660 Ohms)
Primary Action: Check the 4-way connector at the control module.
Secondary Action:Check sensor resistance.
Reterminate the 4-way connector.
Tertiary Action: Replace control module.
Fault 9: 9 beeps
Reason: Compressor has failed to start after 5 attempts
Primary Action: Check the integrity of the compressor
Secondary Action:Replace control module.
Fault 10: 10 beeps
Reason: The control variable resistor has an open circuit fault.
Primary Action: Check the continuity of the circuit between the variable resistor and the control
module and the connections at the variable resistor and the control module.
Secondary Action:Replace control module

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3.2 To Disable Alarm
Turn the control knob fully clockwise and then fully anticlockwise within 5 seconds.
3.3 To Manually Force a Defrost
Open the door for 5 seconds, then shut the door, turn the control knob fully clockwise and then fully
anticlockwise within 10 seconds.
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 mains potential. The product is to be turned off and disconnected from the power supply.
Electrical Safety Check.
Whenever any part of the electrical circuit is services or disturbed in the course of carrying out
service adjustments or repair, it is essential that insulation resistance and earth continuity tests are
carried out using the appropriate test equipment.
4.1 Control Module
 Unplug the refrigerator from the outlet socket.
 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
module needs to be removed before the overload is removed by pulling it from the compressor
terminals. An Ohmmeter is used to test for continuity of the overload.
4.3 FC and Defrost Sensor
The FC and defrost 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 FC Sensor
 Unplug the refrigerator from the outlet socket.
 Remove evaporator cover.
 Remove the affected sensor from its holder.
 Cut the sensor from the loom and replace it by soldering and heat shrinking the new
sensor to the loom.
 Replace sensor into its holder.
 Replace fan cover.

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4.3.2 To Replace Defrost Sensor
 Unplug the refrigerator from the outlet socket.
 Remove evaporator cover.
 Remove the affect sensor from its holder.
 Cut the sensor from the loom and replace it by soldering and heat shrinking the new
sensor to the loom.
 Replace sensor into its holder.
 Replace fan cover.
4.4 Variable Resistor
Built into control module. If faulty, replace control module.
4.5 FC Defrost Element
Defrost element is replaceable as it is located below the evaporator and held in place by two side
plate tabs.
4.6 Reed Switch
 Unplug the refrigerator from the outlet socket.
 Remove the door switch cover (located in the centre of the base rail).
 Unclip the encapsulated reed switch from the housing.
 Replacement of the new switch is done by cutting the wiring back from the switch end and
soldering in a new switch, making sure both connecting wires are not shorting but
insulated with heat shrink sleeving. Take care not to leave too much excess wire as the
reed switch must be able to be fitted back in to the housing.
 Refit in reverse order.
4.7 Fan Motor
 Unplug the refrigerator from the outlet socket.
 Remove food, shelves and baskets.
 Remove long duct cover.
 Remove front cover.
 Pull off fan blade.
 Disconnect motor leads.
 Remove the one screw from fan mounting bracket and lift motor clear.
 Fit replacement fan motor in reverse order.

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5 WIRING DIAGRAM
ΩΩ
ΩΩ

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ΩΩ
ΩΩ

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6 FAULT FINDING
The following faults and probable causes have been listed with the assumption that all basic
checks have been carried out, such as 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 specification).
 Check Run capacitor.
(Manual starting devices can be used to confirm diagnostics.)
6.2 Compressor Starts, Runs and Then Stops.
 Check the connections at the fusite plug, overload and control module connections.
 Check supply voltage.
(Manual starting devices can be used to confirm diagnostics.)
6.3 Compressor Humming
 Check continuity of overload. If no continuity, replace overload.
 Check connections at fusite plug, overload and control module connections.
 Check start and run windings (as per specifications).
 Check run capacitor.
6.4 Freezer Too Cold
 Check resistance of variable resistor.
 Check resistance of FC sensor as per table.
 Check evaporator for frost pattern. Full frost pattern required. If there is not a full frost
pattern, check product for shortage of refrigerant or inefficient compressor.
 Check evaporator temperatures at the entry and exit of the evaporator. If the temperature
of the exit differs by 5 - 10º from that of the entry, further investigation is required.
6.5 Freezer Too Warm
 Check setting of control knob.
 Check resistance of variable resistor.
 Check resistance of FC sensor as per table.
 Check that the fan is operational.
 Check if evaporator is defrosting correctly, if not check the defrost sensor and/or defrost
element.
 If defrost is working, check temperature of the evaporator to rule out or confirm system
and/or compressor fault/s.