Fisher & Paykel RF201A User manual

819091D
Service Manual
RF201A Active Smart
USA
Refrigerator Freezer

819091D
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819091D MARCH 2009
Fisher & Paykel Appliances
5800 Skylab Road
Huntington Beach
CA 92647
Telephone: [phone]
COPYRIGHT ©FISHER & PAYKEL LTD 2007 - ALL RIGHTS RESERVED
3
The specifications and servicing procedures outlined in this manual are subject to change without notice.

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CONTENTS
1SPECIFICATIONS........................................................................................................................8
1.1 CABINET SPECIFICATIONS ................................................................................................8
1.2 COMPRESSOR SPECIFICATIONS ......................................................................................8
1.3 ELECTRICAL SPECIFICATIONS..........................................................................................8
2MODEL NUMBER IDENTIFICATION...........................................................................................9
3SERVICING REQUIREMENTS ..................................................................................................10
3.1 SPECIALISED SERVICE TOOLS .......................................................................................10
Static Strap.....................................................................................................................................10
Interface Pen Mk 2.........................................................................................................................10
3.2 HEALTH & SAFETY............................................................................................................10
Good Work Practices.....................................................................................................................10
Environmental Health And Safety.................................................................................................10
Good Practice And Safety..............................................................................................................10
4INSTALLATION INSTRUCTIONS..............................................................................................11
4.1 LEVELLING COMPONENTS...............................................................................................11
4.2 LEVELLING THE CABINET ................................................................................................12
4.3 AIR SPACE REQUIREMENTS............................................................................................12
5THEORY OF OPERATION.........................................................................................................13
5.1 TERMS.................................................................................................................................13
5.2 DEFROST CYCLE...............................................................................................................14
5.3 THE REFRIGERATION CYCLE ..........................................................................................15
5.4 SERVICING FEATURES .....................................................................................................16
Condensate Disposal......................................................................................................................16
Filter Drier......................................................................................................................................16
Internal Condenser.........................................................................................................................17
Condenser Layout RF210A ...........................................................................................................18
Compressor Compartment Layout.................................................................................................19
5.5 CROSS RAIL .......................................................................................................................19
5.6 DIVIDER PARTITION...........................................................................................................19
6ELECTRONICS SECTION .........................................................................................................21
6.1 DIAGRAMMATIC OVERVIEW FUNCTION DESCRIPTION ...............................................21
6.2 CONTROL & PERIPHERAL FUNCTIONS..........................................................................21
Power/Control Module...................................................................................................................21
Door Switches................................................................................................................................21
Defrost Heater................................................................................................................................21
Thermal Fuse..................................................................................................................................22
Low Ambient Heater......................................................................................................................22
PC / FC Fans..................................................................................................................................23
Lights (PC & FC)...........................................................................................................................24
Thermistor Temperature Sensors...................................................................................................24

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7DISPLAY INTERFACE...............................................................................................................26
7.1 DISPLAY INTERFACE (BUTTON DESCRIPTIONS – Products Before January 2009).. 26
7.2 DISPLAY INTERFACE (BUTTON DESCRIPTIONS – Products After January 2009)..... 26
7.3 DISPLAY FUNCTIONAL SCHEMATIC............................................................................... 27
7.4 DISPLAY INTERFACE FEATURES (Products Before January 2009)............................. 28
7.5 DISPLAY INTERFACE FEATURES (Products After January 2009)................................ 28
7.6 FEATURES (Products Before January 2009)................................................................... 28
7.6.1 Icemaker On/Off .............................................................................................................28
7.6.2 Freezer Chill Mode .........................................................................................................28
7.6.3 Bottle Chill Mode............................................................................................................29
7.6.4 Water Dispensing............................................................................................................29
7.6.5 Measured Fill Water Dispenser......................................................................................29
7.6.6 Sabbath Mode.................................................................................................................29
7.6.7 Key Silent Mode ............................................................................................................30
7.6.8 Dispenser Lock...............................................................................................................30
7.6.9 Key Lock.........................................................................................................................30
7. 6.10 Filter Replacement Alert ……………………………………………………………..30
7.7 FEATURES (Products After January 2009)...................................................................... 30
7.7.1 Icemaker On/Off .............................................................................................................30
7.7.2 Freezer Chill Mode .........................................................................................................30
7.7.3 Bottle Chill Mode............................................................................................................30
7.7.4 Water Dispensing............................................................................................................31
7.7.5 Sabbath Mode.................................................................................................................31
7.7.6 Key Silent Mode ............................................................................................................31
7.7.7 Dispenser Lock...............................................................................................................31
7.7.8 Key Lock........................................................................................................................31
7.7.9 Filter Replacement Alert.................................................................................................31
7.8 ICEMAKER.......................................................................................................................... 32
Ice Production................................................................................................................................32
Information About The Icemaker..................................................................................................32
Ice Bin Full Sequence....................................................................................................................32
Safety First.....................................................................................................................................33
7.9 KEY PRESSES (Products before January 2009)............................................................. 34
7.10 KEY PRESSES (Products after January 2009) ................................................................ 34
7.11 TEMPERATURE SETTINGS............................................................................................... 35
7.12 INTERNAL AIR FLOW ........................................................................................................ 35
7.13 DIAGNOSTICS .................................................................................................................... 35
7.14 FAULT CODES ................................................................................................................ 35
7.15 FAULT CODES ................................................................................................................ 39
7.16 TESTING ICEMAKER SENSOR...................................................................................... 40
7.17 TESTING ICEMAKER MOTOR........................................................................................ 40
7.18 TESTING WATER VALVE ............................................................................................... 40
7.19 TESTING FLOW METER (Products Before January 2009).......................................... 40
7.20 TESTING FLOW METER (Products Before January 2009).......................................... 40
8DIAGNOSTIC MODES............................................................................................................... 41

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9INPUT / OUTPUT STATUS........................................................................................................43
9.1 FAULT HISTORY.................................................................................................................43
9.2 TO MANUALLY FORCE A DEFROST................................................................................43
9.3 LCD DISPLAY......................................................................................................................43
9.4 TO MANUALLY FORCE THE ICEMAKER .........................................................................44
9.5 DATA DOWNLOAD.............................................................................................................44
10 WATER DISPENSER..............................................................................................................45
10.1 PRESSURE DISPENSING PAD.......................................................................................45
10.2 INITIAL USE .....................................................................................................................45
10.3 WATER FILTER AND CARTRIDGE ................................................................................45
10.4 CHANGING THE WATER FILTER...................................................................................45
10.5 TO RESET THE FILTER ICON.........................................................................................46
10.6 TO DISABLE FILTER ALARM (Products Before January 2009)..................................46
10.7 FLOW METER CALIBRATION (Products Before January 2009) .................................46
10.8 TO DISABLE THE FILTER ALARM (Products After January 2009).............................46
11 VARIABLE CAPACITY COMPRESSOR................................................................................47
11.1 VARIABLE CAPACITY COMPRESSOR CONTROL OVERVIEW ..................................47
11.2 BUILT-IN ELECTRONIC PROTECTIONS (WITHIN THE MODULE / INVERTER) .........47
Compressor Start-Up......................................................................................................................47
Overload Detection And Protection...............................................................................................47
Power Limitation (Temperature Protection)..................................................................................47
Short Circuit Protection .................................................................................................................48
11.3 VCC MODULE/INVERTER IDENTIFICATION .................................................................48
11.4 FAULT FINDING...............................................................................................................48
High Voltage Power Supply Circuit ..............................................................................................48
12 SERVICING PROCEDURES...................................................................................................49
12.1 SAFETY CONSIDERATIONS...........................................................................................49
12.2 ELECTRICAL SAFETY TEST..........................................................................................49
12.3 DOOR AND DOOR GASKET...........................................................................................50
12.4 COMPONENT REMOVAL & REPLACEMENT................................................................51
12.4.1 Removal Of Power/Control Module................................................................................51
12.4.2 PC Sensor Replacement...................................................................................................51
12.4.3 PC2 Sensor Replacement.................................................................................................51
12.4.4 Removal Of PC Fan Motor..............................................................................................52
12.4.5 Replacing Cross / Base Rail Door Reed Switches ..........................................................52
12.4.6 Display Module Replacement .........................................................................................52
12.4.7 Water Dispensing Pad Replacement................................................................................53
12.4.8 Removing Water Tank.....................................................................................................54
12.4.9 Refitting Water Tank.......................................................................................................54
12.4.10 Defrost Heating Element.................................................................................................55
12.4.11 Thermal Fuse...................................................................................................................55
12.4.12 Removal Of FC Bins .......................................................................................................55
12.4.13 Removal Of The FC Drawer ...........................................................................................55
12.4.14 Refitting Of The FC Drawer............................................................................................56

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12.4.15 Removal Of The FC Sensor............................................................................................57
12.4.16 Icemaker Unit Replacement............................................................................................57
12.4.17 Replacing Flapper Element.............................................................................................57
12.4.18 Refitting Icemaker...........................................................................................................58
12.4.19 Icemaker Temperature Sensor Replacement...................................................................58
12.4.20 Water Valve Replacement...............................................................................................58
12.4.21 Replacement Of Low Ambient Heater............................................................................59
12.4.22 Replacement Of Interior Lamp .......................................................................................59
12.4.23 Replacement of PC Door ................................................................................................59
12.4.20 Block/Edge Connectors...................................................................................................60
12.5 ACTIVE SMART PC/FC FAN MOTOR TESTER ............................................................. 62
12.6 PRESSURE TESTING OF THE REFRIGERATION SYSTEM......................................... 62
12.7 TRANSPORTING OF REFRIGERATORS....................................................................... 64
12.8 EVAPORATOR REPLACEMENT .................................................................................... 65
12.9 COMPRESSOR REPLACEMENT.................................................................................... 65
13 FAULT FINDING..................................................................................................................... 67
13.1 COMPRESSOR WON'T START - DEAD....................................................................... 67
13.2 COMPRESSOR WON'T START - HUMS ........................................................................ 67
13.3 COMPRESSOR STARTS, RUNS AND THEN STOPS.................................................... 67
14 WIRING DIAGRAM................................................................................................................. 68
15 SERVICE REFERENCE.......................................................................................................... 69
15.1 SERVICE REFERENCE................................................................................................... 69
16 FAULT FINDING FLOW CHART - SERVICING.....................................................................74
16.1 REFRIGERATOR NOT OPERATING .............................................................................. 75
16.2 POWER TO POWER/CONTROL MODULE AND/OR DISPLAY MODULE .................... 76
16.3 PC/FC WARM................................................................................................................... 77
16.4 FC TOO COLD – PC TOO WARM................................................................................... 78
16.5 PC TOO COLD................................................................................................................. 79
16.6 ICE/CONDENSATION FORMING.................................................................................... 80
16.7 NO LIGHT......................................................................................................................... 81
16.8 DOOR SWITCH NOT OPERATING.................................................................................82
16.9 DEFROST HEATER FAULTS.......................................................................................... 83
16.10 COMPRESSOR FAULTS................................................................................................. 84
16.11 COMPRESSOR RUNS CONTINUOUSLY....................................................................... 84
16.12 COMPRESSOR WILL NOT RUN AND IS HOT TO TOUCH ........................................... 85
16.13 COMPRESSOR ELECTRICAL TESTS............................................................................ 85
16.14 REFRIGERATION SYSTEM FAULTS ............................................................................. 86
16.15 NOT DISPENSING WATER............................................................................................. 87
16.16 NOT PRODUCING ICE ....................................................................................................88

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1. SPECIFICATIONS
1.1 CABINET SPECIFICATIONS
DIMENSIONS RF201A
Height 70 inches
Depth 28 ¾ inches
Width 35 ½ inches
CAPACITY GROSS VOLUME
Provision Compartment 14.1 cu.ft.
Freezer Compartment 4.13 cu.ft.
TOTAL 18.25 cu.ft.
ELECTRONICS
Display Module Part No. 814857P
Power/Control Module Part No. 817859P
Module/Inverter Part No. 837126
SUCTION LINE ASSEMBLY
Part Number 817864
DEFROST ELEMENT
Part Number 884125P
1.2 COMPRESSOR SPECIFICATIONS
Make Embraco
Model VEG Y6H
Part Number 884259
Volts 230
Hertz 53 - 150
Phase 3
Input Watts 55.7 - 205
Output Watts 97 - 468
Nominal BTU 330 - 1596
Start Resistance (Ohms) 6.40
Run Resistance (Ohms) 6.40
Starting Device Type Inverter
Oil Charge (cm3) 430
Refrigerant Type R134a
Gas Charge 6.4ozs (180 Grams) of
R134a
1.3 ELECTRICAL SPECIFICATIONS
Rated Voltage 120 Volts
Rated Current 1.75 amps
Frequency 60 Hz
Heater Flapper 12 Volt
10 Watt
15 Ohms
Defrost Element 110V
355 Watts
Light Bulb 12 volt

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2 MODEL NUMBER IDENTIFICATION
1 2 3 4 5 6 7 8 9
RF 201 A D U M 1 FP AA
Product
Type
Cubic
Capacity
of cabinet
201 = 20
cubic feet
French
Doors
Designer
Handles
Ice &
Water
Colour
M = Iridium
X = S/S EZKLEEN
Iteration Brand Market
Refrigerator RF 201 A D U M 1 FP AA
RF PRODUCT TYPE
201 Cubic Capacity
A French Door & Drawer
D Designer Handles
U Ice & Water
M Iridium Door
1 ITERATION
FP Brand
AA Market

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3 SERVICING REQUIREMENTS
3.1 SPECIALISED SERVICE TOOLS
For the servicing of this product, specialised tools are needed.
Static Strap
To be used as ESD protection when replacing the console board.
Interface Pen Mk 2
Used to retrieve and download data from the electronic control module along with the diagnostic programme
on a laptop. Part number 425930.
3.2 HEALTH & SAFETY
Good Work Practices
1. Take care while removing all plastic components, especially when cold.
2. Leave the product clean and tidy when service work is completed.
3. Extreme heat in cabinets will cause plastic deterioration or distortion and thermal fuses in the
evaporator to go open circuit (be careful with heat guns).
Environmental Health And Safety
When servicing products, consider safety and health issues and requirements, which must be adhered to at
all times. Specific safety issues are:
1. Electrical safety.
2. Electrostatic discharge.
3. Mixing of foam insulation.
4. Vapours while brazing.
5. Reclaiming of refrigerant.
Good Practice And Safety
1. Take care when removing or servicing all electrical components to avoid electrical shock or short
circuit conditions.
2. Take care when removing plastic components at low temperatures as breakages can occur with these
components.
3. Extreme heating of plastic components can cause distortion of those parts being heated.
4. Avoid overheating temperature sensitive devices such as the element thermal fuse and cabinet
sensors.
5. Avoid using solvents and citrus based cleaners on all plastic parts. We advise only warm soapy water
be used.

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4 INSTALLATION INSTRUCTIONS
4.1 LEVELLING COMPONENTS
Front and rear rollers are fitted ex factory.
Cabinet levelling can be done by adjustment of the front roller-levelling wheel fitted ex factory. See diagram
4.1B
Weight should be lifted off cabinet for ease of adjustment.
CURRENT TYPE
Diagram A (Rear Roller) Diagram B (Front Leveller & Roller)

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4.2 LEVELLING THE CABINET
The word 'level' is somewhat of a misnomer, as a 'spirit level' need not be used to set the appliance level. It
is preferable to have the appliance level in appearance where both doors will close with the aid of the door
closing components. It is also important that the appliance sits solidly on the floor.
Cabinet levelling can be done by
adjustment of the front roller-levelling
wheel fitted ex factory.
Weight should be lifted off the cabinet for
ease of adjustment.
The product should be levelled with the
majority of the weight on the right hand
hinge side front foot.
The opposite side of the front foot should
then be adjusted to stabilise the product.
Measure the gap between the roller and
the floor. This distance should be the depth
of the rear packing material.
Cut the solid packing material to the depth
and place the material against the wall and
push the product on top of material.
Unlevelled floors:
Gently push the refrigerator back until the
rear rollers contact floor.
Measure the gap under the front foot,
which has come off the floor.
Obtain some solid packing material
(hardwood, plastic etc), which fits firmly
into the gap under the foot.
Note: do not use metallic materials that
may corrode and stain or damage floor
coverings.
4.3 AIR SPACE REQUIREMENTS
On all refrigerators and freezers it is important that an air gap is left around the product:
• 2 inches clearance at the top.
• ¾ inch clearance each side.
• 1 inch clearance at the back.

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5 THEORY OF OPERATION
5.1 TERMS
CABINET WRAPPER
Pre-painted steel.
LINER
A one piece vacuum formed ABS liner with a plug-in divider.
DIVIDER PARTITION
Injected moulding of HIPS, with two outer injected moulded housings, and an insulated ducted moulded
polystyrene inner core.
FAN MOTORS
DC 12 volt brushless variable speed fan motors for air circulation in both 1 x FC and 1 x PC compartments.
EVAPORATOR
Aluminium Fin on Tube type mounted vertically on the back wall of the FC.
SUCTION & CAPILLARY LINE
Foamed into the back of the cabinet with all joints of the evaporator having been brazed in the FC.
POWER / CONTROL MODULE
Contains the microprocessor that controls all functions of the refrigerator and gathers data from the sensors.
This module also contains support circuitry to switch the various outputs.
DISPLAY MODULE
Using signals from the Power Module, this module generates the LED display. The lamp is also switched
from this module.
REED SENSORS
A reed switch encapsulated within a plastic housing, mounted on the cross and base rails behind a plastic
cover. A magnet housed just under the lower end cap of each door activates this reed switch when the door
is closed.
COMPARTMENTS
In this manual we refer to the refrigerator compartments as follows:
PC = Provision or fresh food compartment.
FC = Freezer compartment.
LOW AMBIENT HEATER
Blanket wire type used in divider.

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5.2 DEFROST CYCLE
The following table outlines the defrost cycle of an Active Smart refrigerator.
Defrost Cycle of the Active Smart Refrigerator
(With Fin On Tube Evaporator)
Compressor Defrost element Defrost element Compressor Both PC & FC
turns off turns on turns off turns on fans turn on
Defrost time;
Target is 18 minutes
Maximum is 40 minutes
Normal run 2 Minutes 4 minutes 30 sec Back to normal run
Warm up Defrost Drip time Delay
If 40 minutes has elapsed, defros
t
would be aborted if defrost senso
r
has not reached 8°C. If 2 defrosts
are aborted, Fault code 2 is
displayed.

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5.3 THE REFRIGERATION CYCLE
The compressor discharges high pressure, high temperature gas into the back panel condenser circuit first,
returning via the oil cooler in the compressor and entering the side condenser in the cabinet by way of the
base tube. This tube runs from the compressor compartment forward to the front bottom edge of the cabinet,
returning down the left hand side to be connected to the left hand side condenser coil (viewed from the rear of
the cabinet).
A loop from this condenser coil forms the cross rail mullion on dual temperature cabinets. The condenser then
continues across the top front edge of the cabinet to form the right hand side condenser entering the filter
drier, which is mounted vertically in the unit compartment.
Now the high-pressure gas has been condensed, the liquid refrigerant flows through the capillary tube entering
the evaporator mounted in the freezer compartment. The liquid refrigerant then boils off due to the low suction
pressure applied to within the evaporator from the compressor. The heat-laden vapour is drawn back to the
compressor by way of the suction line to start the cycle all over again.
The above information relates to the cabinet, not the drawing below.
F.F.C.

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5.4 SERVICING FEATURES
Condensate Disposal
During the defrost cycle, which is electronically timed and controlled, live frost is melted off the evaporator by
means of heat from the defrost element. Condensate from the evaporator defrosting drops into a collection
trough, which has an outlet hole in the centre of the liner. A tube then allows the condensate to flow into a
water evaporation tray above the compressor.
Filter Drier
The filter drier or molecular sieve, as the name suggests, is both a filter and a drier. Whenever a system is
opened it is essential that the filter drier is replaced. ALWAYS ensure that replacement filter driers are kept
well sealed and airtight prior to being fitted to a system.
PLEASE NOTE: When filter driers are replaced on systems being serviced, it is important that the filter drier is
either cut from the system or the desiccant is removed before heat is applied to the old filter drier. Failure to
do so will drive any moisture held in the desiccant back into the system.
ALWAYS mount vertically or as near to vertical as possible and use the correct desiccant to suit the refrigerant
being used.
XH7 or XH9 suits R134a.

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Internal Condenser
The internal condenser is made in three sections (see circuit diagram below). One third of the condenser is
attached to the back panel, and the other parts are attached to the inside of the right and left sides of the
cabinet wrapper (as viewed from the back) all being foamed into place. It is very important, if pressure testing
the high side circuit, to split the condenser into its 3 sections to locate which section is at fault. Always ease
the back panel away from the cabinet slightly before pressure testing the internal pipe work. This will prevent
a pressure build-up within the cabinet should any leak be found internally in the foam insulation. Such a leak
could pressurise and damage the cabinet liner.
The back panel condenser comes as part of the back panel and should always be replaced as a complete
assembly if the back panel is ever removed. On fitting a new back panel assembly always replace the mastic
vapour-sealing compound before fitting the back panel into the triple fold of the cabinet.

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Condenser Layout RF610A, RF540A, RF201A
CONDENSER WITH TUBE CROSS RAIL
ALL BRAZED CONDENSER JOINTS ARE EXTERNAL IN UNIT COMPARTMENT
Note: No oil cooler
compressor, used Back panel
condenser to Base tube heater

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Compressor Compartment Layout
The diagrams below will assist in identifying the various pipes within the compressor compartment. They
should be read in conjunction with the full system diagram (See Diagram 0).
1. Service tube (process pipe)
2. Suction line
3. Discharge line into water evaporator tray.
4. Water evaporator to condenser back panel
5. Back panel to base tube
6. Capillary tube
7. Filter dryer
8. External joints from internal condenser circuit.
5.5 CROSS RAIL
The cross rail contains part of the condenser copper tubing (mullion heater) providing heat to the gasket area
between the PC and FC compartments, preventing sweating of the gasket. Also mounted on the cross rail is
the Reed Sensor, under the plastic cover behind each of the French doors and behind the FC drawer.
5.6 DIVIDER PARTITION
This is moulded in two outer pieces and has an inner polystyrene moulded duct assembly that is wax coated.
This provides a barrier between the FC and PC compartments, also allowing return air from the PC to move
back to the FC evaporator. The PC fan motor is housed in the back of the divider. It also houses the low
ambient heater. The divider is fitted into the cabinet as an assembly and cannot be replaced.
1 23
8
4
5
6
7

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“B” DIVIDER PARTITION