Kuppersbusch IKE 458-4-4T User manual

Technical Manual
IKE 458-4-4T

Service Manual: H8-03-02
Responsible: U. Laarmann KÜPPERSBUSCH HAUSGERÄTE AG
E-mail: [e-mail]
Phone: [phone] Kundendienst
Fax: [phone] Postfach 100 132
Date: 10.10.2005 45801 Gelsenkirchen

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Contents
1. Safety ............................................................................................................................... 4
2. General ............................................................................................................................ 5
2.1 Installation and connection.................................................................................... 5
2.2 The differences from the previous model with the electromechanical timer are: .. 5
3. Technical manual ........................................................................................................... 6
3.1 General structure of the appliance ........................................................................ 6
3.2 Air circulation......................................................................................................... 7
3.3 Components .......................................................................................................... 8
3.4 Description of the individual components.............................................................. 8
4. Control panel ................................................................................................................ 10
4.1 Electronics........................................................................................................... 11
4.2 Freezer section ERF 2000 electronic unit ........................................................... 11
4.3 Electronics for refrigerator ERF2020................................................................... 14
5. Functioning ...................................................................................................................17
5.1 Normal (freezer section)...................................................................................... 17
5.2 Defrosting (freezer section) ................................................................................. 17
5.3 Ventilator for the battery-operated evaporator .................................................... 18
5.4 Superfrost function .............................................................................................. 18
5.5 Supercool function (refrigerator section) ............................................................. 18
5.6 Malfunctioning of the freezer air temperature probe ........................................... 18
5.7 Malfunctioning of the refrigerator air temperature probe ..................................... 19
5.8 NTC sensor characteristics ................................................................................. 20
6. Access to the individual components ........................................................................ 21
6.1 Freezer section.................................................................................................... 21
6.2 Replacing the flap thermostat.............................................................................. 22
6.3 Defrost resistor .................................................................................................... 22
7. Customer service program – freezer section ............................................................ 23
7.1 Start of the customer service program ................................................................ 23
7.2 Acknowledge the customer service program ...................................................... 23
7.3 Functions of the customer service program ........................................................ 23
8. Alarm indication ........................................................................................................... 25
8.1 Alarm freezer temperature .................................................................................. 25
8.2 Alarm freezer section door open ......................................................................... 25
9. Installation instructions ............................................................................................... 26
9.1 Adjusting the height............................................................................................. 26
9.2 Mounting the side panels .................................................................................... 26
9.3 Installation of the doors ....................................................................................... 27
9.4 Installing the appliance........................................................................................ 29
9.5 Attaching the base............................................................................................... 29
10. Circuit diagram IKE 458-4-4T....................................................................................... 31

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1. Safety
Danger!
Repairs may only be carried out by a qualified electrician! Inexpert repairs may
lead to danger and injury to the user!
To prevent electric shocks, please observe the following instructions:
• In the event of a fault, housing and frame may be live!
• Touching live components inside the appliance may cause dangerous currents to flow through your
body!
• Prior to repairs, disconnect the appliance from the mains!
• When inspecting live parts, a residual current operated device must be used at all times!
• The ground wire resistance must not exceed that specified in the standard! It is of vital importance
for ensuring the safety of people and the functioning of the appliance.
• On completion of repairs, an inspection must be carried out in accordance with VDE 0701
[Association of German Electrical Engineers] or the corresponding regulations for your country!
Caution!
Make sure you observe the following instructions:
• The appliances must be disconnected from the mains prior to all repairs. If inspections need to be
carried out on live appliances, make sure you use a residual current operated device.
Sharp edges: Use protective gloves.
Components may be electrostatic!
Observe handling precautions!

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2. General
This manual describes electronic refrigerators with four doors. This series is equipped with electronic
control elements instead of electromechanical thermostats. There is no electromechanical timer
because the electronics with the designation ERF2000 have an integrated electronic timer.
2.1 Installation and connection
Dry, well ventilated rooms present the best conditions for installing the fridge-freezers. In order to keep
electricity consumption low, the appliances should not be installed next to a cooker or a radiator. Avoid
direct sunlight.
When installed in a kitchen, fridge-freezers are arranged to fit in with normal work routines. It must be
ensured that the direction in which the door opens is the right one for the type of work carried out in the
kitchen.
The sign indicating the limits appears on the rating label. The fridge-freezers used in Germany almost
all belong to class “N”, i.e. avoid installing them in a room where a temperature of less than +16 °C or
more than +32 °C can be reached as the temperature regulator of the appliances will then fail to function
correctly. This has particularly adverse effects in refrigerators with an evaporator compartment and in
fridge-freezers with only one cooling circuit.
On no account should the appliance be installed in a place where the temperatures exceed +32 °C.
Fridge-freezers are supplied ready to plug in and are connected to an earthed socket. The rating is
between approx. 145 W and 265 W.
2.2 The differences from the previous model with the electromechanical
timer are:
Temperature control
Electro-mechanical with 4 doors: electro-mechanical thermostats
Electronic with 4 doors: ERF2000 electronics (freezer) and ERF2020 electronics (fridge)
Cooling circuit
Electro-mechanical with 4 doors: horizontal condenser (in the compressor area) with drop collector
Electronic with 4 doors: only vertical condenser
Defrosting
Electromechanical with 4 doors: electromechanical timer
Electronic with 4 doors: ERF2000 electronics (freezer)
Temperature switch
Electromechanical with 4 doors: 1 temperature protection switch for the end of defrosting (+10 °C)
1 temperature protection switch (+40 °C)
Electronic with 4 doors: 2 safety temperature switches (+40°C)

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3. Technical manual
3.1 General structure of the appliance
The electronic operating elements of the device are found inside the central transverse support. The
fridge with 4 doors has 3 refrigeration zones available so that every type of food can be stored optimally.
The appliance is equipped with two compressors and has two separate cooling circuits:
1 View of the refrigeration section
2 Cooling circuit of the zero-degree zone and the freezer section.
A Refrigerator section
B Zero-degree zone
C Freezer section
A – Refrigerator section
Thanks to the natural air circulation in the refrigerator section, the temperature and humidity values
required for correct storage of fresh foodstuff can be guaranteed.
The ERF2020 electronics located on the right-hand side of the operating panel controls the temperature
(these electronics form a single component because the functional electronics and the display
electronics are connected by means of a soldered ribbon cable).
B – Zero-degree zone
This refrigeration zone is maintained at an even temperature of between 0 °C and +3 °C. Refrigeration
is provided by means of forced air convection from the freezer section below.
The temperature control is regulated by means of a special flap thermostat opening and closing the
opening for the air from the freezer section.
A
B
C

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C – Freezer section
The cold air is generated by a battery-operated evaporator, while the forced circulation of the air is
affected by means of a ventilator. This means that moist air in the form of frost only condenses on the
evaporator and not on the freezer walls or on food packages.
A timer activates a defrost resistor at regular intervals (approx. every 14 hours) melting any collected
frost.
The ERF2000 electronics located on the right-hand side of the operating panel control the temperature
(these electronics consist of two parts because the functional electronics and the display electronics are
connected by means of a plug-connected ribbon cable).
3.2 Air circulation
Freezer section
The cold air produced by the battery-operated evaporator is circulated by the ventilator located above
the battery. The air flows into the right-hand compartment within the freezer and flows out again through
two slits. The temperature is controlled by the thermostat bulb which can be seen installed immediately
above the battery.
Zero-degree zone
The air flows in through a foam-mounted channel above the fan and flows out through the slits on the
flap thermostat. The air can flow back into the freezer section through a slit on the bottom left of the zero-
degree zone. The temperature is regulated by the flap thermostat.
Refrigerator section
The air is circulated by means of natural air convection.

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3.3 Components
1. Refrigerator section compressor
2. Freezer compressor
3. Battery-operated evaporator
4. Ventilator for the battery-operated
evaporator
5. Flap thermostat (only for some
models)
6. Flush-mounted refrigerator
evaporator
7. Thermal protection device
8. Defroster resistor
9. Condensation water channel
resistor
D.A.C. (only for some models).
A. NTC probe of the freezer
B. NTC probe of the battery-operated
evaporator
C. NTC probe of the refrigerator
D. NTC probe of the battery-operator
refrigerator evaporator
NOTE! The probes A, B and C have been foam-mounted and hence cannot be replaced.
3.4 Description of the individual components
Battery-operated evaporator and ventilator
The battery-operated evaporator cools extremely well in
spite of the fact that it takes up little space.
This is made possible because the evaporator surface
has been enlarged by numerous aluminium ribs inserted
into a zinc serpentine tube.
Active air circulation, generated by a ventilator (power
output: 3.1 W, speed: 2400 rpm) installed above the
evaporator ensures that all of the humidity present is
deposited on the evaporator which is the coldest part
within the interior of the appliance.
1
2
3
4
5
6
7
8
9
10
A
B
C
D

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Defrost resistor
The ice which builds up on the evaporator needs to be
defrosted at regular intervals.
To do this, approx. every 14 hours, the freezer
electronics switch on a resistor (303 Ohm; 240 V)
consuming 190 W which is in direct contact with the
battery.
Condensation water channel resistor
In order to prevent condensation water from turning into
ice, a 21.5 W resistor (resistance: 2679 Ohm, voltage:
240 V) is installed beneath the condensation water
channel.
This resistor is connected in parallel with the defrost
resistor.
Overheating protection switch
Two identical overheating protection switches in direct
contact with the battery cut off the power supply to the
defrost resistor if +40 °C is reached
(Cable colour: black).
Rubber valve
The condensation water is drained off through a silicone
plastic valve located in the condensation water drainage
hole. Thanks to the characteristics of this valve, the
condensation water can drain freely.
During the cooling phase, however, the valve closes due
to the underpressure which is produced inside the
appliance, hence preventing moist air from the outside
being sucked in.
Flap thermostat (only for some models!)
In the rear part of the zero-degree zone, the flap
thermostat is located inside a transparent protective
housing. The thermostat opens or closes the opening
through which the air coming from the freezer section
flows.
Position min. Position max.
+2.5 °C -3.5 °C

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4. Control panel
Freezer section key
A. ON/OFF control lamp
B. ON/OFF button of the freezer section
C. Button to raise the temperature (+)
D. Temperature display in the freezer section
E. Button to decrease the temperature (-)
F. Alarm lamp
G. Button for switching off the alarm
H. Superfrost function control lamp
I. Button for the Superfrost function
Refrigerator section key
J. ON/OFF control lamp
K. ON/OFF button of the refrigerator section
L. Button to raise the temperature (+)
M. Display of the refrigerator section temperature
N. Button to decrease the temperature (-)
O. Supercool control lamp
P. Button for the supercool function
Q. D.A.C. control lamp (only for some models!)
R. Button for the D.A.C. function (only for some models)
Freezer section Refrigerator section
G

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4.1 Electronics
The appliance is controlled by two independent electronic systems:
A. Electronic system of freezer section
B. Electronic system of refrigerator section
4.2 Freezer section ERF2000 electronic unit
The freezer section electronics are type ERF2000 and comprise:
1. Power electronics
2. Display electronics
The two electronic systems are connected by a ribbon cable with plug connectors and therefore they are
available individually as replacement parts.
A B
Refrigerator sectionFreezer section

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4.2.1 Power electronics (freezer section)
View of the power electronics (components side):
1. Earth contact
2. Not used
3. Cable
4. Freezer section compressor
5. Neutral wire
6. Not used
7. Not used
8. Neutral wire
9. Defrost resistor
1. Ventilator for the battery-operated evaporator
2. Not used

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1. Not used
2. Not used
3. Evaporator probe (black cable)
4. Evaporator probe (black cable)
5. Freezer probe (brown cable)
6. Freezer probe (brown cable)
1. Freezer section door switch
2. Freezer section door switch
1. Not used
2. Not used
3. Not used
4. Not used
1. Not used
2. Not used

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4.2.2 Display electronics for freezer section
Key
S1 = Button to switch off the alarm
S2 = Button for the superfrost function
S3 = Button to raise the temperature (+)
S4 = Button to decrease the temperature (-)
S5 = ON/OFF button for freezer
S6 = Reed element (optional)
DS1 = Alarm control lamp
DS2 = Control lamp for the superfrost function
DS3 = Symbol (-)
DS4 = Display
DS5 = Display
DS8 = ON/OFF control lamp
4.3 Electronics for refrigerator ERF2020
The refrigerator electronics are type ERF2020 and consist of power electronics and display electronics
(1).
The power electronics and display electronics are connected by means of a soldered on ribbon cable.
For this reason only one RP no. 432502 is provided for both electronic systems.

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4.3.1 Power electronics and display electronics (refrigerator)
View of the power electronics (welded side):
Key
S1 = Button for the supercool function
S2 = Button for the D.A.C. function (only for some models!)
S3 = Button to raise the temperature (+)
S4 = Button to decrease the temperature (-)
S5 = ON/OFF button for the refrigerator section
S6 = Reed element (optional)
DS1 = Supercool control lamp
DS2 = D.A.C. control lamp (only for some models!)
DS4 = Display
DS8 = ON/OFF control lamp

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1. Cable
2. Compressor of the refrigerator section
3. Neutral wire
4. Lamp
5. Neutral wire
1. Not used
2. D.A.C. fan (only for some models).
3. Neutral wire
1. Not used
2. Not used
3. Not used
4. Not used
1. Refrigerator section probe (white cable)
2. Refrigerator section probe (white cable)
3. Evaporator probe (black cable)
4. Evaporator probe (black cable)
1. Not used
2. Not used

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5. Functioning
5.1 Normal (freezer section)
ZThe electronics are supplied with a 220-240 V / 50 Hz voltage, even when the appliance is
switched off (OFF). Before the electronics are handled, therefore, the mains supply plug
must be disconnected.
Thanks to the air circulation, any humidity in the freezer section is collected on the evaporator battery
and this prevents the formation of frost on the foodstuff.
During the normal operating time, the ERF2000 electronics of the freezer supply the freezer compressor
and battery-operated evaporator ventilator.
The ventilator is switched on and off with a delay of 2 minutes after the compressor.
The operating time, which corresponds to the period between two subsequent defrosting periods, is, if
the doors are opened, normally approx. 14 hours (if the door is never opened it can extend up to 71
hours!)
5.2 Defrosting (freezer section)
All humidity present inside the appliance will collect on the evaporator, the coldest part in the freezer.
For this reason the ice forming on the battery must be melted at regular intervals, when the door is
opened normally approx. every 14 hours (if the door is never opened, it is sufficient to do it after 71
hours).
The electronics will switch off the electric circuit supplying the battery-operated evaporator and will
supply the defrost resistors for a period of at least 20 minutes.
The heat generated by the defroster heating element has no influence on the temperature in the freezer
or on that of the food packages since the total thermal energy is consumed for melting the ice on the
evaporator.
After 20 minutes, the electronics will measure the temperature of the battery-operated evaporator and
will interrupt the supply to the defrost resistors if +10 °C has been reached.
The electronics will then restart the compressor after a 5 minute delay. After a further 2 minute delay,
when the air is already cold, the ventilator will also be switched on again.
If the electronics fail to interrupt the supply to the defrost resistors and the battery temperature rises to
+40 °C, the resistors will be switched off by safety temperature switches
If half an hour after the start of the melting process the temperature switch has not switched off the
defrost resistors, the electronics will deactivate them in any case and continue with normal operation.

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5.3 Ventilator for the battery-operated evaporator
As long as the freezer doors are not opened, the ventilator of the battery-operated evaporator will run for
as long as the compressor is running (when the compressor is switched off the ventilator will be
deactivated after a 2 minute delay).
If the ventilator of the battery-operated evaporator is running and one of the two freezer doors is opened,
the ventilator will be switched off (it will be reactivated when the doors have been closed again).
If the ventilator of the battery-operated evaporator is not running and one of the two freezer doors is
opened, the ventilator will be switched on for 2 minutes when the door has been closed again.
5.4 Superfrost function
The superfrost function is activated by pressing button “I”. The control lamp H will glow and on the
display the message SP will appear. The compressor runs for approx. 52 hours without interruption and
will then be automatically switched off.
For deactivating this function early, press button “I” again .
5.5 Supercool function (refrigerator section)
The supercool function can be used to cool large quantities of food in the refrigerator quickly, e.g. for
drinks or salads for a party.
The supercool function is activated by pressing the button P. The control lamp Owill glow and the
superfrost function will now ensure intensive cooling and the compressor will run for approx. 6 hours in
the thermostatic mode and not in the continuous operation mode (as if the temperature dial had been
turned to the max position in order to achieve approx. +2 °C) and then it will switch off automatically; the
D.A.C. ventilator is switched on (if available), however, the control lamp associated with the D.A.C.
function will not glow.
For deactivating this function early, press button Pagain.
5.6 Malfunctioning of the freezer air temperature probe
Should the NTC temperature probe malfunction during normal operation (i.e. the signal from the probe
falls outside the limiting values), then:
• The appliance will follow a predetermined programme sequence during which the freezer
compressor is alternately supplied for 40 minutes and then switched off for 40 minutes;
• The display will show one of the following symbols:
Freezer air temperature probe defective
Temperature probe of the battery-operated evaporator of the
freezer section defective
Once the probe functions again properly the two operating modes described above will be terminated.

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5.7 Malfunctioning of the refrigerator air temperature probe
Should the NTC temperature probe malfunction during normal operation (i.e. the signal from the probe
falls outside the limiting values), then:
• The appliance will follow a predetermined programme sequence during which the refrigerator
compressor is alternately supplied for 30 minutes and then switched off for 40 minutes;
• The display will show one of the following symbols:
Refrigerator section air temperature probe defective
Battery-operated evaporator temperature probe of the refrigerator section
defective
Once the probe functions again properly, the two operating modes described above will be terminated.

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5.8 NTC sensor characteristics
Conversion table