Traulsen G-Series User manual

.
G-Series Reach-In & Pass Thru
Refrigerator & Freezer Service Manual
This manual is applicable for all models using R-450a and R448a
Refrigerants.
2018-2023
TR35731

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Table of Contents
1. Introduction ....................................................................................................................................................................4
1.1 The Serial Tag..........................................................................................................................................................4
1.2 Serial Tag & Location:..............................................................................................................................................5
1.2.1 Reading the Serial Tag:....................................................................................................................................5
1.3 Understand G-Series Model Numbers....................................................................................................................6
1.4 Reading Traulsen Serial Number.............................................................................................................................6
1.5 Refrigerants.............................................................................................................................................................7
1.5.1 Terminology: ...................................................................................................................................................7
1.5.2 R-450A Refrigerant..........................................................................................................................................7
1.5.3 R-488A Refrigerant..........................................................................................................................................9
1.6 Specifications: .......................................................................................................................................................11
2. Preventative Maintenance............................................................................................................................................15
2.1 Inspect and Clean Unit:.........................................................................................................................................15
2.2 Inspect and Clean Door Gasket:............................................................................................................................15
2.3 Clean Condenser Coil: ...........................................................................................................................................16
3. Doors & Hardware ........................................................................................................................................................18
3.1 Hinges....................................................................................................................................................................18
3.1.1 Removing the Doors and Hardware:.............................................................................................................18
3.2 Adjustments..........................................................................................................................................................22
3.3 Gaskets..................................................................................................................................................................23
3.4 Locks......................................................................................................................................................................24
3.4.1 Door lock assembly exploded view:..............................................................................................................24
3.4.2 Door lock replacement instructions..............................................................................................................25
4. Controls.........................................................................................................................................................................28
4.1 Understanding the display....................................................................................................................................28
4.2 Unlocking the display............................................................................................................................................29
4.3 Change the Setpoint..............................................................................................................................................29
4.4 Initiate a Defrost ...................................................................................................................................................29
4.5 Decode Alphabet...................................................................................................................................................31
4.6 Understanding the Menu System .........................................................................................................................32
4.7 Defrost Settings.....................................................................................................................................................33
4.8 Defrost Setpoint....................................................................................................................................................34
4.9 Defrost Mode........................................................................................................................................................34

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4.10 Defrost Interval .....................................................................................................................................................35
4.11 Diagnostic Menu ...................................................................................................................................................36
4.12 Control Cover Removal & Components................................................................................................................39
4.12.1 Removing the Display:...................................................................................................................................39
4.12.2 Installing the Display:....................................................................................................................................39
4.12.3 Accessing the Power Module (Control Board):.............................................................................................40
4.13 Power Module Connections Overview .................................................................................................................41
4.14 Power module Led’s & Reset Button Overview:...................................................................................................42
5. Sensor Location.............................................................................................................................................................44
5.1 Sensor Control Value Test.....................................................................................................................................46
5.2 Sensor Resistance Test..........................................................................................................................................47
6. Troubleshooting............................................................................................................................................................48
6.1 Condensate Overflow Troubleshooting................................................................................................................48
6.1.1 Condensate Overflow: ..................................................................................................................................48
6.2 Compressor Troubleshooting................................................................................................................................49
6.2.1 Terminology: .................................................................................................................................................49
6.2.2 Accessing the Compressor: ...........................................................................................................................50
6.2.3 Compressor Not Running:.............................................................................................................................51
6.2.4 Testing the Windings of the Compressor......................................................................................................51
6.2.5 Resistance and Amp Values of G-Series Compressors:.................................................................................51
6.2.6 Troubleshooting External Overload Protector:.............................................................................................51
6.2.7 Measuring for Excessive Voltage Drop: ........................................................................................................52
6.2.8 Troubleshooting Potential Relay:..................................................................................................................52
6.2.9 Troubleshooting Start Capacitor (Black Plastic Casing): ...............................................................................52
6.2.10 Troubleshooting Run Capacitor (Metal Casing):...........................................................................................52
6.2.11 Locked Up Compressor: ................................................................................................................................53
6.2.12 Current Climbs Above RLA: ...........................................................................................................................53
6.2.13 Replacing the Compressor: ...........................................................................................................................54
6.2.14 Compressor Wiring Schematics: ...................................................................................................................55
6.2.15 Compressor Short Cycles on Overload Protection:.......................................................................................57
6.2.16 Compressor not Trying to Start:....................................................................................................................58
6.3 Evaporator Fan Troubleshooting: .........................................................................................................................59
6.3.1 Steps for troubleshooting G-series Evaporator Fan......................................................................................59
6.4 Condenser Fan Troubleshooting...........................................................................................................................63

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6.4.1 Troubleshooting the Condenser Fan Motor on G-Series:.............................................................................63
6.4.2 Motor Bearing Failure:..................................................................................................................................64
6.4.3 Replacing the Condenser Fan Motor: ...........................................................................................................66
6.5 Troubleshooting Thermostatic Expansion Valve ..................................................................................................66
6.5.1 Three Pressures.............................................................................................................................................67
6.5.2 Non-Bleed Type.............................................................................................................................................67
6.5.3 Maximum Operating Pressure ......................................................................................................................67
6.5.4 Measuring Superheat....................................................................................................................................67
6.5.5 Restrictions....................................................................................................................................................68
6.5.6 Replacing the TXV .........................................................................................................................................68
6.6 Removing the Refrigeration System .....................................................................................................................69
6.6.1 Condenser Assembly :...................................................................................................................................69
6.6.2 Defrost Troubleshooting...............................................................................................................................70
7. General Wiring Diagrams..............................................................................................................................................72
7.1 Refrigerator (Off-Cycle Defrost) 115 Volt .............................................................................................................72
7.2 Refrigerator Electric Defrost/ Freezer 115 Volt ....................................................................................................73
7.3 Lighting Circuits.....................................................................................................................................................74
7.4 3-Section Freezer 208-230/115 Volt.....................................................................................................................75
8. TRAULSEN EQUIPMENT WARRANTY.............................................................................................................................76
8.1 U.S. Domestic Warranty........................................................................................................................................76

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1. Introduction
Traulsen provides this manual as an aid to the service technician in installation, operation, and maintenance.
When used properly, this service manual can help the service technician maintain, troubleshoot, and diagnose
the majority of issues that may occur. While we believe that most aspects of service are covered in this
manual; should you encounter a condition not addressed, please contact:
ITW Refrigeration
Traulsen
4401 Blue Mound Road Fort Worth, TX 76106
Attn: Service Department
Call for Technical Support: [phone] Option 1, and then option 3
Fax: [phone]
[email protected]
[email protected]
IMPORTANT: To improve your service communication experience; be sure to have the following available
when contacting technical support:
✓Serial number
✓Model number
✓A detailed description of the problem
1.1 The Serial Tag
Figure 1 Sample serial tag

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1.2 Serial Tag & Location:
The serial tag is a permanently affixed label on which is recorded vital electrical and refrigeration data about
your Traulsen product, as well as the model and serial number. This tag is in the upper left interior
compartment on all G-Series refrigerator and freezer models.
1.2.1 Reading the Serial Tag:
Model = The model # of your Traulsen unit
(S/N) Serial Number = The permanent ID# of your Traulsen unit
Refrigerant SYS1 = System 1 Refrigerant type used and refrigerant charge
Design Pressure = System 1 High and Low Pressure
Refrigerant SYS2 = System 2 Refrigerant type used and refrigerant charge
Design Pressure = System 2 High and Low Pressure
Volts = Voltage
Hz = Cycle
PH = Phase
Total Current = Maximum amp draw
Min Circuit Amps = Minimum circuit ampacity
Lights = Light wattage
Agency Labels = Designates agency listings
Components = Component Ratings
Note: Design Pressure is the maximum pressure system components can handle and NOT the operating
pressure.

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1.3 Understand G-Series Model Numbers
Figure 2: R450 & R448 G-Series Reach-In Model Numbers
1.4 Reading Traulsen Serial Number

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Figure 3: Understanding Traulsen Serial Number
1.5 Refrigerants
1.5.1 Terminology:
Zeotropic Blend –A mixture of two or more refrigerants that have different boiling points that evaporate or
condense at different temperatures. All 400 Series Refrigerants are zeotropic blends.
Azeotropic Blend –A mixture of two or more refrigerants that boil at the same temperature so that they
evaporate and condense together. All 500 Series Refrigerants are azeotropic blends.
Temperature Glide –The temperature difference between the starting and ending temperature of a
refrigerant phase change within a system at a constant pressure. This can be seen on a Pressure Temperature
chart as the difference between bubble and dew temperatures.
Fractionation of Refrigerant –The change in composition of a blend because one or more of the components
is lost or removed faster than the others.
Bubble Point –The temperature at which the liquid of a refrigerant blend starts to boil.
Dew Point –The temperature at which the vapor of a refrigerant blend starts to condense.
Superheat –The heat added to a refrigerant after its saturation point. Or in other words, heat added to a
refrigerant after it boils.
Subcooling –The removed from a refrigerant after its saturation point. Or in other words, heat removed from
a refrigerant after it condenses.
1.5.2 R-450A Refrigerant
R-450 Refrigerant is a refrigerant Traulsen uses in medium temperature applications. This refrigerant is
technically a zeotropic blend but has such a small temperature glide that it could be considered a near
azeotropic blend.

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Figure 4: R-450 Blend
Table 1 R-450 Refrigerant Composition
When charging any G-Series Refrigerator with R-450A refrigerant care should be taken to weigh the proper
amount of liquid refrigerant into the system according to the data plate. It is important to charge with
refrigerant in a liquid state to avoid fractionating.
1.5.2.1 Pressure/ Temperature Chart for R-450A Refrigerant
Pressure
Dew
Bubble
10 PSIG
13.2°F
12.9°F
15 PSIG
21.7°F
20.6°F
20 PSIG
29.2°F
28.0°F
25 PSIG
35.8°F
34.7°F
30 PSIG
41.8°F
40.7°F
35 PSIG
47.4°F
46.2°F
40 PSIG
52.5°F
51.4°F
58%
R134A
42%
R1234ZE

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45 PSIG
57.3°F
56.2°F
50 PSIG
61.8°F
60.7°F
55 PSIG
66.1°F
64.9°F
60 PSIG
70.1°F
68.9°F
65 PSIG
73.9°F
72.7°F
70 PSIG
77.5°F
76.4°F
75 PSIG
81.0°F
79.9°F
80 PSIG
84.4°F
83.2°F
85 PSIG
87.6°F
86.4°F
90 PSIG
90.6°F
89.5°F
95 PSIG
93.6°F
92.5°F
100 PSIG
96.5°F
95.3°F
105 PSIG
99.3°F
98.1°F
110 PSIG
102.0°F
100.8°F
115 PSIG
104.6°F
103.4°F
Table 2 R-450 Refrigerant Pressure & Temperature Chart
Note: Use the Dew temperatures when calculating superheat and bubble temperatures when calculating
subcooling.
1.5.3 R-488A Refrigerant
R-448A Refrigerant is a refrigerant Traulsen uses in low temperature applications. This refrigerant is a
zeotropic blend with a large temperature glide.

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Figure 5 R-448A Blend
R-32
26%
R-125
26%
R-134A
21%
R-1234yf
20%
R-1324ze
7%
Table 3 R-448 Refrigerant Composition
When charging any G-Series Freezer with R-448A refrigerant care should be taken to weigh the proper amount
of liquid refrigerant into the system according to the data plate. It is important to charge with refrigerant in a
liquid state to avoid fractionating.
1.5.3.1 Pressure/ Temperature Chart for R-448 A Refrigerant
Pressure
Dew
Bubble
5 PSIG
-28.8°F
-39.8°F
10 PSIG
-19.7°F
-30.6°F
15 PSIG
-12.0°F
-22.8°F
20 PSIG
-5.23°F
-15.9°F
25 PSIG
0.8°F
-9.8°F
30 PSIG
6.3°F
-4.3°F
35 PSIG
11.3°F
0.8°F
40 PSIG
16.0°F
5.5°F
50 PSIG
24.4°F
14.5°F
60 PSIG
31.9°F
21.6°F
70 PSIG
38.7°F
28.5°F
80 PSIG
44.8°F
34.8°F
90 PSIG
50.5°F
40.6°F
100 PSIG
55.8°F
45.9°F
110 PSIG
60.8°F
51.0°F
130 PSIG
69.8°F
60.2°F
140 PSIG
74.0°F
64.5°F
150 PSIG
78.0°F
68.6°F
160 PSIG
81.3°F
72.5°F
170 PSIG
85.4°F
76.2°F
180 PSIG
88.9°F
79.8°F
190 PSIG
92.3°F
83.3°F
200 PSIG
95.5°F
86.6°F
210 PSIG
98.7°F
89.8°F
220 PSIG
101.7°F
93.0°F
230 PSIG
104.6°F
96.0°F
240 PSIG
107.5°F
99.0°F

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250 PSIG
110.2°F
102.0°F
260 PSIG
112.9°F
104.6°F
270 PSIG
115.5°F
107.2°F
Table 4 R-448 Refrigerant Pressure & Temperature Chart
Note: Use the Dew temperatures when calculating superheat and bubble temperatures when calculating
subcooling.
1.6 Specifications:
SPECIFICATIONS
DIMENSIONS
1 Section Cabinet
2 Section Cabinet
3 Section Cabinet
Height–Overall on
6” casters
83- 7/16” (211.9cm)
83- 7/16” (211.9cm)
83- 7/16” (211.9cm)
Width
29- 7/8” (75.9cm)
52- 1/8” (132.4cm)
76- 5/16” (193.8cm)
Depth
35” (88.8cm)
35” (88.8cm)
35” (88.8cm)
Net Capacity cu. ft.
23.37
46.5
69.1
Table 5 Traulsen Cabinets specifications
Figure 6 Front view of cabinets

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Figure 7 Top view of 1 & 2 section cabinets
Figure 8 Top view of 3 section cabinets

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Figure 9 Side view of Reach-in cabinets

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Figure 10 Reach-in cabinet Components

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2. Preventative Maintenance
This section is to inform the recommended preventative maintenance (PM) procedures. Depending on
application, PM schedule may vary.
2.1 Inspect and Clean Unit:
Why
Sanitation and prolong cabinet life
Frequency
Daily
Time required
3 minutes to prepare
3 minutes to complete
Preparation
Have a Soft Cloth. Baking soda and water mixed to a 1 TBSP (15mL) baking soda to 1-
pint (473.2mL) water ratio.
Cleaning
Apply with a dampened cloth, wipe in the direction of the metal grain.
(Avoid the use of strong detergents and gritty, abrasive cleaners as they may tend to
mar and scratch the surface. Do NOT use cleansers containing chlorine; this may
promote corrosion of the stainless steel.)
Inspection
Visually inspect the unit for signs of wear that may require repair.
Table 6 Cleaning PM Procedure
2.2 Inspect and Clean Door Gasket:
Table 7 Door Gasket Cleaning PM Procedure
Why
Long reliable service life
Frequency
Every 3 Months
Time required
10 minutes to complete
Inspection
Open cabinet door (s) to inspect gasket.
Pull gasket with hand and visually inspect gasket for tears, dirt, mold or
worn gasket. Clean with mild soap and water. Do not use cleaners
containing chlorine or chlorides. Replace as needed.
341-60256-00 Full Height Gasket
341-60257-00 Half Height Gasket

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2.3 Clean Condenser Coil:
Disconnect electrical power supply before cleaning any parts of the unit.
Why
Long reliable service life, extended compressor life.
Frequency
Every 3 Months
Time
required
5 minutes to prepare
15 minutes to complete
Preparation

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To clean the condenser, first disconnect electrical power to the cabinet and lift the
front louver assembly. To lift this, remove the two screws located on both sides at the
bottom of the louver assembly (see Figure 5). Oncethe screws areremoved,the panel
can be pivoted upwards allowing full access to the front facing condenser
Cleaning
Use a soft bristle brush to remove any dirt, lint or dust from the finned condenser coil,
around the compressor and other cooling system parts as indicated. Be sure to brush
in the direction of the fins to prevent damage. If significant dirt is clogging the
condenser fins, use compressed air to blow this clear. When finished reverse the
louver removal process as instructed above. Compressor warranty claims will not
be paid for units with dirty condensers.
Table 8 Condenser Coil Cleaning PM Procedure

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3. Doors & Hardware
3.1 Hinges
3.1.1 Removing the Doors and Hardware:
To fit through narrow (less than 35”) doorways, it may benecessary to remove the door(s), and/or
hinges. To remove any solid door, begin by removing the safety screw at the bottom of the top hinge
which secures the door in place. Remove this with a #2 Phillips screwdriver and thedoor can then be
lifted off the hinges. After removing the door, it may be necessary to remove the hinge assembly and
hardware from the door itself. If it is necessary to remove the hinge hardware from the cabinet,begin
byremovingthethreePhillips head screwswhich hold it in place. Set these components aside for later
reassembly. Pay special attention not to lose the door switch actuator button.
The lock keeper may also require removal to reduce the overall cabinet depth to 32”.
Firstremovethelockkeeper strikeplateby removingthetwo Phillips head screws which secure it in place exposing
the adjustment screws. Then remove both adjustment screws from the mounting plate to remove. See figure
11. To re-install the door and/or hinges, please reverse the appropriate sections of the preceding procedure.
Figure 11 Hinge assembly

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Figure 12 Hinge Exploded view.
HINGE
COVER344-
28486-00
ADJUSTING PLATE
344-28485-00
HINGE BRACKET
344-28487-00
CAM
344-28488-00
ACTUATOR
344-28484-00
DOOR SWITCH
337-28235-00
SAFETY SCREW
351-28483-00
MACHINE SCREW
#10-32 X .75” PHILLIPS
351-60002-07
HINGE BODY
344-28482-00