Norcold 121X series Service Manual Download Page 1

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Publication No. 630613B (08-10-07)

SERVICE MANUAL

121X Series Gas/Electric Refrigerators

Summary of Contents for 121X series

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Page 3: ...rs Section 3 Troubleshooting Flowcharts This section covers troubleshooting information and flowcharts for faults displayed through the optical control display assembly screen Section 4 Ventilation Th...

Page 4: ...m high temperature monitoring system cooling system replacement cooling system testing diagnostic flow chart and cooling unit replacement procedure Section 9 Diagnostics This section covers accessing...

Page 5: ...er ANSI Z21 19B standards for installation in mobile homes or recreational vehicles and under Canadian Standards Association CAN CGA 1 4 M94 Electrical components comply with UL standards Replacement...

Page 6: ...XXXXXXX MODEL N de modele GROUP CODE code de INPUT puissance 1210LRIM For recreational vehicle installation Min Installation clearance 0 sides top bottom back Install only with Kit 3 See installation...

Page 7: ...ty goggles and other required protection should be used during any process that can cause material to become airborne such as removing a leaking cooling unit or cleaning components Safety Symbols and...

Page 8: ...luding AC and DC heaters To prevent shock hazard disconnect the AC power cord from the electrical outlet before attempting to remove the power board cover Electrical connections and repairs to electri...

Page 9: ...r heater 0 42 A Lamp fresh food compartment 0 46 A Gas valve 0 146 A Fans 2 0 400 A per fan Valve water dispenser 10 W 12 VDC Heater water dispenser models water line 0 44 A Heater ice maker only wate...

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Page 11: ...no continuity Page 31 L1 oP fault High temperature limit switch open Off level operation Insufficient obstructed or downdraft ventilation Heat deflector cap blocking flue opening Cooling system Page...

Page 12: ...4 volts DC input to power board Fresh food compartment door open or ajar for more than two 2 minutes Page 13 Page 12 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 Less than 10 5 volts DC input to p...

Page 13: ...Alternating ALARM AUDIBLE Alternating Display Flame present with gas off Page 26 Open circuit high temperature limit switch No AC voltage input to power board AC cord unplugged at power board Power bo...

Page 14: ...ors Repair as needed then recheck for voltage 1 Unplug wire harness at Power Board P1 con nector 2 Check for voltage across Power Board P1 1 and P1 6 See Figure 3 2 page 15 Replace fuse Voltage output...

Page 15: ...7a Voltage across Green wire White Violet wire terminals See Figure 3 4 page 16 Optical Control Display overlay ribbon cable plugged incorrectly See Figure 3 6 page 16 Controls okay Go to page 14 NO...

Page 16: ...17 3 Press and release the OFF ON switch button to turn ON refrigerator 12 NO YES NO YES NO YES YES Controls okay 1 Unplug the Wire Harness at the P1 Power Board connector 2 Check the Wire Harness Bl...

Page 17: ...ITS 1 Seconds TRUE RMS MULTIMETER V V P1 6 P1 1 10 5 to 15 4 VDC 12 VDC in 12 VDC in F1 Fuse 5 Amp 100 B ANSI Z21 2 JW5 P3 RT424F12 12V 05 43 07 3 D5 R50 R49 07 3 07 3 07 3 4 C Q3 4 C D8 CPC E 94 V 0...

Page 18: ...oard connector Green White Violet Figure 3 5 Measuring DC voltage across White Violet wire and Blue wire at the optical control display assembly circuit board connector White Violet Blue Optical Contr...

Page 19: ...4 U4 C3 C5 U3 U6 JW11 Z4 AC heater wires See NOTE MIN MAX RANGE HOLD H Hz REL mA A mV V V OFF A COM V mA A 1000V MAX 400mA MAX FUSED 10A MAX FUSED PEAK MIN MAX A CAT II 4 1 2 DIGITS 1 Seconds TRUE RMS...

Page 20: ...turns off Backup operating system BOS BOS is a duty cycle designed to maintain cooling anytime the thermistor is sensed open or shorted When the refrigerator is operating in BOS changing the temperatu...

Page 21: ...1000V MAX 400mA MAX FUSED 10A MAX FUSED PEAK MIN MAX A CAT II 4 1 2 DIGITS 1 Seconds 87 TRUE RMS MULTIMETER III Temperature Resistance C F kohms 29 85 8 1 9 0 27 80 9 1 10 0 24 75 10 1 11 0 21 70 11...

Page 22: ...nge is 58 to 68 ohms YES NO Replace heaters Replace power board The AC HE fault is recorded in either the AUTO or Manual AC mode The following may apply AUTO MODE When AC heaters current input falls b...

Page 23: ...code displays and is recorded in non volatile memory approximately 25 seconds after the fault occurs IMPORTANT MODE ON OFF SET TEMP on 1 COLD 9 COLDEST 1 COLD 9 COLDEST Power board AC heater relay co...

Page 24: ...history Correct RV DC output to refrigerator NO Check RV DC power output to refrigerator YES 1 Connect a charged 12 volt bat tery If the fault code does not display check the DC circuit feeding power...

Page 25: ...NO Check RV DC power output to refrigerator YES YES 1 Connect a fully charge 12 volt bat tery If the fault code does not display check the DC circuit feeding power to the refrigerator 2 If the fault c...

Page 26: ...f after the two minute period The dr code displays and is recorded in non volatile memory approximately 25 seconds after the fault occurs IMPORTANT Begin Fresh food compartment doors latch ing when cl...

Page 27: ...ce as needed Door damaged or warped 4 YES Replace door NO Switches turn off light when held closed 5 Replace switch NO YES From page 24 Adjust door hinges until the left door and the right door rail a...

Page 28: ...ower board NO Check for DC voltage at gas valve solenoid terminals YES Gas valve leaking internally or stuck open Replace gas valve Replace power board NO YES The FL fault is recorded in all operating...

Page 29: ...he switch In both cases troubleshoot for the L1 oP fault cause IMPORTANT MODE ON OFF SET TEMP on 1 COLD 9 COLDEST 1 COLD 9 COLDEST Begin Refrigerator cooling before L1 Op fault displayed 1 Burner over...

Page 30: ...heck fans operation 1 Replace fans 2 Replace reset high temperature limit switch 3 Test cooling system performance on AC and LP gas operation 1 Clear obstructions 2 Replace reset high temperature limi...

Page 31: ...ult to occur in AC Manual Mode AC voltage input has to fall below 85 volts with the controls calling for cooling The alarm sounds and the fault displays approximately 25 seconds later IMPORTANT Begin...

Page 32: ...ction 2 page 7 79 to 85 kOhms NO Verify spark sense electrode air gap NO Check spark sense assembly See Figure 3 12 page 31 YES NO Replace assembly Check gas valve solenoid coil resistance Go to page...

Page 33: ...S 1 Seconds TRUE RMS MULTIMETER V P1 Connector P2 Connector From page 30 6 6 Voltage present during trial for ignition Check voltage output to solenoid coil See Figure 3 14 5 Check continuity of solen...

Page 34: ...uit present when it is not supposed to be 3 Gas valve drive circuit not present when it is supposed to be 4 Internal memory fault The fault registers approximately 25 seconds later in Diagnostic scree...

Page 35: ...erves as the service access or door The air intake vent needs be kept clear of obstructions that may restrict the flow of fresh air into the enclosure Figure 4 1 illustrates a typical air intake vent...

Page 36: ...ffle 0 1 in clearance max 1 4 in clearance max 622293 Roof cap 616319 Exhaust vent Aluminum or galvanized steel sheet baffle full width of enclosure 0 1 in clearance max Vent even or below enclosure f...

Page 37: ...le 4 to 4 in B ottom baffle Top baffle 1 in clearance max 1 in clearance max Aluminum or galvanized steel sheet baffle full width of enclosure Angle not to exceed 45 622293 Roof cap 616319 Exhaust ven...

Page 38: ...nce max 621156 Vent Vent even or below enclosure floor 1 4 in clearance max Aluminum or galvanized steel sheet baffle full width of enclosure Wood aluminum or galvanized steel sheet solid baffle Full...

Page 39: ...of the enclosure and the top of the upper vent opening 62 in Vent even or below enclosure floor Enclosure depths of more than 24 in and less then 26 in Bend of baffle flush with bottom edge of vent d...

Page 40: ...op surface of baffle flush with bottom edge of vent frame Minimum distance between the bottom of the enclosure and the top of the upper vent opening 62 in Distance between the top of the lower vent op...

Page 41: ...and 11 1 5 w c provide necessary amount of gas for efficient combustion and heat generation Gas pressure below 10 5 w c Gas pressure below 10 5 w c results in a weak flame with low heat input to the...

Page 42: ...SI Operation In AUTO LP gas mode or LP gas mode operation the controls energize the solenoid coil to open the gas valve Spring pressure closes the valve when the electronic controls de energize the so...

Page 43: ...he potential for gas leaks 11 Open the gas valve s at the LP gas container s 12 Leak test the LP gas supply line fitting 13 Plug the AC cord into the RV outlet 14 Connect 12 VDC power to the power boa...

Page 44: ...llips screws 2 LP gas supply line connection fitting RV LP Gas supply line Solenoid coil 12 VDC power connections Bracket W hite W hite ON OFF ON ON ON Burner tube connection fitting Torque 75 to 95 i...

Page 45: ...illustrated in Figure 5 4 Coil resistance should be within 77 and 85 ohms Burner Tube Assembly The burner tube is 1 4 inch OD aluminum tubing The anti vibration loop absorbs vibration to prevent meta...

Page 46: ...e orifice adapter 8 Remove the orifice assembly from the burner 9 Remove the burner retaining screw then pull the burner out of the burner box WARNING Always use two wrenches to disconnect the burner...

Page 47: ...pter assembly or burner threads A damaged orifice adapter for burner creates a potential for gas leaks Burner retaining screw 8 32 X 3 8 Phillips head Figure 5 7 Installing burner in burner box 10 Che...

Page 48: ...33 U1 LP1 Q1 Q2 Q6 C9 D10 R11 R12 C7 R16 R15 R17 R19 R13 R22 R32 R31 Z2 D7 R14 U4 C3 C5 U3 U6 JW11 Z4 Fresh Food Compartment Light The fresh food compartment light off and on operation is controlled b...

Page 49: ...ach the thermistor to the fin to the second fin from the right and position it 1 to 1 1 2 inch from the top edge of the fin 10 Power on the refrigerator Light Thermistor Wire Assembly The light and th...

Page 50: ...supplied by the power board Figure 6 6 Thermostatic switch for fans Thermostatic switch The thermostatic switch is illustrated in Figure 6 6 Incoming 12 volt DC is fed through upper terminal The switc...

Page 51: ...Y jumper See Figure 6 7 2 Remove fan and bracket assembly from cooling unit 3 Remove the existing fan and bracket from sump Save the screws and spacers to reinstall the new fan 4 Reverse steps 3 to 1...

Page 52: ...refrigerator automatically energizes the flapper heater circuit Heater operation can be detected by touching the exterior surface of the flapper assembly The overall surface should be slightly warm to...

Page 53: ...er to Figure 6 9 for location of components 1 Power off refrigerator 2 Open the left fresh food compartment door 3 Remove the bottom and top flapper hinge screws 4 Lift the flapper assembly until the...

Page 54: ...food compartment door 2 Pull out the existing spring pin from the flange 3 Push and seat the replacement spring pin into the contact flange 4 Check spring pin operation a Push the pin all the way unt...

Page 55: ...e cord is attached to the refrigerator back plate with a 8 32 x 1 hex head screw The cord ground wire lug is also attached to the back plate with a 8 32 x 1 hex head screw AC Power Cord 1211IM Ice Mak...

Page 56: ...ation illustrated on Figure 6 14 is an 8 amp fast acting 1 4 x 1 1 4 x 1 AGC fuse Figure 6 15 illustrates how to check fuse continuity 120 Volt AC Heaters Two 120 volts AC heaters generate the heat lo...

Page 57: ...all the internal connections in place NOTE The wire harness is foamed into the cabinet It is not a replaceable component Figure 7 1 Power board Figure 7 2 Base power board Figure 7 3 Cover power boar...

Page 58: ...30VDC RES 30VDC RES 700514 D4 R37 R34 4 6 5 D 12 D 11 Z3 C 1 Potter Brumfield T77V1D10 09 CHINA 10A 120VAC 30VDC RES 700514 JW4 JW6 D2 R9 R7 R24 R46 R4 R5 R23 R20 R18 R21 R21 JW7 JW9 JW10 JW8 R36 R41...

Page 59: ...trol display troubleshooting instructions may be found on Section 3 of this manual Optical control display assembly side Decorative box assembly side Screw 4 Striker Plate Figure 7 6 Optical control d...

Page 60: ...ex head screws b Pull the cover off the power board For steps 7 8 9 10 See Figure 7 12 page 60 7 Disconnect the AC heater wires at power board a Black wires at terminals AC_HT_LO and AC_HT_LO2 b Yello...

Page 61: ...Section 7 59 12 volt DC connections AC power cord Figure 7 10 Power board external connections Cover 8 32 x 1 Hex head screw Figure 7 11 Cover retaining screws location Spark sense electrode Assembly...

Page 62: ...ard up to remove from base To install power board on base 1 Insert bottom edge into the base bottom tabs 2 Press evenly on upper edge to lock power board in the base Figure 7 13 Power board removal in...

Page 63: ...ve are not covered with insect screen plastic sheeting leaves or a birds nest Loose insulation is not blocking air flow over the condenser or absorber or the flue opening Both fans are working DC volt...

Page 64: ...cap location is illustrated in Figure 8 1 Operation over maximum leveled limits The refrigeration cycle works on gravity flow Exceeding off level limits during operation affects the flow of refrigeran...

Page 65: ...o cooling sensed 1 COLD 9 COLDEST ON OFF MODE TEMP SET on 1 COLD 9 COLDEST Figure 8 2 Diagnostic screen 5 segment 7 no cooling sensed The cooling system monitoring control monitors the cooling perform...

Page 66: ...er to provide the best possible monitoring of temperature Figure 8 3 illustrates the original high temperature limit switch configuration with a resettable switch Figure 8 4 illustrates the present co...

Page 67: ...Testing The cooling System Diagnostic Flowchart on page 66 through page 67 provides sequential steps to troubleshoot the cooling system Before attempting to replace the cooling system 1 Make sure the...

Page 68: ...s 2 Signs of cooling system leakage Yellow ammonia residue Ammonia smell Installation ventilation meet guidelines Replace cooling system YES YES YES Correct installation and ventilation NO 3 Heat inpu...

Page 69: ...taken in step 4 NO 1 Reconnect thermistor to wire harness 2 Set controls to Diagnostic Mode 3 Select diagnostic Screen 3 4 Record temperature displayed in Screen 3 5 Monitor fin temperature for 3 hour...

Page 70: ...em replacement requires removing the refrigerator from the enclosure Protect the front of the refrigerator Cover the floor with a moving blanket pad or similar soft material to protect the floor as we...

Page 71: ...hermal Mastic sealant supplied with the replacement cooling unit Each tube tip must be cut wide to dispense a bead approximately no wider than 3 4 inch wide Apply the sealant as outlined in the follow...

Page 72: ...ion Screw condenser bracket Screw condenser bracket Screw absorber bracket Screw absorber bracket Permagum sealer Wire tie Screw Wire tie Power board cover 7 slot burner Dip cup Fans 2 Thermostatic sw...

Page 73: ...attempt to install cooling unit in the the enclosure without the assistance of an able person Attempting the installation without additional help may cause personal injury and or extensive property d...

Page 74: ...ten each screw 30 to 55 in pound 25 Install the fin assembly screws Tighten each screw 30 to 55 inch pounds 26 Attach the thermistor to the second fin counting from the right After installing the refr...

Page 75: ...Figure 91 shows the screen number location and LED segments numbering Setting Display to Diagnostics To set the display to diagnostics 1 Press and hold down the mode and SET TEMP switch buttons at th...

Page 76: ...ldest Fin Temperature Displays fin temperature as sensed by the temperature sensing circuit through the thermistor This is not freezer or fresh food cabinet air temperature The example illustrated bel...

Page 77: ...eating is sensed in the cooling unit boiler area The system sensing algorithm still present and will sense a no cool condition however it will not lock out heat sources or display the no co fault code...

Page 78: ...assigned LED segments and information are illustrated below 4 10 5 to 15 4 volts DC 1 Over 15 4 volts DC 7 Below 10 5 volts DC 1 cold 9 coldest Pressing the mode switch button displays screen 1 cold...

Page 79: ...enses the mold temperature At approximately 17 to 14 degrees Fahrenheit 8 3 to 10 degrees Celsius the thermostat energizes the stepper motor and the heater As the motor turns the ejector blades begin...

Page 80: ...s color coding and application Figure 10 2 illustrates the AC power cords installed on 1210 IM and 1211 IM The cord connect to the ice maker four wire harness AC power to the ice maker is to be suppli...

Page 81: ...ent Water Line Heater In ambient temperatures of 42 to 38 degrees Fahrenheit 5 5 to 3 3 degrees Celsius and lower the water line heater keeps the fill line and water valve body from freezing when the...

Page 82: ...10 7 page 81 Solenoid coil RV water connection Water to ice maker Bracket Figure 10 6 Water valve and water connections 4 Disconnect thermostatic switch and the water fill line heater 5 Disconnect the...

Page 83: ...nts L and H Before starting shut off the water supply to the water valve and make sure the AC power cord is plugged into an energized receptacle To manually cycle the ice maker 1 Remove the ice bin an...

Page 84: ...Celsius The motor should run smoothly throughout the cycle until the ejector is parked If the motor does not run stops or makes grinding noises replace ice maker See section Replacing Ice Maker page 8...

Page 85: ...shown in Figure 10 12 6 2 8 1 3 5 D O N O T ROTATE 6 2 8 3 5 8 DISCONNECT POWER TO MODULE 106 626649 IM REMOVE S W2 01 13 03 185W 115V 60 HZ 14 AW G IN S U LA TE D Figure 10 11 Jumpering test points V...

Page 86: ...from the evaporator plate Do not to pull on the wire harness 3 Rotate the ice maker so the module cover faces toward the freezer door then remove the cover 4 Roll the ice maker so the shut off arm si...

Page 87: ...ion then insert one probe into point L and the other into point H as Figure 10 14 illustrates The multimeter test probe tips must be at least 1 2 inch long to contact the test points Figure 10 15 Meas...

Page 88: ...container s in freezer 1 Check freezer door gasket wire harness Permagum seal 2 Containers that contain liquids have to be sealed prior to placing in freezer Not cycling AC power available 1 Mold heat...

Page 89: ...Figure 10 17 Figure 10 17 Ice maker fasteners and back plate Back plate Figure 10 19 Harness plug and thermal fuse To unplug wire harness Press locking tab in then pull back on harness Open spring cli...

Page 90: ...compression style fitting which feeds both the water dispenser valve and the ice maker water valve Ice Maker Water Valve Figure 10 21 and Figure 10 22 illustrate and provide information on the ice mak...

Page 91: ...der mounted water dispenser Figure 11 1 the reservoir Figure 11 2 and the water valve Figure 11 3 Figure 11 1 Water dispenser external view Figure 11 2 Reservoir in cabinet recess and cover Figure 11...

Page 92: ...y the coil opens the water valve allowing water flow into the reservoir Water flows from top of the reservoir to the spigot The water flowing out of the spigot is replaced by water flowing into the re...

Page 93: ...C WHITE wire from the water valve solenoid coil 5 Disconnect thermostatic switch and the water fill line heater as follows a The switch BROWN wire from the heater WHITE wire b The remaining thermostat...

Page 94: ...llow water to drain into the container placed in step 4 7 Disconnect the water fill line from the reservoir See Figure 11 9 8 Remove the retaining screws then pull the reservoir out of the cabinet rec...

Page 95: ...circuit board from bracket See Figure 11 11 B C and D 7 Reverse steps 6 through 1 to install replacement LED circuit board Striker plate Hinge cover Retaining screws Figure 11 10 Cover water dispenser...

Page 96: ...94 Section 12 Section 12 Wiring Diagrams and Pictorials Figure 12 1 Wiring diagram...

Page 97: ...Section 12 95 Figure 12 2 Wiring pictorial...

Page 98: ...Coil Water valve 6 Ice Maker 7 Mold Heater 8 Mold Thermostat 9 ON OFF Switch 10 Fill Switch 11 Hold Switch 12 Stepper Motor N G L GRN VERT BRN BRUN WHT BLANC BLK NOIR NEUTRAL RIBBED NEUTRE NERVURES W...

Page 99: ...Section 12 97 This page intentionally left blank...

Page 100: ...121X Series Service Manual Publication No 630613B 08 10 07 NORCOLD Inc Customer Support Dept Telephone 800 543 1219 Fax 937 497 3183 www norcold com NORCOLD Inc P O Box 4248 Sidney OH 45365...

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