Thermo Electron 8600 Series Troubleshooting Service Manual Download Page 19

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Temp°C 4-20

4-0mA
with
250
Ohm
resistor

0-1V 0-5V

50 20.000

5.000

1.000

5.000

49 19.893

4.973

0.993

4.967

48 19.787

4.947

0.987

4.933

47 19.680

4.920

0.980

4.900

46 19.573

4.893

0.973

4.867

45 19.467

4.867

0.967

4.833

44 19.360

4.840

0.960

4.800

43 19.253

4.813

0.953

4.767

42 19.147

4.787

0.947

4.733

41 19.040

4.760

0.940

4.700

40 18.933

4.733

0.933

4.667

39 18.827

4.707

0.927

4.633

38 18.720

4.680

0.920

4.600

37 18.613

4.653

0.913

4.567

36 18.507

4.627

0.907

4.533

35 18.400

4.600

0.900

4.500

34 18.293

4.573

0.893

4.467

33 18.187

4.547

0.887

4.433

32 18.080

4.520

0.880

4.400

31 17.973

4.493

0.873

4.367

30 17.867

4.467

0.867

4.333

29 17.760

4.440

0.860

4.300

28 17.653

4.413

0.853

4.267

27 17.547

4.387

0.847

4.233

26 17.440

4.360

0.840

4.200

25 17.333

4.333

0.833

4.167

24 17.227

4.307

0.827

4.133

23 17.120

4.280

0.820

4.100

22 17.013

4.253

0.813

4.067

21 16.907

4.227

0.807

4.033

20 16.800

4.200

0.800

4.000

19 16.693

4.173

0.793

3.967

18 16.587

4.147

0.787

3.933

17 16.480

4.120

0.780

3.900

16 16.373

4.093

0.773

3.867

15 16.267

4.067

0.767

3.833

14 16.160

4.040

0.760

3.800

13 16.053

4.013

0.753

3.767

12 15.947

3.987

0.747

3.733

11 15.840

3.960

0.740

3.700

10 15.733

3.933

0.733

3.667

9 15.627

3.907

0.727

3.633

8 15.520

3.880

0.720

3.600

7 15.413

3.853

0.713

3.567

6 15.307

3.827

0.707

3.533

5 15.200

3.800

0.700

3.500

4 15.093

3.773

0.693

3.467

3 14.987

3.747

0.687

3.433

2 14.880

3.720

0.680

3.400

1 14.773

3.693

0.673

3.367

0 14.667

3.667

0.667

3.333

Temp°C 4-20

4-20mA
with
250
Ohm
resistor

0-1V 0-5V

-1 14.560

3.640

0.660

3.300

-2 14.453

3.613

0.653

3.267

-3 14.347

3.587

0.647

3.233

-4 14.240

3.560

0.640

3.200

-5 14.133

3.533

0.633

3.167

-6 14.027

3.507

0.627

3.133

-7 13.920

3.480

0.620

3.100

-8 13.813

3.453

0.613

3.067

-9 13.707

3.427

0.607

3.033

-10 13.600

3.400

0.600

3.000

-11 13.493

3.373

0.593

2.967

-12 13.387

3.347

0.587

2.933

-13 13.280

3.320

0.580

2.900

-14 13.173

3.293

0.573

2.867

-15 13.067

3.267

0.567

2.833

-16 12.960

3.240

0.560

2.800

-17 12.853

3.213

0.553

2.767

-18 12.747

3.187

0.547

2.733

-19 12.640

3.160

0.540

2.700

-20 12.533

3.133

0.533

2.667

-21 12.427

3.107

0.527

2.633

-22 12.320

3.080

0.520

2.600

-23 12.213

3.053

0.513

2.567

-24 12.107

3.027

0.507

2.533

-25 12.000

3.000

0.500

2.500

-26 11.893

2.973

0.493

2.467

-27 11.787

2.947

0.487

2.433

-28 11.680

2.920

0.480

2.400

-29 11.573

2.893

0.473

2.367

-30 11.467

2.867

0.467

2.333

-31 11.360

2.840

0.460

2.300

-32 11.253

2.813

0.453

2.267

-33 11.147

2.787

0.447

2.233

-34 11.040

2.760

0.440

2.200

-35 10.933

2.733

0.433

2.167

-36 10.827

2.707

0.427

2.133

-37 10.720

2.680

0.420

2.100

-38 10.613

2.653

0.413

2.067

-39 10.507

2.627

0.407

2.033

-40 10.400

2.600

0.400

2.000

-41 10.293

2.573

0.393

1.967

-42 10.187

2.547

0.387

1.933

-43 10.080

2.520

0.380

1.900

-44 9.973

2.493

0.373

1.867

-45 9.867

2.467

0.367

1.833

-46 9.760

2.440

0.360

1.800

-47 9.653

2.413

0.353

1.767

-48 9.547

2.387

0.347

1.733

-49 9.440

2.360

0.340

1.700

-50 9.333

2.333

0.333

1.667

Temp°C 4-20

4-0mA
with
250
Ohm
resistor

0-1V 0-5V

-51

9.227 2.307 0.327 1.633

-52

9.120 2.280 0.320 1.600

-53

9.013 2.253 0.313 1.567

-54

8.907 2.227 0.307 1.533

-55

8.800 2.200 0.300 1.500

-56

8.693 2.173 0.293 1.467

-57

8.587 2.147 0.287 1.433

-58

8.480 2.120 0.280 1.400

-59

8.373 2.093 0.273 1.367

-60

8.267 2.067 0.267 1.333

-61

8.160 2.040 0.260 1.300

-62

8.053 2.013 0.253 1.267

-63

7.947 1.987 0.247 1.233

-64

7.840 1.960 0.240 1.200

-65

7.733 1.933 0.233 1.167

-66

7.627 1.907 0.227 1.133

-67

7.520 1.880 0.220 1.100

-68

7.413 1.853 0.213 1.067

-69

7.307 1.827 0.207 1.033

-70

7.200 1.800 0.200 1.000

-71

7.093 1.773 0.193 0.967

-72

6.987 1.747 0.187 0.933

-73

6.880 1.720 0.180 0.900

-74

6.773 1.693 0.173 0.867

-75

6.667 1.667 0.167 0.833

-76

6.560 1.640 0.160 0.800

-77

6.453 1.613 0.153 0.767

-78

6.347 1.587 0.147 0.733

-79

6.240 1.560 0.140 0.700

-80

6.133 1.533 0.133 0.667

-81

6.027 1.507 0.127 0.633

-82

5.920 1.480 0.120 0.600

-83

5.813 1.453 0.113 0.567

-84

5.707 1.427 0.107 0.533

-85

5.600 1.400 0.100 0.500

-86

5.493 1.373 0.093 0.467

-87

5.387 1.347 0.087 0.433

-88

5.280 1.320 0.080 0.400

-89

5.173 1.293 0.073 0.367

-90

5.067 1.267 0.067 0.333

-91

4.960 1.240 0.060 0.300

-92

4.853 1.213 0.053 0.267

-93

4.747 1.187 0.047 0.233

-94

4.640 1.160 0.040 0.200

-95

4.533 1.133 0.033 0.167

-96

4.427 1.107 0.027 0.133

-97

4.320 1.080 0.020 0.100

-98

4.213 1.053 0.013 0.067

-99

4.107 1.027 0.007 0.033

-100 4.000 1.000 0.000 0.000

Analog Output Reference Table

Summary of Contents for 8600 Series

Page 1: ...7998600 Rev 4 ...

Page 2: ...dental arising out of or related to the use of this manual MANUAL NO 7998600 4 FR 1789 6 27 05 Revised VRP troubleshooting section for Release 3 aks 3 22216 3 22 04 Added 120V 23 cu ft units aks 2 22179 2 24 04 Revised electrical schematic start capacitor part number aks 8 21 03 Door gap high stage revisions aks 8 13 03 Revised compressor information page B 1 aks 6 27 03 Revisions per A Thomas aks...

Page 3: ...er alarm 2 7 2 10 High stage system failure alarm 2 8 2 11 Power failure alarm 2 9 2 12 Wrong power 2 10 2 13 Low Temperature 2 10 2 14 High temperature alarm or system not maintaining temperature 2 11 2 15 Troubleshoot compressor 2 13 2 16 Voltage Compensation Failure 2 14 Section 3 Charts and Schematics 3 1 Analog Output Reference Table 3 1 3 2 RTD Temperature vs Resistance 3 2 3 3 Pressures vs ...

Page 4: ...is warmer than 50 C 7 Set point achieved fans and compressors cycle off 8 Steps 2 though 7 repeat cycle Items or functions unique to this system 1 2 Expansion Tank Assembly and Solenoid Valve Location Suction side of low stage system Purpose Tank assembly increases low stage system refrigeration capacity Prevents excessive low stage pressures at temperatures warmer than 50 Operation The tank assem...

Page 5: ...2 3 and 4 Failure Alarm ALL PROBES FAIL Order Possible Cause Verification Action Re seat connector 1 Control probe not installed Startup only Verify wires are fully seated in connectors and connectors are seated together Reinitialize re start unit Reseat all connections Replace probe if necessary Bad control probe Display reads 99 Bad control probe will also cause a high temperature alarm and lock...

Page 6: ...mpare with Analog Output Reference Table page 3 1 Call the factory service department 888 213 1790 See section 4 2 p Analog Calibration page 4 3 2 Analog Output Check that all connections are tight and properly wired Missing wires Tighten and or correct wiring Verify address is correct in configuration menu and matches the 1535 address Change so that the unit address of the freezer matches the 153...

Page 7: ...connector seating on ribbon cables Replace if required 3 Micro board Micro LED LD1 on micro board not functioning Is unit operating fans compressors If no replace micro board If yes continue to step 4 Turn unit off then turn unit back on Miscellaneous characters displayed Replace display board 4 Micro board Micro LED LD1 functioning no display LED LD2 Check connection of 25 pin D sub cable at both...

Page 8: ...t the wire connection Door switch connector not seated to board connector Verify connectors are seated together Re seat connection 3 Installed in wrong connector Verify the plug is in the correct receptacle Re seat plug in correct receptacle 4 Improper door alignment Verify door gap Single door 600 Double door 700 both measured from the hinge side Make adjustment as required 5 Bad door switch Veri...

Page 9: ...ng power supply On the 6 pin connector measure between pins 1 and 6 14V 0 5V Check and reseat connectors between switching power supply and high voltage board Also check and reseat connections between high voltage board and micro board Verify unit is colder than 50 C Cabinet temperature must be colder than 50 C to activate vacuum relief heater 90 130VAC at heater YES Ohm out heater Heater to be 10...

Page 10: ...y test after 2 days 48 hours of operation If voltage 12 1 replace battery and continue to step 8 8 Micro board Battery test circuit Battery charging circuit Disconnect battery and measure voltage at the battery wires If 13 5 13 8 VDC is present replace battery If not present replace micro board and battery 2 8 Symptom Noise Order Possible Cause Verification Action 1 Loose screws on panels or compr...

Page 11: ...tie wrap If no voltage check voltage between U13 10 and J11 1 U16 10 and J11 1 on micro board If less than 10VDC replace micro board Else if DC voltage across D11 and D14 on high voltage board is less than 10VDC check ribbon cable If ribbon cable OK replace high voltage board 3 Fan s not running Confirm voltage to each fan by verifying voltage at pins J29 1 to J29 7 and J29 2 to J29 8 on the high ...

Page 12: ...m out pressure switch Switch to be closed Switch OK measure voltage between pins 4 and 5 of J30 If no voltage replace high voltage board Switch defective jumper around switch and continue to test No voltage at compressor LD5 HS is off and should be on If voltage between U13 15 and J11 1 on micro board is less than 10VDC replace micro board Else if DC voltage across D12 on high voltage board is gre...

Page 13: ...if required If trips above rating go to step 5 3 Loose wires Circuit Breaker Power switch High voltage board Switching power supply Verify line voltage connection from circuit breaker power switch to high voltage board inputs and ribbon cable connection from high voltage board to DC switching power supply Seat or replace as required 4 Defective switching power supply Verify input line voltage and ...

Page 14: ...age board 5 High voltage board failure Measure frequency between pins 4 and 5 of U1 Frequency is not twice the frequency of wall outlet Replace high voltage board Measure AC voltage across R40 on micro board Voltage should be between 25 and 95 VAC No voltage replace ribbon cable Good voltage replace micro board 6 Micro board failure Measure frequency between pin 10 of U14 and pin 8 of U28 No measu...

Page 15: ...and verify control RTD temperature is accurate Troubleshoot control probe with Probe 1 2 3 4 failure procedure 3 Defective control probe See procedure for troubleshooting probes Probe 1 2 3 or 4 Failure Single Probe 4 Normal relay s on high voltage board LD 2 and LD 4 on high voltage board are not lit 120v units Line voltage 105 140 230V 60Hz units Line voltage 210 260 230V 50Hz units Line voltage...

Page 16: ...10VDC check ribbon cable If ribbon cable OK go replace high voltage board If D13 voltage greater than 10VDC Go to previous verification LD6 maybe defective AC power to low stage compressor Voltage at compressor Check continuity of compressor thermal switch Check winding resistance of compressor See Appendix B Check compressor starting hardware Replace parts as needed 5 LS compressor cycles on high...

Page 17: ... pressures on high and low stages identical Yes replace interstage and recondition both the high and low stages No go to next verification 2 Unit at room temperature heat exchanger at room temperature Static pressure unacceptable Suspect under or overcharge Recondition refrigeration system for system in question Measurements of wall voltage Unit off Unit at start up If unacceptable work with custo...

Page 18: ...ormer s and high voltage board Check transformer Check relay contacts Restart unit Take following readings when LD1 or LD3 should be on LD1 Line voltage should be read between J5 and J22 Replace high voltage board as required 1 Voltage Compensation Failure Unit will operate normally Turn unit off and then back on If unit goes into Boost LD2 or Buck LD4 unit does not function and then goes into Nor...

Page 19: ...3 2 667 21 12 427 3 107 0 527 2 633 22 12 320 3 080 0 520 2 600 23 12 213 3 053 0 513 2 567 24 12 107 3 027 0 507 2 533 25 12 000 3 000 0 500 2 500 26 11 893 2 973 0 493 2 467 27 11 787 2 947 0 487 2 433 28 11 680 2 920 0 480 2 400 29 11 573 2 893 0 473 2 367 30 11 467 2 867 0 467 2 333 31 11 360 2 840 0 460 2 300 32 11 253 2 813 0 453 2 267 33 11 147 2 787 0 447 2 233 34 11 040 2 760 0 440 2 200 ...

Page 20: ... 00 25 901 90 3 90 24 905 90 4 00 23 909 80 3 90 C Ohms Difference 22 913 70 3 90 21 917 70 4 00 20 921 60 3 90 19 925 50 3 90 18 929 50 4 00 17 933 40 3 90 16 937 30 3 90 15 941 20 3 90 14 945 20 4 00 13 949 10 3 90 12 953 00 3 90 11 956 90 3 90 10 960 90 4 00 9 964 80 3 90 8 968 70 3 90 7 972 60 3 90 6 976 50 3 90 5 980 40 3 90 4 984 40 4 00 3 988 30 3 90 2 992 20 3 90 1 996 10 3 90 0 1000 00 3 ...

Page 21: ... 110 120 130 140 150 160 170 180 190 200 90 80 70 60 50 40 30 20 10 0 10 20 Cabinet Temperature C Discharge Pressure psig 10 8 6 4 2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 Suction Pressure psig for Positive Pressures inches Hg for Negative Pressures HS Disch Pressure LS Disch Pressure HS Suct Pressure LS Suct Pressure ...

Page 22: ...3 4 ...

Page 23: ...3 5 ...

Page 24: ...3 6 ...

Page 25: ...3 7 ...

Page 26: ...3 8 ...

Page 27: ...3 9 ...

Page 28: ...3 10 ...

Page 29: ...3 11 ...

Page 30: ...3 12 MICRO BOARD HIGH VOLTAGE BOARD ...

Page 31: ...r is manually turned ON OFF as used in normal operation c Fan 1 Fan 1 is manually turned ON OFF as used in normal operation d Fan 2 Fan 2 is manually turned ON OFF as used in normal operation e Heaters The freezer heaters are manually turned ON OFF as used in normal operation f High Stage Heat Exchange Temperature Displays the temperature g High Stage Condenser Temperature Displays the temperature...

Page 32: ...et is reset to factory default g Reset Analog Calibration Offset 1 Press the right arrow until RST DAC OFST is displayed in the message center 2 Press Enter to save to memory The analog calibration offset is reset to factory default h Serial RS232 RS485 1 Press the right arrow until SERIAL RS232 is displayed in the message center 2 Press up down arrow to toggle to RS485 3 Press Enter to save to me...

Page 33: ...0 to 1 volt or 0 to 5 volt or CRNT for 4 to 20mA 3 Press Enter to save to memory This option must match the analog output dip switch settings on the micro board p Analog Calibration Connect a decade box set at 250 Ohms to pin 1 positive and pin 2 negative on the remote alarm analog connector on the freezer Connect a digital volt meter across the decade box 1 Press the right arrow until ANALOG CAL ...

Page 34: ...tage board to turn on compressors solenoid fans and heaters Initializes communication with display board The micro board stores all set points receives signal from high voltage board to indicate line voltage and then signals high voltage board to engage or disengage boost buck Probe 1 Control probe A defective control probe will cause a probe failure and a high temperature alarm Both compressors w...

Page 35: ... 370VAC 3ARR3CT10V5 RF41C1E CAA 3 220Ω 0 415Ω 189 227uf 250VAC 35uf 370VAC 3ARR3CT10S5 RF40C1E CAV 18 300Ω 2 100Ω 43 52uf 250VAC 10uf 440VAC 3ARR3CT10V5 RF41C1E CAV 6 300Ω 1 650Ω 108 130uf 250VAC 20uf 440VAC 3ARR3CT10V5 KALB 010L CAV 4 525Ω 1 370Ω 145 174uf 370VAC 40uf 370VAC 3ARR3CT24ES AFE13C3E IAA 7 32 5 1 09 5 189 227uf 165VAC 041 147 AFE13C3E IAZ 34 40 5 5 00 5 50 60uf 330VAC 041 183 ...

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Thermo Electron 8600 Series, Troubleshooting Service Manual

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