Norcold DC-0040 Bedienungsanleitung

Refrigerator

Service Manual

Models:

DC0040(K), DC0051(K)

DE0040, DE0051

DE0240T, DE0251T

Norcold, Inc.

P.O. Box 4248

Sidney, OH 45365-4248

Part No.623011A(08/03)

Troubleshooting – Table of Contents

Ø Procedure A – Thermostat “ON” compressor does not run… 3

Ø Procedure B – Compressor resistance……………………….. 4

Ø Procedure C – Power supply output voltage…………………. 5

Ø Procedure D – Compressor amp draw…………………………6

Ø Procedure E – Evaporator thermistor resistance…………….. 7

Ø Procedure F – Insufficient cooling………………………………8

Ø Procedure G – Refrigerator too cold……………………………8

Ø Procedure H – Auto shut-off device…………………………….8

Ø Procedure I – Ventilation…………………………………………9

Ø Wiring schematic………………………………………………….9

Ø Quick reference repair sheet…………………………………….10

Warning

Perform all tests using a fully charged 12V DC battery.

Using other equipment that supplies DC voltage may

cause permanent refrigerator component failure.

Troubleshooting – Procedure A

Thermostat “ON” Compressor Does Not Run

Measure Terminal

Voltage Of Temperature

Control Between TP1 &

TP2. (See Figure 1)

DC 0V

DC 5V

DC 2V

Short Circuit

Normal

DC Power

Supply Failure Change DC

Power Supply

Change DC

Power Supply

See

Procedure B

Measure Terminal

Voltage of Temperature

Control Between TP2 &

TP3. (See Figure 1)

Is Temperature

Control LED on? YES

Correct

Voltage OK

Check Supply

Voltage

(10.5 – 32V DC)

(85 – 132V AC)

CORRECT

INCORRECT Compressor

Runs YES

Replace

10A Fuse

(See Figure 2)

Reverse Polarity

& Check Operation

(Red + / Black -) OK

Replace

10A Fuse

(See Figure 2) OK

Check DC

Polarity INCORRECT

Compressor

Runs YES

Check Both

DC Fuses BLOWN

Compressor

Runs YES

DC 0V

DC 12

to 32V

DC Power

Supply Failure

Normal

Change DC

Power Supply

See

Procedure B

Note: Measurements taken with 12.8V DC or 120V AC power supply.

Check AC

Power Supply

(37 – 45V DC)

(See Figure 5)

Change AC

Power Supply

Short Circuit Change DC

Power Supply

GOOD

BAD

OPERATION

Power

Source DC

Check AC

Power Supply

(37 – 45V DC)

(See Figure 5)

DC Power

Supply Failure Change DC

Power Supply

Change AC

Power Supply

GOOD

BAD

OPERATION

Red

TP3

TP1

TP2

Figure 1 – Temperature Control

Brown Black

Figure 2 – Fuse Locations

Note: If 10 Amp fuse is blown,

check wiring of vehicle.

Troubleshooting – Procedure B

Compressor Resistance

Measure

Compressor

Resistance

(See Figure 3)

0 W

¥ W

1.4 – 3.5 WNormal

Internal

Compressor

Failure

See

Procedure C

Change

Cooling Unit

Note: Perform procedure at room temperature.

Figure 3 – Measuring Compressor

Resistance

Turn the refrigerator to OFF.

Remove the black wire to the compressor. Measure the

resistance of the compressor between point A and point B.

Troubleshooting – Procedure C

Power Supply Output Voltage

Measure Voltage

BetweenA & B

At the Compressor

(See Figure 4)

Less than

15V AC

0V AC

15 –25V

DC Power

Supply Failure

DC Power

Supply Failure

Normal

Go to

Procedure E

Change DC

Power Supply

Change DC

Power Supply

Change

Thermistor

FAULTY

THERMISTOR

GOOD

THERMISTOR

See

Procedure D

Note: Measurements taken with 12.8V DC or 120V AC power supply.

OPERATION Check AC Power

Supply.

(37 – 45V DC)

(See Figure 5)

OPERATION DC Power

Supply Failure Change DC

Power Supply

Change AC

Power Supply

Power

Source

Check AC Power

Supply.

(37 – 45V DC)

(See Figure 5)

DC Power

Supply Failure Change DC

Power Supply

Change AC

Power Supply

GOOD

BAD

GOOD

BAD

Figure 5 – Measuring AC Power

Supply Output

Figure 4 – Measuring Power

Supply Output Voltage

Troubleshooting – Procedure D

Compressor Amp Draw

Measure Amperage at

‘A’ on the Compressor

(See Figure 6) Normal

40Watt = 1.6 - 2.0Amps

60Watt = 2.7 - 3.3Amps

40Watt < 1.6Amps

60Watt < 2.7Amps

40Watt > 2.0Amps

60Watt > 3.3Amps

Compressor

Failure

Compressor

Failure

Change

Cooling Unit

Change

Cooling Unit

Note: Measurements taken with 12.8V DC power supply.

Compressor

Figure 6 – Measuring Amp Draw

of Compressor

Troubleshooting – Procedure E

Thermistor Operation Verification

To measure the resistance of the

evaporator thermistor, turn the

refrigerator to the OFF position.

Disconnect the three-pole connector

(Figure 7), and measure resistance

across the two pins. (Figure 8)

Check the evaporator thermistor by

measuring the temperature and

resistance of the thermistor. Refer to

Table 1 for a listing of acceptable

resistance ranges.

In general:

1.6K – 29KW= good thermistor.

¥W = defective thermistor. An open

thermistor will stop normal compressor

operation. Replace the defective

thermistor.

Evaporator Thermistor Resistance

Thermistor Temperature

( °F ) ( °C ) Resistance Allowable

Resistance Range

0 -18

9.7 KW8.7 - 10.7 KW

10 -12

7.8 KW7.0 – 8.6 KW

20 -7

6.4 KW5.7 – 7.0 KW

30 -1

5.3 KW4.8 – 5.7 KW

40 4

4.5 KW4.0 – 4.9 KW

50 10

3.6 KW3.2 – 4.0 KW

60 16

2.8 KW2.5 – 3.1 KW

70 21

2.1 KW1.9 – 2.3 KW

80 27

1.9 KW1.7 – 2.0 KW

90 32

1.8 KW1.6 – 1.9 KW

(Table 1)

Figure 8 – Measure Resistance

cross Pins

Figure 7 – Evaporator Thermistor

Connection (inside power supply)

Troubleshooting – Procedure F

Insufficient Cooling

Note: Check input voltage before

proceeding. Refer to Procedure A.

If compressor runs continuously:

Ø Check the voltage across the fan

leads. There will be a slight

voltage reading even if the fan isn’t

operational. The fan will only

operate when the compressor is

running, and the ambient

temperature is sufficient to engage

the fan. The operational voltage of

the fan is between 17 and 22VDC.

If this is present at the leads and

the fan is not running, replace the

fan. (Note: When servicing fan,

do not short the wires; this will

damage the power supply.

Ø Make sure the ventilation vents are

not blocked. Refer to Procedure I.

Ø Make sure the auto shut-off device

is operational. Refer to Procedure

Ø If the reason for insufficient cooling

is not found, start with Procedure

Replace cooling unit if:

Ø Compressor is hot to the touch and

not vibrating.

Ø Compressor vibrates and no

cooling

Troubleshooting – Procedure G

Refrigerator too Cold

Ø Adjust temperature control to lower setting. (#1 = Warm, #5 = Coldest.)

Ø Make sure thermistor is securely mounted to the evaporator plate.

Ø If the reason is not found, refer to Procedure E.

Troubleshooting – Procedure H

Auto Shut-off Device

Note: Only the 12/24V DC models are

equipped with the auto shut-off device

within the power supply.

Shut-off Device Operation

To protect the cooling unit from

overheating, the refrigerator will

automatically shut-off when the ambient

air temperature is approximately 110°F. If

shut-off occurs, the refrigerator will sound

an intermittent alarm tone. To stop the

alarm, the refrigerator must be restarted.

This can be done by turning the

thermostat knob counterclockwise to the

OFF position and then turning it back to

the desired setting. The refrigerator will

not restart until the ambient conditions

allow for normal operation. The

functionality of the shut-off device can be

tested by heating it with a heat gun (See

Figure 9).

TH2

Figure 9 – High Temperature

Shut-off Device

Ventilation – Procedure I

Ventilation is necessary for the correct

operation of the refrigerator. Good

ventilation also increases the life of the

refrigerator cooling system. The current

models are equipped with built-in

ventilation systems that draw cooler air

through the lower intake vent. This air is

then circulated over the cooling unit to

remove excess heat from the cooling

system. The heated air is then rejected

through the upper vent. If this airflow is

blocked or decreased, the refrigerator

will not cool correctly. Do not block the

vents by closet or cabinet doors. Vent

blockage that reduces the vent area can

cause:

Ø Shortened life of the refrigeration-

cooling unit.

Ø Poor cooling performance of the

refrigerator.

Ø Continuous operation of the

refrigerator.

Ø Fast battery discharge.

Ø Void the refrigerator warranty.

Troubleshooting – Wiring Schematic

AC 85~132V

ORANGE

WHITE

AC IN(L)

AC IN(N)

B3P-VH AC/DC

converter

AC/DC PART

DC OUT + RED

DC OUT - BLACK

DC INPUT

CN1

B2P-VH

FAN MOTOR

24V DC

RED BLACK

XHP-2

B2B-XH-A

CONDENSOR

COUPLING

CN2

B3P-VH VHR-3N

SK515-N

INVERTER

ELECTRONIC

CURRENT

PROTECTOR

RED

BLACK

BATTERY IN +

BATTERY IN -

FUSE

BATTERY

MONITOR

(OPTIONAL)

ELECTRONIC

THERMOSTAT

DC/DC

converter

INPUT HIGH

VOLTAGE

PROTECTOR

HIGH TEMPERATURE

PROTECTER

BUZZER (OPTIONAL)

LOW TEMPERATURE

PROTECTER

DC 39V FOR 40W

DC 41V FOR 60W

CN4

B2B-EH

EHR-2

BLACK BLACK

EVAPORATOR

THERMISTOR

AMBIENT

THERMISTOR

AMBIENT

THERMISTOR

DC/AC PART

DC 12~32V

FUSE

Troubleshooting – Quick Reference

1. Check for supply voltage at rear of the refrigerator. Turn refrigerator ON. The

operating voltage should be between 10.5V and 32V DC. There will be some

variation in these readings depending on the supply voltage.

2. Check for voltage (15V – 25V AC) at compressor

between points A and B (See Figure 10). If voltage

is not within range, refer to Procedure C on page 5.

Figure 10

3. Take an Ohm reading (1.4 – 3.5W) at compressor

between points A and B (See Figure 11). If Ohm

reading is not within range, refer to Procedure B on

page 4.

Figure 11

4. Take an Amp reading (1.6 – 3.3 Amps) at the black

wire with the rubber boot (See Figure 12). If amperage is

not within range, refer to Procedure D on page 6.

Figure 12

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