599356105

SERVICE MANUAL REFRIGERATION

© ELECTROLUX HOME PRODUCTS S.p.A. Publication no. Spares Operations Italy 599 35 61-05 Corso Lino Zanussi, 30 021218 I - 33080 PORCIA / PN (ITALY) ITZ/SERVICE/AA Fax +39 0434 394096

NOFROST REFRIGERATORS

with electronic timer

NOFROST REFRIGERATORS WITH ELECTRONIC TIMER 2/29


CONTENTS

1. INTRODUCTION........................................................................................................................................................ 5

2. REFRIGERATION CIRCUIT ..................................................................................................................................... 7

3. ELECTRIC WIRING................................................................................................................................................... 8

4. FUNCTIONAL DIAGRAM......................................................................................................................................... 9

5. OPERATION ............................................................................................................................................................ 10 5.1 NORMAL............................................................................................................................................................. 10 5.2 NORMAL WITH FIRST SWITCHING ON OR POWER FAILURE ................................................................... 11 5.3 DEFROSTING .................................................................................................................................................... 12 5.4 NTC SENSOR MALFUNCTIONING.................................................................................................................. 13

6. COMPONENTS........................................................................................................................................................ 14 6.1 CONTROL PANEL : ........................................................................................................................................... 14 6.2 REFRIGERATOR COMPARTMENT :............................................................................................................... 14 6.3 FREEZER COMPARTMENT : ........................................................................................................................... 15 6.4 COMPRESSOR COMPARTMENT : ................................................................................................................. 16 6.5 ZCP TERMINAL BOARD ................................................................................................................................... 17 6.6 ELECTRONIC BOARD ...................................................................................................................................... 18

7. ACCESSIBILITY ...................................................................................................................................................... 21 7.1. ACCESS TO CONTROL PANEL...................................................................................................................... 21 7.2. ACCESS TO REFRIGERATOR COMPARTMENT......................................................................................... 23 7.3. ACCESS TO FREEZER COMPARTMENT ..................................................................................................... 24

8. TROUBLESHOOTING ............................................................................................................................................ 26 8.1 DRAIN CIRCUIT: ................................................................................................................................................ 26 8.3 FAILED DEFROSTING: ..................................................................................................................................... 27 8.4 BURN OUT LAMP: ............................................................................................................................................. 27 8.5 MANUAL DEFROSTING PROCEDURE........................................................................................................... 28


1. INTRODUCTION

This manual describes the NOFROST models WITH ELECTRONIC TIMER. These models differ from the previous (see SM 599356104) as they do not feature the electromechanical timer because an electronic timer has been incorporated in the control and power board called ERF1050-01.X (where X represents a variant of the board). The three basic models differ only for the volume: 260 litres (ex C9, pnc 925886…), 262 litres (ex C10, pnc 925887…) and 290 litres (ex C11, pnc 925888…).

pnc Date Model Brand 92588670000 20021220 672.700 2/40032 Privileg 92588670100 20030606 CZC16/9FA Zanussi - Electrolux 92588670300 20030321 ZEBF250W Zanussi - Electrolux 92588770000 20030418 ZEBF262W Zanussi - Electrolux 92588870000 20021220 672.694 7/40033 Privileg 92588870100 20030418 ZEBF290W Zanussi - Electrolux 92588870200 20030606 ZEBF290SI Zanussi-Electrolux

The NOFROST refrigerators consist of a refrigerator compartment A and a freezer compartment B. The cold, produced by the battery evaporator in the freezer compartment, is then distributed in the refrigerator and freezer compartments by the fan placed over the battery.


REFRIGERATOR COMPARTMENT (A) The air is pushed by the fan down the foam duct at the bottom of the compartment: it enters by nozzle 1 and comes out of nozzle 2. Manual flap C enables to regulate the flow of cold air and therefore the temperature inside the compartment. The thermostat bulb is located inside the flap and reacts both to the air temperature of the air coming out of nozzle 2, and to the air temperature inside the refrigerator compartment. The air returns to the air compartment through the foam duct at the bottom of the compartment, entering from nozzle 3 and leaving from nozzle 4. FREEZER COMPARTMENT (B) The cold air is pushed into the compartment by the fan through the two nozzles 5 and 6. After circulating, the air is rechannelled to the evaporator battery through opening 7, under the protection panel.


2. REFRIGERATION CIRCUIT

Key:

1. compressor 2. condenser 3. filter 4. capillary 5. heat exchanger 6. battery evaporator


3. ELECTRIC WIRING

( check the specific diagram for each model! ) Key: 1. ZCP terminal board a. yellow-green 3. terminal board of freezer compressor b. brown 5. motor protector d. white 9. stylus defrosting heater c. blue 9a. armoured defrosting heater e. black 13. refrigerator lamp 15. light switch 24. battery fan 26. safety thermal switch (+40°C) 27. defrosting cut-out switch (+10°C) 28. running capacitor (only for the models which feature it) 41. electronic thermostat assembly with timer 56. NTC sensor


4. FUNCTIONAL DIAGRAM

( check the specific diagram for each model! )

Key: 1. ZCP terminal board a. yellow-green 3. terminal board of freezer compressor b. brown 5. motor protector d. white 9. stylus defrosting heater c. blue 9a. armoured defrosting heater e. black 13. refrigerator lamp 15. light switch 24. battery fan 26. safety thermal switch (+40°C) 27. defrosting cut-out switch (+10°C) 28. running capacitor (only for the models which feature it) 41. electronic thermostat assembly with timer 56. NTC sensor


5. OPERATION

5.1 NORMAL When the thermostat knob is on (OFF) position it means that:

the compressor is off; all Leds are off; the electronic board is powered ( 220-240V 50Hz ! ! ! ).

Warning: the electronic board is powered with a 220-240V 50Hz voltage even if the thermostat knob is on (OFF) position. Therefore, disconnect the appliance from the electric power before operating with the electronic board.

By rotating clockwise the thermostat knob the green LED switches ON. In NOFROST refrigerators, the humidity inside the freezer or refrigerator compartments accumulates on the evaporator battery, thanks to the air circulation, thus preventing the formation of frost on food. During normal operation time the electronic board powers the compressor (3) and the fan (24) circuits. The operation time which corresponds to the interval between the following defrosting lasts about 14 hours with normal opening of the door ( it can last up to 71 hours if the door is never opened !). The arrows in the picture indicate the current path.


5.2 NORMAL WITH FIRST SWITCHING ON OR POWER FAILURE In case of fault when the appliance is switched on for the first time or in case of a power failure, one of the two conditions described below occurs:

1. If the internal temperature is higher or the same as the cut-in temperature of the thermostat (CUT-IN), when the power is restored, the electronic board activates the compressor and the fan till the set temperature is reached and after 5 hours the electronic board activates the defrosting procedure.

2. If the internal temperature is lower than the cut-in temperature of the thermostat (CUT-IN), when

the power is restored, the compressor functions in thermostatic conditions and after 5 hours the electronic board starts the defrosting procedure.

The electronic board activates, anyway, the defrosting procedure after 5 hours in case of both the first switching on and a power failure.

Warning: if you turn the thermostat knob anti-clockwise till the zero position (OFF), all the counters will be reset (apart from those necessary to the manual defrosting procedure) and once the thermostat knob has been turned clockwise in ON position, the compressor will operate in thermostatic conditions.


5.3 DEFROSTING

All the humidity in the compartment accumulates on the evaporator, which is the coldest part of the compartment; periodically, every about 14 hours minimum with normal door openings (till 71 hours if the door is never opened!), it is necessary to defrost the ice which forms on the battery, therefore, the electronic board disconnect the circuit which powers the compressor (3) and the fan (24) and, after checking for the defrosting heater, it powers the defrosting heater (9 e 9a) for about 20 minutes minimum. In case the defrosting heater is interrupted or its connector is disconnected, the LED ON flashes and the defrosting heater lasts 1 hour. The heat generated by the defrosting heater does not affect the temperature of the freezer compartment or the temperature of the food packages, since the whole thermal energy is consumed in the defrosting process of the ice on the evaporator. After 20 minutes, the board detects every minute the signal of the defrosting process in order to determine the intervention of the defrosting cut-out switch (27). When the defrosting cut-out switch intervenes, the electronic control switches on the compressor again (3) with a 5 minute delay. After another 3 minute delay, when the air is already cold, the fan also switches on again (24). If for any reason, the defrosting cut-out switch does not intervene (27) and the temperature of the battery rises up to +40 °C, the defrosting heater (9) will be switched off by the safety thermal switch (26). Moreover, if 1 hour after the defrosting start the safety thermal switches did not switch off, the electronic board switches off anyway the defrosting heater and the process carries on. The arrows in the picture indicate the current path.

N.B.: The defrosting activates with about half an hour delay if the door is opened between the 14th and 70th hour after the last defrosting.


5.4 NTC SENSOR MALFUNCTIONING

If during the normal functioning a NTC sensor failure occurs (the signal coming from the sensor is out of range, then:

The appliance functions with a predefined cycle, by which the compressor is powered for 30 minutes

and remains off for 45 minutes alternatively; The defrosting procedure starts every 14 hours.

When the sensor returns to normal operation the above mentioned functions end. Characteristics of NTC sensor:


6. COMPONENTS 6.1 CONTROL PANEL: - pilot light B. - thermostat knob T. - light button P. 6.2 REFRIGERATOR COMPARTMENT: - flap C: it allows to regulate the air flow

coming from the freezer compartment by means of the M knob. - lampholder A.


6.3 FREEZER COMPARTMENT: - fan D; - couple of thermal overload cut-outs E (for technical data see Tab. A) - evaporator battery F - defrosting heater G (for technical data see Tab. B) Tab. A

Tab. B

pnc Refrigerating gas

Voltage Resistance Power Notes

925886xxx R134a 240 V 242 Ω 238 W -

925886xxx R600a 240 V 213 Ω (see notes) 271 W Total value of the 2 heating

elements 925887xxx R134a 240 V 220 Ω 262 W -


elements 925888xxx R134a 240 V 220 Ω 262 W -


elements

CUT-IN TEMPERATURE TYPE OF THERMAL OVERLOAD CUT-OUT OPENING CLOSURE

DEFROSTING + 8 °C - 1 °C SAFETY + 40 °C + 30 °C


6.4 COMPRESSOR COMPARTMENT: At the back of the appliance it is placed the ZCP terminal board which contains the electrical connections of the defrosting and fan heating element.


6.5 ZCP TERMINAL BOARD - A electric wiring cable (from the electronic board) A1 fan line (brown)

A2 neutral (blue) A3 defrosting heaters line (black)

- B defrosting heaters cable

B1 neutral (blue) B2 defrosting heaters line (brown)

- C fan cable

C1 fan line (brown) C2 neutral (blue) C3 earth (yellow-green)


6.6 ELECTRONIC BOARD - A J1 connector board powering and compressor control; - B J2 connector power fan components, defrosting heaters and lamp; - C J3/J6 connector NTC sensor; - D J7 connector lamp switch.

ATTENTION: the electronic board features a protection which avoids the activation of the compressor 5 minutes before the last switching off!


VIEW OF THE ELECTRONIC BOARD (WELDING SIDE): Optional components: - A reed element; - B thermostat knob; - C SUPER button.

1. compressor 2. free 3. line 4. neutral

1. lamp 2. neutral 3. neutral 4. defrosting heaters 5. fan

1. NTC 2. NTC


1. NTC 2. free 3. NTC

4. lamp switch 3. lamp switch

To identify the functionalities of the electronic boards, please refer to the following table (for the part no. see the spare part lists of the specific model):

Type of electronic board

Type of thermal

Buzzer Green LED

Yellow LED

Red LED

Reed element

SUPER button

ERF1050-01.E A NO YES NO NO NO NO

Pos. min Pos. max Cut-in Cut-out Cut-in Cut-out

SUPER Temperature

Type of thermal

[°C] [°C] [°C] [°C] [°C] A +4 -6,5 +4 -25,5 +40

N.B.: If the NTC sensor detects a temperature higher than the SUPER temperature (for example, the thermal A has a SUPER temperature of +40°C), then the electronic board activates the compressor for the Super function. High SUPER temperature values indicate that the Super function must not activate.


7. ACCESSIBILITY

7.1. ACCESS TO CONTROL PANEL To gain access to the control panel (electronic board, NTC sensor and light button) perform the following operations: 1- remove the 2 fixing screws to the hinges; 2- remove the 2 fixing screws placed behind the appliance; 3- extract the top forward.


4- insert the screwdriver pushing the hook teeth of the control support to the top; 5- extract the control support forward.


7.2. ACCESS TO REFRIGERATOR COMPARTMENT

To access to the flap: - remove the caps which cover the two screws; - remove the two screws;

The NTC sensor is inserted into the back side of the flap (see particular).


7.3. ACCESS TO FREEZER COMPARTMENT

To gain access to the components of the freezer compartment remove protection I. Evaporator battery

The evaporator battery F is hooked to the conveyor K by means of two side clips L and three hooks which can be removed by a screwdriver placed on the bottom N.

Thermal overload cut-outs The two +8°C and +40°C overload cut-outs E, are connected together with the defrosting heaters and are not available as single spare part. They are fitted to the pipes of the evaporator battery.


The battery, once it has been detached, can be folded, as the picture shows, to gain access to the heating elements taking care of the pipes.

Heating elements and thermal overload cut-outs assembly The defrosting heaters are inserted into the wings and hooked to the battery by means of three clamps J; to replace them, release the clamps with a pliers (but it is not necessary to cut them because they can be used again) and remove the heaters from the wings paying attention not to deform them.

The fan The fan is fixed with two screws.


8. TROUBLESHOOTING

WARNING!

Unplug the appliance before operating. 8.1 DRAIN CIRCUIT: In case of refrigerating gas leakage, the troubleshooting must be carried out not only in the traditional welding, but also in the junctions with LOKRING ring of the battery-capillary R pipes and battery-return pipe S and in the welding of cylinder T (for the R600a version). 8.2 EXCESSIVE ICE ON THE BATTERY: If the rubber valve remains open, the humid air outside the freezer compartment penetrates inside and forms excessive ice on the battery. The valve remains open if there are foreign bodies or if it loses elasticity, therefore, in the first case it is necessary to remove the foreign bodies, while in the second case it is necessary to replace the rubber valve.


8.3 FAILED DEFROSTING: If no defrosting cycle occurs, the possible causes could be: Sequence

no° POSSIBLE CAUSES

HOW TO CHECK SOLUTION

1 One or both defrosting heaters are interrupted

Freeze the battery, then unplug the appliance, detach the heaters connectors and check with the tester the correct resistance value to the connector clamps.

If the value of the resistances does not correspond to the technical data, replace the heaters and overload cut-outs assembly.

2 One or both thermal overload cut-out switches are open

Freeze the battery, then unplug the appliance, detach the heaters connectors and check with the tester the correct resistance value to the connector clamps.

If the value of the resistances does not correspond to the technical data, replace the heaters and overload cut-outs assembly.

8.4 BURN OUT LAMP: After replacing the burn out lamp, check the correct operation of the light button P with the manual actioning then check again actioning the light button by closing the refrigerator door and control the switching off of the lamp by moving a little the magnetic gasket of the door. Warning: the lampholder seal Q is a component which concerns the safety of the appliance;

therefore it is mandatory that it is inserted again into the lampholder after a replacement of the lamp!


8.5 MANUAL DEFROSTING PROCEDURE To perform the test and the technical service, a new manual defrosting procedure has been introduced to be carried out with cold internal temperatures (this is in order to avoid the possible opening of the thermal overload cut-out of the defrosting heater). To start the procedure, check that:

the electronic board is powered with the thermostat knob on ON - position 5 (or on a position between 90° and 270°);

the refrigerator door is closed. Carry out the 3 following operations:

1. Rotate the thermostat knob to OFF position; 2. Open and close the refrigerator door for 4 times (wait at least 1 second between every opening

/closure); 3. Rotate the thermostat knob to ON position 5 (or to a position between “min” and “max”);

At this point the electronic board check the thermal cut-outs all LEDs flash for 5 seconds, then if there are no anomalies, the manual defrosting phase starts, if not, the LEDs continue to flash and the buzzer sounds (if featured). WARNING: since the thermostat knob is in OFF position (operation 1), there are 15 seconds to perform in the correct sequence the other 2 operations (operation 2-3). In case of error or incorrect execution of the operations, before performing once again the manual defrosting procedure, it is necessary reset the standard functionality cutting the power to the appliance. The manual defrosting phase consists of:

defrosting heater ON; ON/OFF green LED on; compressor and fan OFF;

In this case the electronic board performs the defrosting phase as the standard functionality and continues to function normally.


Available time ON Thermostat knob OFF open Door closed ON Defrosting phase OFF ON Green Led OFF Key: T = 15 seconds; t = 5 seconds (to check thermal cut-outs); F = standard functionality.

599356105

Documents

electronic board

control panel

refrigerator compartment

freezer compartment

compressor compartment

refrigeration circuit

spares operations italy

zcp terminal board