Service Manual

ManualsBrandsTraulsen ManualsFreezerG22000 Freezer

G22010 MODEL SHOWN

This Manual is prepared for the use of trained Hobart Service Technicians

and should not be used by those not properly qualified.

This manual is not intended to be all encompassing. If you have not

attended a Hobart Service School for this product, you should read, in its

entirety, the repair procedure you wish to perform to determine if you

have the necessary tools, instruments and skills required to perform the

procedure. Procedures for which you do not have the necessary tools,

instruments and skills should be performed by a trained Hobart Service

Technician.

The reproduction, transfer, sale or other use of this Manual, without the

express written consent of Hobart, is prohibited.

This manual has been provided to you by ITW Food Equipment Group LLC

("ITW FEG") without charge and remains the property of ITW FEG, and by

accepting this manual you agree that you will return it to ITW FEG

promptly upon its request at any time in the future.

SERVICE MANUAL

TRAULSEN G SERIES

FREEZER

G12000 Model Series

G22000 Model Series

G31300 Model Series

A product of TRAULSEN Fort Worth, TX 76106-1988

F25393 (August 2010)

Summary of content (32 pages)

PAGE 1
SERVICE MANUAL TRAULSEN G SERIES FREEZER G12000 Model Series G22000 Model Series G31300 Model Series G22010 MODEL SHOWN This Manual is prepared for the use of trained Hobart Service Technicians and should not be used by those not properly qualified. This manual is not intended to be all encompassing.
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G SERIES FREEZER TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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G SERIES FREEZER - GENERAL GENERAL INTRODUCTION CLEANING General All G series freezers are Energy Star efficient and include a wide range of one, two, & three sectional reach in freezers. All models are capable of -10EF in up to 90EF ambient. The cabinets are equipped with anti-condensate door perimeter heaters. These units aid in preserving food quality, texture and nutritional value.
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G SERIES FREEZER - GENERAL CONTROL PANEL SPECIFICATIONS DIMENSIONS 1 Section Cabinet 2 Section Cabinet 3 Section Cabinet Height- overall on casters 83-1/4" (211.46cm) 83- 1/4" (211.46cm) 83- 1/4" (211.46cm) 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) 24.2 46.0 69.1 Net Capacity cu. ft.
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G SERIES FREEZER - GENERAL Page 5 of 32 F25393 (August 2010)
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS DATA 1 Section Cabinet 2 Section Cabinet 3 Section Cabinet 3 Section Cabinet 115/60/1 115/60/1 115/60/1 208/60/1 Amps Full Load 9.5 11.2 16.0 11.0 OPERATING DATA 1 Section Cabinet 2 Section Cabinet 3 Section Cabinet R-404A R-404A R-404A 500 500 500 250 250 250 1930 @ -20EF Evaporator Temp. & 90EF Ambient 2970 @-20EF Evaporator Temp. & 90EF Ambient 4710 @-20EF Evaporator Temp.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS 4. Reverse the procedure to install. NOTE: Replace adhesive seal as needed. Harness Raceway Cover 3. Lift cover from cabinet. 4. Reverse the procedure to install. 1. Access harness raceway cover at top of cabinet. 2. Remove screws securing cover to raceway housing. 3. Lift cover up from raceway housing. 4. Reverse the procedure to install. Evaporator Cover Control Box Cover 1. Access evaporator cover at top of cabinet. 2.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS other mounting clip. 3. Remove lens from cabinet. 4. Turn lamp to remove from lamp socket. 5. Reverse the procedure to install. INTELA-TRAUL CONTROL 7. Push Intela-Traul control out from front top panel. 8. Reverse the procedure to install. Removal 1. Remove front panel as outlined under COVERS & PANELS. 2. Access control at top of cabinet. 3. Remove control box cover as outlined under COVERS & PANELS.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS NOTE: Use care not to damage lead wires. 4. Disconnect all lead wire connectors from IntelaTraul relay box. 5. Remove both nuts securing Intela-Traul relay module to control box cover. 6. CABINET AIR SENSOR 1. Access cabinet air sensor at top of cabinet. 2. Remove evaporator cover as outlined under COVERS & PANELS. 3. Remove screw securing sensor & mounting clip to evaporator compartment. Reverse the procedure to install. COMPRESSOR RELAY 1.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS EVAPORATOR COIL SENSOR THERMAL EXPANSION VALVE 1. Access cabinet coil sensor at top of cabinet. 1. 2. Remove evaporator cover as outlined under COVERS & PANELS. Access thermal expansion valve at top of cabinet. 2. 3. Pull sensor out from evaporator fins. Remove evaporator cover as outlined under COVERS & PANELS. 3. Cut wire ties off from refrigerant line insulation. 4. Remove pipe insulation from refrigerant line. 5.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS NOTE: Sensor must be insulated. NOTE: It is recommended that the filter/drier be changed when this part is replaced. EVAPORATOR COIL / DEFROST HEATER 1. Access defrost heater at top of cabinet. 2. Remove evaporator cover as outlined under COVERS & PANELS. 3. Remove harness raceway cover as outlined under COVERS & PANELS. 4. Disconnect heater lead wire connector. 7.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS EVAPORATOR FAN 1. Access evaporator fan lead wires at top of cabinet. 2. Remove evaporator cover as outlined under COVERS & PANELS. 3. Disconnect lead wires to evaporator fans. NOTE: Mark lead wires for later installation. To Install: 1. Run a small bead of food grade silicone in gasket retainer channel. 2. Install gasket starting at corners pressing into retainer gasket channel and work towards center. DOOR ASSEMBLY 1.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS box. NOTE: Mark wire location for installation. 7. Allow evaporator fan housing to lower out of cabinet. 8. Reverse the procedure to install. CONDENSING UNIT COMPONENTS 5. Remove insulation from refrigerant line. 6. Disconnect suction and discharge lines from compressor. 7. Remove bolts securing compressor to cabinet. 8. Install new compressor and connect wire leads at compressor junction box. 9. Install new filter drier. Compressor 1.
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS 5. 4. Remove the screws securing mounting bracket to condenser fan. Reverse procedure to install coil, then proceed to next step. NOTE: It is recommended that the filter drier be changed when this part is replaced. 6. Evacuate refrigeration system. NOTE: The use of reclaiming equipment is mandatory. 7. Charge system and put unit into operation. Filter Drier 5. 1. Remove condenser / compressor cover as outlined under COVERS & PANELS. 2.
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS 3. Lift the retaining bracket up out from insert slot in cabinet. 4. Lift the hot gas coil out of condensate pan. 5. Pull hot gas pan from cabinet. 6. Reverse procedure to install. SERVICE PROCEDURES AND ADJUSTMENTS CHECK REFRIGERANT CHARGE (SUPERHEAT, SUB COOLING & SPLIT TEMPERATURES) Introduction Superheat is the heat that the refrigerant vapor absorbs above the boiling point.
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS 5. Let refrigerant system run. Temperature readings should be taken after the cabinet is at pull down temperature & just before the compressor cycles off. 6. Take readings of evaporator coil inlet (C) & evaporator coil outlet (D) lines. Example: [(condenser inlet (A) + condenser outlet (B)) / 2] !ambient temp. = split temperature. A. 6. If split temperature reading is out of spec, call Refrigeration Service Support. 7.
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS 7. EVACUATING SYSTEM Introduction Refrigeration reclaiming equipment is required. Repeat steps 5 and 6 once. 8. Pull vacuum to 500 microns. 9. Charge system and check for proper operation. CHARGING SYSTEM The goal in system evacuation is to remove all the non-condensables as possible. No evacuation method will remove 100% of the moisture and air from within the refrigeration circuit.
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS • Contained - compressor oil not acidic, no oil discoloration. • Contaminated compressor - oil acidic, discoloration of oil, contamination limited to compressor. The control program software version can be determined by: • Massive contamination - contaminated oil and / or refrigerant pumped into system. 1. Turn power on to the Intela-Traul control. 2.
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS CONTROL PARAMETERS NOTE: Not all control parameters can be adjusted at the customer level of access. To adjust parameters not at the customer level it will be necessary to access the engineering level. NOTE: If 30 seconds elapse between keypad presses, the controller will revert to a cabinet temperature display (normal operation). If the wrong security code is entered, the controller will revert to a cabinet temperature display (normal operation).
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS DEFAULT PARAMETER SETTINGS (FREEZER MODEL SERIES) PARAMETER DISPLAYED DESCRIPTION / ACCESS LEVEL RANGE Standard Freezer Model G1, G2, & G3 Hex File GF1 -10 EF Freezer Model G1 & G2 Hex File GF3 SLL software ver. C28 Set point low-low/ Eng. level -40EF. up to current setting for SLH -6.0 EF -13.0 EF SLH software ver. C28 Set point low-high/ Eng. level from current setting for SLL up to 266 EF -2.5 EF -10 EF RO Room ambient offset / Cuc.
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS DEFAULT PARAMETER SETTINGS (FREEZER MODEL SERIES) PARAMETER DISPLAYED DESCRIPTION / ACCESS LEVEL RANGE DAY Set the clock date / Cus. level (Y=year, N=month, E=day # in week example: Sun=1 Sat=7) DS Daylight Savings / Cus. level ON / OFF ON ON DL1 Defrost lockout 1 / Cus. level 2:00 to 8:00 in. 30 min. increments & OFF OFF OFF DL3 Defrost lockout 3 / Cus. level 14:00 to 20:00 in. 30 min.
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G SERIES FREEZER - ELECTRICAL OPERATION 4. EVAPORATOR COIL SENSOR TEST Verify multi meter reading to the temperature conversion chart as follows. Temperature EF Ohm Reading K Ohms Temperature EC -5.0 99.9 -20.5 1. Access the customer level by pressing the Set keypad until CUS is displayed. 2. Press the Set keypad until left zero is flashing with three zeros displayed. 0 85.2 -17.7 3. Press the Set keypad until center zero is flashing with three zeros displayed. 5.0 72.9 -15.0 4.
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G SERIES FREEZER - ELECTRICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION Intela-Traul Control . . . . . Performs the following functions: A. Displays all data for the current software revision & mode of operation. B. Cycles refrigeration system to maintain cabinet temperatures. C. Cycles defrost relay to defrost evaporator coil. D. Monitors power losses as well as component malfunctions. E. Monitors door position. Compressor . . . . . . . . . . . . . .
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G SERIES FREEZER - ELECTRICAL OPERATION SEQUENCE OF OPERATION Refrigeration System 1. The control must be powered on. 2. The control monitors cabinet air temperature and senses a need for cooling. 3. The compressor motor is energized and refrigerant is pumped through the system. 4. The TXV monitors the evaporator superheat and meters the amount of refrigerant entering the evaporator. 5. The control senses the cabinet air temperature requirements have been met. 6.
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G SERIES FREEZER - ELECTRICAL OPERATION COMPONENT LOCATION Page 25 of 32 F25393 (August 2010)
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G SERIES FREEZER - ELECTRICAL OPERATION WIRING DIAGRAMS 115V/60HZ/1PH F25393 (August 2010) Page 26 of 32
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G SERIES FREEZER - ELECTRICAL OPERATION 220V/50-60HZ/1PH Page 27 of 32 F25393 (August 2010)
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G SERIES FREEZER - TROUBLESHOOTING TROUBLESHOOTING SYMPTOM Nothing runs, blank control. Compressor will not run, no current draw. Compressor will not run, current draw and trips breaker. Defrost time too long. Compressor short cycles. Compressor run time lengthy. Continuous compressor operation. Low suction pressure. High head pressure. F25393 (August 2010) 3. 4. 5. 6. 7. 8. 9. POSSIBLE CAUSES Main circuit breaker open. Main on/off switch off. Power cord unplugged. Cabinet temperature satisfied.
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G SERIES FREEZER - TROUBLESHOOTING SYMPTOM Iced Evaporator coil. Will not defrost. Control display blank. 1. 2. 3. 4. 5. 6. 7. 8. 1. 2. 3. 4. 5. 1. 2. 3. 4. POSSIBLE CAUSES Evaporator fan(s) malfunctioned. Verify defrost control parameter settings. Evaporator coil sensor malfunctioned. Compressor relay malfunctioned. Control relay module. Cabinet air sensor malfunctioned. Control malfunctioned. Refrigerant system malfunctioned. Defrost heater(s) malfunction. Incorrect wiring.
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G SERIES FREEZER - TROUBLESHOOTING -NOTES- F25393 (August 2010) Page 30 of 32
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G SERIES FREEZER - TROUBLESHOOTING -NOTES- Page 31 of 32 F25393 (August 2010)
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G SERIES FREEZER - TROUBLESHOOTING -NOTES- F25393 (August 2010) Printed in U.S.A.