Norcold 1200 series Service Manual
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Norcold 1200 series Service Manual

Norcold 1200 series Service Manual

Gas/electric refrigerators
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See also: Service Manual , Owner's Manual
Service Manual
Gas/Electric Refrigerators
INC.
MODELS
1200XX
120X-IMXX
!
WARNING
DO NOT install this refrigerator in below deck marine applications. Do not
install this refrigerator in fixed indoor cabin or other dwelling applications. This
refrigerator must use only NORCOLD designed and approved outside air in-
take and exhaust ventilation for correct and safe operation. Any other ventila-
tion could cause lethal combustion exhaust fumes and or/explosive propane
gas fumes to be in the living area and/or below deck.
© 2005 THETFORD CORP., NORCOLD, INC. All rights reserved.
Publication No. 618968B (02-18-05)

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Summary of Contents for Norcold 1200 series

  • Page 1 DO NOT install this refrigerator in below deck marine applications. Do not install this refrigerator in fixed indoor cabin or other dwelling applications. This refrigerator must use only NORCOLD designed and approved outside air in- take and exhaust ventilation for correct and safe operation. Any other ventila- tion could cause lethal combustion exhaust fumes and or/explosive propane gas fumes to be in the living area and/or below deck.

  • Page 2: Table Of Contents

    Flame Fails to Ignite or Flame Goes Out ......44 Flue Cap ................26 Flue Baffle ................. 26 Diagnostic Mode - S/N 832170 and Lower ------------ 45 Flame Appearance ............. 26 Diagnostic Mode ..............45 Burner Cleaning Procedure ..........27 Refrigerator Service Manual 1200XX/120X-IMXX Models www.norcold.com/cda...
  • Page 3 Cycle Testing Ice Maker ............. 59 Checking Water Valve Operation ........59 Water Fill Adjustment ............60 Checking Water Valve Solenoid Resistance ....60 Checking Mold Heater Resistance ........61 Checking Voltage to Motor ..........61 Winterization ............... 61 Refrigerator Service Manual 1200XX/120X-IMXX Models www.norcold.com/cda...

  • Page 4: Introduction

    ® Use only authorized NORCOLD, INC. replacement Letter(s) appended to the model number identify parts. Generic parts do not meet NORCOLD, INC. ® factory installed accessories. For example, a 1200- specifications for safety, reliability, and performance. IMSS is a 2-way refrigerator equipped with an ice The use of unauthorized aftermarket or generic maker and stainless steel doors.
  • Page 5 NORCOLD. INC. TESTED FOR LP GAS: EQUIPPED FOR PROPANE / Teste 1 COLD- pourle GPL, equipped por le propan SET TEMP MODE ON/OFF 9 COLDEST SIDNEY, OHIO SUPPLY BURNER 11 "WC 10.5 "WC alimentati bruleur SERIAL # / N de serie...

  • Page 6: Safety Awareness

    Make sure all hardware, such as hinges and fasteners conductive and pose the potential for an electric shock (retaining screws, etc.), is properly fastened. hazard, short electrical components, damage electronic circuits, and/or ignite a fire. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 7: Specifications

    Heat input ---------------------------------------------------------------------------------------------------- 2200 Btu/h @ 11 in. w.c. Orifice, old style ---------------------------------------------------------------------------------------------------------- 0.190 jeweled Orifice, new style -------------------------------------------------------------------------------------------------------------------- LP18 Gas ignition ---------------------------------------------------------------------------------- Automatic with flame sensing circuit Electrode tip-to-burner air gap ----------------------------------------------------------------------------------------- 1 /8 3 /16 www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 8: Troubleshooting - Quick Reference Guide

    Level unit. See page 32. Dirty burner. Clean burner. See page 28. Low AC voltage. Check AC voltage input. Cooling fan inoperative (if present). Test fan operation. Improper installation. Check installation. See pages 19-23 and 1200 Installation Manual. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...
  • Page 9 AUTO LP GAS "no" Flashing Cold Coldest No AC power available to refrigerator. TEMP See page 13. AC cord not plugged into power board. MODE F3 fuse open. AUTO LP GAS "AC" LED Flashing www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...
  • Page 10 MODE See page 16. 2 minutes. Lamp switches faulty. AUTO LP GAS Temperature LED Flashing Cold Coldest TEMP Backup operating system in operation. See page 17. MODE AUTO LP GAS Selected Mode LED "ON" Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...
  • Page 11 Fresh food compartment door open more than 2 minutes. See page 16. Lamp switches faulty. Flashing Backup operating system in operation. See page 17. Temp Setting See pages 18 No cooling detected by the controls. and 32-35. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 12: Troubleshooting Flowcharts

    4 1/2 DIGITS PEAK MIN MAX 1 Seconds µA mA µA 400mA MAX CAT II FUSED 10A MAX 1000V MAX FUSED Figure 4. Measurement points for wire harness voltage Figure 3. Checking the DC fuse continuity Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 13: No Lp - No Fl Fault Code - Burner Failed To Ignite Or Reignite

    Check gas valve solenoid Replace gas valve wires. Continuity? wires for continuity. Check voltage across power Voltage Replace power board. board terminals GV and See page 40. present? GV_GND. Faulty gas valve. Replace gas valve. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 14: Dc Lo Fault Code - Low Dc Voltage

    To troubleshoot a "dc LO" fault, connect a charged 12 volt automotive battery to the power board. If the "dc LO" code clears, the fault was caused by unfiltered DC power. If the "dc LO" code does not clear, replace the power board (see page 40). Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 15: Dc Hi Fault Code - Dc Voltage High

    Cold Coldest TEMP MODE 1 COLD - 9 COLDEST TEMP MODE ON / OFF AUTO LP GAS "AC" and "rE" Flashing "AC" LED Flashing AC relay stuck closed. Replace power board. See page 40. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 16: No Ac Fault Code - No Ac Power Available

    Check that fuse holder clips Adjust clips to ensure fuse contacts are are making full contact with Clips okay? firm in clips and making full contact. fuse. Replace power board. See page 40. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 17: Ac Lo Fault Code - Ac Voltage Low

    Measure voltage at power board AC cord connection. Voltage Fault related to RV AC power distribution higher than component or circuit supplying AC power 132 Vac? to refrigerator. Replace power board. See page 40. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 18: Ac He Fault Code - Ac Heater Failed Open

    MIN MAX RANGE HOLD 4 1/2 DIGITS PEAK MIN MAX 1 Seconds µA mA µA 400mA MAX CAT II FUSED 10A MAX 1000V MAX FUSED Yellow Black Figure 5. Checking AC heater resistance Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 19: Dr Fault Code - Door Open For More Than 2 Minutes

    Door(s) Check fresh food aligned Install Door Shim Kit, part number 625129. compartment door(s) for properly? vertical play. Lights off Check operation of when switches Replace switch(es). light/door switches. pressed? Magnetic tip screwdriver www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 20: Thermistor Failure Fault - Controls In Backup Operating System Mode

    5, raising the setting operation, the temperature setting flashes for ten to 6 will lengthen the cooling cycle, making the seconds when the TEMP button is pressed. After ten cabinet colder. seconds, the "ON" LED displays. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 21: Power Board Resetting Procedure

    Grounding probe 8. Turn OFF the refrigerator. or jumper wire 9. Turn ON refrigerator. If "no co" code displays, repeat steps 7 - 9. Figure 8. Resetting the power board www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 22: Ventilation

    (if wider see Figure 10, page 20) Baffles required when opening between outside wall Fans (2) and cooling unit is over 1 inch. Absorber coils Must be between 3 and 4 inches Intake vent Figure 9. Roof exhaust venting arrangement Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 23: Baffles

    Sides (each) 0 inch 1/8 inch Intake vent 0 inch 1/4 inch Rear 0 inch 1 inch Figure 11. Baffles required for an inboard Table 1. Clearances for roof vented installations roof exhaust vent installation www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 24: Double Sidewall Venting

    NORCOLD has developed venting page 23 for details. guidelines for double sidewall vent applications. This ensures NORCOLD refrigerators meet the ANSI Z21.19 standards for cooling performance when used in slide out applications. The challenge with slide out installations is that the "chimney effect"...
  • Page 25 Aluminum or galvanized steel sheet full width baffle Aluminum or galvanized steel sheet full width baffle 32.69 62 in. 63.38 in. Figure 12. Baffle arrangement for enclosures depths of more than 24 inches and less than 26 inches www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...
  • Page 26 Aluminum or galvanized steel sheet full width baffle. Aluminum, wood, or galvanized steel sheet full width baffle. 32.69 63.38 Figure 13. Baffle arrangement for enclosures with depths of 26 inches or greater Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 27: Lp Gas System

    LP gas tank and the refrigerator LP gas system. To prevent damage to connections, piping, and components, always use two wrenches to tighten or loosen connections. Damaged connections, piping, and components create the potential for gas leaks. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 28: Components

    Hidden joints should be examined thoroughly When replacing an old style solenoid valve with a new using an inspection mirror. style valve, use the NORCOLD gas valve conversion kit, part number 621334. This kit contains the new Components style solenoid gas valve, the required hardware, and instructions.

  • Page 29: Orifice

    The burner tube is 1/4 inch OD aluminum tubing with an anti-vibration loop. Each end of the tube is double- flared. See Figure 19. Size stamped on orifice end Burner connection Gas valve connection Figure 19. Burner tube Figure 23. N18 orifice www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 30: Flue

    Burner Electrode getting into the flue. Cooling performance may be Serial Number Serial Number 700000 700000 NORCOLD NORCOLD Made in USA Made in USA affected if the flue cap is not installed or is not Burner installed correctly. Flue Baffle...

  • Page 31: Burner Cleaning Procedure

    Do not attempt to repair LP gas leaks with the refrigerator in operation. Before attempting to repair a gas leak: Turn OFF the refrigerator. Close the LP gas valve and the solenoid gas valve manual shut-off. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 32: Electrical Requirements And Components

    The controls constantly monitor power board voltage output to the heater through built in diagnostics (see pages 47 and 51). Turning the refrigerator on automatically energizes the heater. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 33: Ac Power Requirements

    Measure heater amp draw. c. If amp draw is not as specified, measure the heater's resistance at ambient temperature. NOTE Figure 29. Power board AC power cord Heater resistance must be measured at ambient temperature. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 34: Ice Maker Ac Power Cord

    From power board Figure 33. Fan thermostat Short white wire/female connector To water valve solenoid Smooth wire/male connector To black ice maker wire Brown wire/female connector To water valve solenoid Figure 31. Ice maker power cord Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 35: Cooling Unit

    (resampling starts when door closes). The AC heater is open. The cooling unit or its performance are not affected when the vehicle is in motion. AC voltage is low. Frost management is active. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 36: Cooling Unit Monitoring Control Operation

    If the refrigerator does not complete a full cooling cycle after the user turns the refrigerator back on, a power board reset is required. The power board reset must be performed by a service center according to the procedure on page 18. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 37: Cooling System Diagnostic Flowchart

    LP gas pressure. Level refrigerator as outlined Refrigerator in Owner's Manual and operating leveled? "Specifications." Maximum off-level limits: ■ 3 degrees side to side. ■ 6 degrees front to back. Continued on page 35. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...
  • Page 38 8-12 hours. normal ■ Freezer -5 F to -10 °F. ° ■ Fin temperature 18 °F to 25 °F. Check thermistor and power board operation. See pages 17 and 18. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 39: Removing The Refrigerator And Cooling Unit

    Power coils board Liquid heat exchanger cord Serial Number Serial Number 700000 700000 NORCOLD NORCOLD Made in USA Made in USA Drip valve Burner Water valve Figure 34. Cooling unit and components Ice maker and/or dispenser models NOTE a. Disconnect the ice maker AC power cord from the This procedure supplements the instructions packaged RV outlet.

  • Page 40: Removing Cooling Unit

    CAUTION: 1. Remove the fan, bracket assembly, thermostat, Use only the NORCOLD approved sealant that is and fan wiring from the cooling unit. packaged with the new cooling unit. Do not use silicon, 2.
  • Page 41 21. Connect the flapper heater wires. 1/2 in. bead of sealant 22. Plug the AC cord into the power board. 23. Connect the spark/sense electrode assembly to the power board. Figure 36. Application of sealant www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 42: Reinstallation Of Refrigerator Into Enclosure

    11. Open the LP gas tank valve(s), then leak test LP gas connection at solenoid gas valve. 12. Leak test the burner solenoid gas valve and orifice assembly burner tube connections. 13. Place refrigerator in service. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 43: Electronic Components

    13. Turn ON refrigerator, then check all power board control functions before placing in service. 12. Remove the two 1/4” hex head screws attaching the board to the base, then remove the power board along with its base. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 44: Controls

    832170 and higher have the controls shown in Figure overtighten the retaining screws. 41. Two screws hold the optical control assembly into 6. Turn on the refrigerator, then check all of the place. optical control assembly functions. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 45: Auto Ac Operation

    See NOTE 1. Page 10, "no FL/no LP" fault codes troubleshooting flowchart. Page 13, "no AC" fault codes troubleshooting flowchart. Page 47, Diagnostic Mode, Screen 3 or page 50, Diagnostic Mode, Screen 4. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 46: Ac Manual Mode

    Use the following references to identify, troubleshoot, and correct a no AC fault. Page 13, "no AC" fault codes troubleshooting flowchart. Page 47, Diagnostic Mode, Screen 6 or pages 50- 51, Diagnostic Mode, Screens 5 and 8. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 47: Auto Ac Operation

    30 Diagnostic Mode, Screen 4. seconds trial-for-ignition. 4. Once the controls sense the flame, they turn off the "AU" and "LP", and display the ON LED. See NOTE 4. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 48: Ac Manual Mode

    Troubleshooting "no AC" Fault Use the following references to identify, troubleshoot, and correct a "no AC" fault. Page 13, "no AC" fault codes troubleshooting flowchart. Page 47, Diagnostic Mode, Screen 3, page 50, Diagnostic Mode, Screen 4. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 49: Diagnostic Mode

    1. Press and hold buttons at the MODE same time. TEMP 2. Release the buttons when the MODE controls leave the diagnostic mode. Turning the refrigerator OFF then back ON also exits the Diagnostic Mode. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 50: Screens And Diagnostic Leds Information, Units With S/N 832170 And Lower

    MODE AUTO LP GAS AUTO LP GAS **Lighted LEDs on this screen indicate a previous failure. Press the button to bring up screen 4. MODE Press the button to bring up screen 7. MODE Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...
  • Page 51 LP GAS Indicates AC voltage measurment *Shown: 10 + 2.0 = 12.0 Vdc Shown: 100+20=120 Vac Press the button to return to screen 1. MODE Press the button to bring up screen 9. MODE www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 52: Diagnostic Mode

    ON Light same time. 2. Release the buttons as soon as the Figure 44. Diagnostic LEDs segments identification. TEMP MODE display shows Turning the refrigerator OFF then back ON also exits the Diagnostic Mode. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 53: Screens And Diagnostic Segments Information

    3. Wait five seconds. 4. Press and hold the button until shows TEMP on the screen. Press the button to bring up screen 4. MODE Press the button to bring up screen 7. MODE www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...
  • Page 54 DC power to ignition circuit AC voltage lower than 108 volts DC power to light switch Press the button to bring up screen 9. Press the button to return to screen 1. MODE MODE Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 55: Wiring Pictorials And Diagrams

    WIRING PICTORIALS AND DIAGRAMS - SN 832170 AND BELOW Figure 47. 1200XX/120X-IMXX wiring pictorial - SN 832170 and below www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...
  • Page 56 Figure 48. 1200XX/120X-IMXX wiring diagram - SN 832170 and below Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...
  • Page 57 5 amp fuse (120 Vac) Dispenser light* Temperature switch** 5 amp fuse (12 Vdc) * Water dispenser models only ** Ice maker models only *** Gas models only Figure 49. 1200XX/120X-IMXX pictorial - SN 832171 and above www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...
  • Page 58 Temperature switch Water line heater** TEMP SET button Door contacts Overlay * Water dispenser models only ** Ice maker models only *** Gas models only Figure 50. 1200XX/120X-IMXX wiring diagram - SN 832171 and above Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 59: Ice Maker Components And Service

    NOTE The ice maker wire harness is not the same as nor connected to the wire harness that serves the power board and the optical display assembly, as described on pages 40 and 41. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 60: Water Fill Tube

    48°F. From AC power cord Brown from wire harness Thermostat To refrigerator wire harness Retaining clips (2) Water line heater connection To refrigerator wire harness Figure 52. Water fill tube, line, and heater Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 61: Water Valve

    AC power cord. screws and spacers. 13. Place refrigerator in service. From AC power cord Wire harness (brown) 2-wraps maximum Thermostat Black To ice maker Figure 53. Solenoid water valve (models without water dispenser) www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 62: Ice Maker Troubleshooting Chart

    Seat the diffuser plate firmly against the orifice. c. Seat the strainer firmly against the orifice Figure 54. Solenoid water valve components plate. d. Reconnect the inlet fitting adapter to the water valve. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 63: Replacing Ice Maker

    Figure 56. Wire harness connection to ice maker NOTE Plug white AC power cord into AC outlet labeled “Ice Maker.” Plug black AC power cord in outlet labeled “Refrigerator.” 12. Place refrigerator in service. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 64: Cycle Testing Ice Maker

    (as shown in Figure 57). The solenoid should click and buzz if it is operating properly. If the solenoid does not click and buzz, replace the water valve (see page 58). Figure 59. Checking water valve operation Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...

  • Page 65: Water Fill Adjustment

    295 to 360Ω–water valve solenoid operating Figure 61. Checking solenoid resistance properly. OL–check for loose wire harness connections at water valve or an open solenoid coil. 00.0Ω–check resistance at solenoid terminals and wire harness continuity. www.norcold.com/cda Refrigerator Service Manual 1200XX/120X-IMXX Models...

  • Page 66: Checking Mold Heater Resistance

    NOTE Do not unwrap the water line heater wire from the water valve outlet connection. 5. Drain RV water supply line and ice maker water fill line. 6. Bag and tape shut all connections. Refrigerator Service Manual www.norcold.com/cda 1200XX/120X-IMXX Models...
  • Page 67 Publication No. 618968B (02-18-05) NORCOLD, INC. CUSTOMER SERVICE Telephone ......... 1-800-444-7210 NORCOLD, INC.® Fax ..........937-497-3183 P. O. Box 4248 World Wide Web ... www. norcold.com/cda Sidney, OH 45365-4248...

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120-im series

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