Thermo Electron 8600 Series Troubleshooting Service Manual
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Thermo Electron 8600 Series Troubleshooting Service Manual

Controlled environment equipment, ultra low temperature freezer
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7998600 Rev. 4

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Summary of Contents for Thermo Electron 8600 Series

  • Page 1 7998600 Rev. 4...
  • Page 2 The material in this manual is for information purposes only. The contents and the product it describes are subject to change without notice. Thermo Electron Corporation makes no representations or warranties with respect to this manual. In no event shall Thermo be held liable for any damages, direct or incidental, arising out of or related to the use of this manual.

  • Page 3: Table Of Contents

    Table of Contents Section 1 – General Operation Section 4 -Hidden Functions 1.1 Initial Start Up........1-1 4.1 Hidden Test ........... 4-1 1.2 Equipment Explanation......1-1 4.2 Hidden Calibration ........ 4-2 1.3 Operating Pressure “High and low stage systems”....1-1 Appendix A - Glossary Glossary of terms ........

  • Page 4: Section 1 - General Operation

    General Operation 1.1 Initial Start Up 1. Power Switch on. 2. Cabinet temperature 0.5°C or warmer than set point. 3. Fans 1 and 2 turn ON. 4. High stage compressor turns ON, after ten seconds delay. 5. Low stage compressor turns ON when: A.
  • Page 5 2.1 Symptom: Probe 1, 2, 3, or 4 Failure Alarm - SINGLE PROBE FAILURES Order Possible Cause Verification Action Probe Unplugged. Re-seat connector. Re-seat all connections. Not fully seated Verify wires are fully seated in connectors and Replace probe if necessary. connectors are seated together Bad probe Short.

  • Page 6: Unit Will Not Communicate With Alarm System

    2.3 Symptom: Unit will not communicate with alarm system (Remote Alarm Contacts/Analog System/Serial communication) Order Possible Cause Verification Action Remote Alarm Contacts Check that all connections are tight and properly Tighten and / or correct wiring. wired. Missing wires? Measure continuity of alarm contacts between Replace micro board if contacts do not change pins 6 &...

  • Page 7: Display/Keyboard Not Functioning

    2.4 Symptom: Display / Keyboard Not Functioning Order Possible Cause Verification Action Turned battery on before AC power is Ask customer/end user. Turn unit power off. Turn battery off. Reapply AC power applied. before the battery is turned on. (initial start up issue only) No AC power and no battery power.

  • Page 8: Door Ajar Alarm

    2.5 Symptom: Door Ajar Alarm Order Possible Cause Verification Action No magnet Visually inspect for magnet in door handle. Replace magnet as required. Worn door handle Inspect inside of door latch for signs of metal Replace latch if necessary and verify vacuum relief (aluminum) wear (wobbly handle).

  • Page 9: No Door Access

    2.6 Symptom: No Door Access Order Possible Cause Verification Action Door locked. Check to ensure door is not locked. Unlock door. Vacuum relief assembly is frozen over. Visually inspect vacuum relief port for any Clean as necessary. Follow routine maintenance restrictions.

  • Page 10: Low Battery Alarm

    2.7 Symptom: Low Battery Alarm Order Possible Cause Verification Action New battery / new unit or freezer just placed Ask customer/end user. If yes, batteries required 36 hours for charging. into service? Complete steps 2,3, & 4. If no, continue to step 5. Missing battery Visually look for battery.

  • Page 11: Hot Condenser Alarm

    2.9 Symptom: Hot Condenser Alarm Order Possible Cause Verification Action High ambient. Measure ambient temperature. Move to cooler location / lower ambient. Is ambient above 33°C? Educate customer. Alarm will cycle with compressors. If ambient is above 37°C, alarm is on constantly. Restricted / reduced airflow.

  • Page 12: High Stage System Failure Alarm

    2.10 Symptom: High Stage System Failure Alarm Order Possible Cause Verification Action Clear HS System Failure Alarm in Configuration Mode. Fan(s) not running. See procedure for troubleshooting fans under “Hot Condenser” alarm. High stage compressor not starting or not running. Inadequate power at the customer’s Check voltage at the wall and monitor for large If voltage drops below 90V for 120V units or 180V for 230V...

  • Page 13: Power Failure Alarm

    2.10 Symptom: High Stage System Failure Alarm (continued) Order Possible Cause Verification Action Restriction in high stage capillary Measure the temperature at the heat exchanger. Recondition high stage. tube. If a restriction exists, the heat exchanger will be warmer than normal. 2.11 Symptom: Power Failure Alarm Order Possible Cause...

  • Page 14: Wrong Power

    2.12 Symptom: Wrong Power Order Possible Cause Verification Action Sequence that battery and power switch was Was battery switch turned on before power switch Turn both switches off. Turn power switch on, then turned on (start-up only) was turned on? turn battery switch on.
  • Page 15 2.14 Symptom: High Temperature Alarm or System is not maintaining temperature Order Possible Cause Verification Action Door Inspect gasket for ice or excessive frost. Clear ice or frost from door and gasket. Check door adjustment: fit and gasket Adjust door to restore uniform gasket compression. compression.
  • Page 16 2.14 Symptom: High Temperature Alarm or System is not maintaining temperature (continued) AC power to low stage compressor. No voltage at compressor, LD6 (LS) on high Check connections: enclosure, high-pressure cutout voltage board is on. switch. Ohm out pressure switch. Switch to be closed.

  • Page 17: Troubleshoot Compressor

    2.15 Symptom: Troubleshoot compressor Action Order Possible Cause Verification Low suction pressure Verify compressor starts and run continuously. If yes, install gauges and go to next step. problem If no, go to order 3 of “Compressor starting problem”. Verify suction pressure is above: If suction pressure is below limits, conduct equalization test: if High Stage –...

  • Page 18: Voltage Compensation Failure

    2.15 Symptom: Troubleshoot compressor continued Action Order Possible Cause Verification Verify if compressor tripping on high pressure switch If tripping on high pressure switch and pressure is not running at and confirm that discharge is reaching 375 psig (+ 25 375 psig (+25), then replace pressure switch.

  • Page 19: Analog Output Reference Table

    Analog Output Reference Table Temp°C 4-20 4-20mA 0-1V 0-5V Temp°C 4-20 4-0mA 0-1V 0-5V Temp°C 4-20 4-0mA 0-1V 0-5V with with with resistor resistor resistor 14.560 3.640 0.660 3.300 9.227 2.307 0.327 1.633 20.000 5.000 1.000 5.000 14.453 3.613 0.653 3.267 9.120 2.280...

  • Page 20: Rtd Temperature Vs. Resistance

    RTD Temperature vs. Resistance Table For European Curve, Alpha = .00385, ITS-90 1° Celsius Increments Source: http://www.omega.com/temperature/Z/pdf/z252-254.pdf °C Ohms Difference °C Ohms Difference °C Ohms Difference °C Ohms Difference 759.30 4.00 913.70 3.90 17 1066.30 3.90 -100 602.60 4.10 763.30 4.00 917.70 4.00...

  • Page 21: Pressures Vs. Cabinet Temperature

    Pressures vs. Cabinet Temperature Thermo Forma Model 8695 (23ft Upright ULT - 230V, 50Hz) Cabinet Temperature (°C) HS Disch Pressure LS Disch Pressure HS Suct. Pressure LS Suct. Pressure 3 - 3...
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  • Page 30: Micro Board

    MICRO BOARD HIGH VOLTAGE BOARD 3 - 12...

  • Page 31: Section 4 -Hidden Functions

    Section 4 - Hidden Functions j. EEPROM Initialize 4.1 Hidden Test This function is used for field software updates. All settings will be reset to factory default settings upon The Hidden Test Mode is used for testing freezer initialization. components. The test functions are listed and described 1.

  • Page 32: Hidden Calibration

    g. Reset Analog Calibration Offset 4.2 Hidden Calibration 1. Press the right arrow until RST DAC OFST is displayed in the message center. The Hidden Calibration Mode is used for calibrating 2. Press Enter to save to memory. freezer control and voltage components. These The analog calibration offset is reset to factory default.
  • Page 33 n. Sample Probe Zero Offset (optional) 1. Press the right arrow until SAM OF = +XX.X is displayed in the message center. 2. Press Enter or right arrow key. This function displays the amount of offset the sample probe currently carries. The amount is displayed in degrees Celsius with a .1 degree of accuracy.

  • Page 34: Appendix A - Glossary

    Appendix A - Glossary Display board – customer interface for entering and displaying information. All settings are sent to micro board for storage. High stage system – removes heat from the interstage heat exchanger and transfers heat to condenser. High voltage board – distributes AC power to boost/buck transformers, compressors, fans, solenoids, and heaters.

  • Page 35: Compressor Information

    Compressor Information Resistance @ 25°C ± 7% Compressor Hardware Compressor Start Start capacitor Run capacitor Start relay Winding Winding RF40C1E-CAA 2.800Ω 0.510Ω 88-106uf, 40uf, 370VAC 3ARR3CT10V5 250VAC RF41C1E-CAA 3.220Ω 0.415Ω 189-227uf, 35uf, 370VAC 3ARR3CT10S5 250VAC RF40C1E-CAV 18.300Ω 2.100Ω 43-52uf, 10uf, 440VAC 3ARR3CT10V5 250VAC RF41C1E-CAV...

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