Traulsen G Series Service Manual
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Traulsen G Series Service Manual

Traulsen G Series Service Manual

Reach-in & pass thru refrigerator & freezer
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G-Series Reach-In & Pass Thru
Refrigerator & Freezer Service Manual
This manual is applicable for all models using R-450a and R448a
Refrigerants.
2018-2023
TR35731

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Summary of Contents for Traulsen G Series

  • Page 1 G-Series Reach-In & Pass Thru Refrigerator & Freezer Service Manual This manual is applicable for all models using R-450a and R448a Refrigerants. 2018-2023 TR35731...

  • Page 2: Table Of Contents

    The Serial Tag ................................4 Serial Tag & Location: .............................. 5 1.2.1 Reading the Serial Tag: ............................ 5 Understand G-Series Model Numbers ........................6 Reading Traulsen Serial Number ..........................6 Refrigerants ................................7 1.5.1 Terminology: ..............................7 1.5.2 R-450A Refrigerant ............................7 1.5.3...
  • Page 3 4.10 Defrost Interval ..............................35 4.11 Diagnostic Menu ..............................36 4.12 Control Cover Removal & Components ........................ 39 4.12.1 Removing the Display:........................... 39 4.12.2 Installing the Display: ............................ 39 4.12.3 Accessing the Power Module (Control Board): ..................... 40 4.13 Power Module Connections Overview ......................... 41 4.14 Power module Led’s &...
  • Page 4 General Wiring Diagrams .............................. 72 Refrigerator (Off-Cycle Defrost) 115 Volt ......................72 Refrigerator Electric Defrost/ Freezer 115 Volt ....................73 Lighting Circuits ..............................74 3-Section Freezer 208-230/115 Volt ........................75 TRAULSEN EQUIPMENT WARRANTY ..........................76 U.S. Domestic Warranty ............................76...

  • Page 5: Introduction

    1. Introduction Traulsen provides this manual as an aid to the service technician in installation, operation, and maintenance. When used properly, this service manual can help the service technician maintain, troubleshoot, and diagnose the majority of issues that may occur. While we believe that most aspects of service are covered in this manual;...

  • Page 6: Serial Tag & Location

    The serial tag is a permanently affixed label on which is recorded vital electrical and refrigeration data about your Traulsen product, as well as the model and serial number. This tag is in the upper left interior compartment on all G-Series refrigerator and freezer models.

  • Page 7: Understand G-Series Model Numbers

    Understand G-Series Model Numbers Figure 2: R450 & R448 G-Series Reach-In Model Numbers Reading Traulsen Serial Number...

  • Page 8: Refrigerants

    1.5.2 R-450A Refrigerant R-450 Refrigerant is a refrigerant Traulsen uses in medium temperature applications. This refrigerant is technically a zeotropic blend but has such a small temperature glide that it could be considered a near...
  • Page 9 Figure 4: R-450 Blend R134A R1234ZE Table 1 R-450 Refrigerant Composition When charging any G-Series Refrigerator with R-450A refrigerant care should be taken to weigh the proper amount of liquid refrigerant into the system according to the data plate. It is important to charge with refrigerant in a liquid state to avoid fractionating.

  • Page 10: R-488A Refrigerant

    Table 2 R-450 Refrigerant Pressure & Temperature Chart Note: Use the Dew temperatures when calculating superheat and bubble temperatures when calculating subcooling. 1.5.3 R-488A Refrigerant R-448A Refrigerant is a refrigerant Traulsen uses in low temperature applications. This refrigerant is a zeotropic blend with a large temperature glide.
  • Page 11 Figure 5 R-448A Blend R-32 R-125 R-134A R-1234yf R-1324ze Table 3 R-448 Refrigerant Composition When charging any G-Series Freezer with R-448A refrigerant care should be taken to weigh the proper amount of liquid refrigerant into the system according to the data plate. It is important to charge with refrigerant in a liquid state to avoid fractionating.

  • Page 12: Specifications

    83- 7/16” (211.9cm) 6” casters 29- 7/8” (75.9cm) 52- 1/8” (132.4cm) 76- 5/16” (193.8cm) Width 35” (88.8cm) 35” (88.8cm) 35” (88.8cm) Depth Net Capacity cu. ft. 23.37 46.5 69.1 Table 5 Traulsen Cabinets specifications Figure 6 Front view of cabinets...
  • Page 13 Figure 7 Top view of 1 & 2 section cabinets Figure 8 Top view of 3 section cabinets...
  • Page 14 Figure 9 Side view of Reach-in cabinets...
  • Page 15 Figure 10 Reach-in cabinet Components...

  • Page 16: Preventative Maintenance

    2. Preventative Maintenance This section is to inform the recommended preventative maintenance (PM) procedures. Depending on application, PM schedule may vary. Inspect and Clean Unit: Sanitation and prolong cabinet life Frequency Daily Time required 3 minutes to prepare 3 minutes to complete Have a Soft Cloth.

  • Page 17: Clean Condenser Coil

    Clean Condenser Coil: Disconnect electrical power supply before cleaning any parts of the unit. Long reliable service life, extended compressor life. Frequency Every 3 Months Time 5 minutes to prepare 15 minutes to complete required Preparation...
  • Page 18 To clean the condenser, first disconnect electrical power to the cabinet and lift the front louver assembly. To lift this, remove the two screws located on both sides at the bottom of the louver assembly (see Figure 5). Once the screws are removed, the panel can be pivoted upwards allowing full access to the front facing condenser Use a soft bristle brush to remove any dirt, lint or dust from the finned condenser coil, around the compressor and other cooling system parts as indicated.

  • Page 19: Doors & Hardware

    3. Doors & Hardware Hinges 3.1.1 Removing the Doors and Hardware: To fit through narrow (less than 35”) doorways, it may be necessary to remove the door(s), and/or hinges. To remove any solid door, begin by removing the safety screw at the bottom of the top hinge which secures the door in place.
  • Page 20 HINGE BRACKET 344-28487-00 344-28488-00 HINGE COVER344- 28486-00 HINGE BODY 344-28482-00 ADJUSTING PLATE 344-28485-00 MACHINE SCREW #10-32 X .75” PHILLIPS ACTUATOR 344-28484-00 351-60002-07 DOOR SWITCH 337-28235-00 SAFETY SCREW 351-28483-00 Figure 12 Hinge Exploded view.
  • Page 21 Figure 13 Hinge position when door is closed Closing the Door: The Hinge Bracket travels along the Cam and the thicker portion of the Hinge Bracket Stem pushes the Actuator into the Door Switch; opening the circuit. • Light turns off. •...
  • Page 22 Opening the Door: The Hinge Bracket travels along the Cam, exposing the thinner Hinge Bracket Stem and the Door Switch pushes the Actuator out; closing the circuit. • Light turns on. • Fans turn off (this helps prevent ice accumulating on evaporator coil from ambient air moisture) Figure 14 Hinge position when door is open.

  • Page 23: Adjustments

    Adjustments Performing a Door Adjustment: These instructions are intended to aid the technician in the field perform hinge adjustments and may not cover all situations that may arise. Final diagnosis of field-based equipment is the sole responsibility of the technician performing any work required. 1.

  • Page 24: Gaskets

    Gaskets DOOR GASKET REPLACEMENT: Remove an old gasket by grasping it firmly by one corner and pull it out. Install the new gasket by inserting all four corners first then after the corners are properly inserted, work your way towards the center from both ends pushing the dart into the retainer until the gasket is completely seated in place.

  • Page 25: Locks

    Locks 3.4.1 Door lock assembly exploded view: HUDSON LOCK BARREL (NOT REPLACEABLE) 346-13187-00 HUDSON LOCK CYLINDER 358-13186-42 T42 KEY 358-28924-42 HUDSON LOCK BOLT (SOLID DOOR): 358-13189-00 HUDSON LOCK BOLT (GLASS DOOR): 358-15242-02 CORE REMOVAL 358-60024-00 Figure 18 Door lock exploded view. NOTE: Core removal key should only be used to remove door lock assembly.

  • Page 26: Door Lock Replacement Instructions

    3.4.2 Door lock replacement instructions LOCK STUD SPLINE Figure 19 Unlock position Figure 20 Lock Position 3.4.2.1 Disassembly of lock: To remove the lock cylinder for replacement, insert the Core Removal Key into the lock, causing the Spline to lower so the lock cylinder can be removed. Move the key up and down, then pull backwards; the core key will pull the lock cylinder along with it.
  • Page 27 3.4.2.3 Lock keeper exploded view: Figure 21 Lock keeper exploded view .
  • Page 28 3.4.2.4 Lock Keeper Adjustment: Figure 22 Lock keeper Adjustment Adjusting the Lock Keeper Remove the (2) machine screws holding the strike plate to the mounting plate using a #2 Phillips screwdriver. Remove the strike plate. Loosen the (2) machine screws holding the mounting plate to the cabinet. Adjust the mounting plate (left or right) Until: a.

  • Page 29: Controls

    4. Controls Understanding the display Figure 23 Traulsen Display Figure 24 Display Status Icons...

  • Page 30: Unlocking The Display

    Unlocking the display The Unlock Key is a white dot on the right side of the display, centered between the other 4 keys. Press the Unlock key twice within a second to unlock the keypad (think “tap-tap”). The Keypad Unlocked LED will turn on to indicate the keypad is now live.
  • Page 31 Figure 26 Defrost Icon illuminates in Electric Defrost ONLY Figure 27 ONLY Fan Icon Illuminates with Off Cycle Defrost Electric Defrost Off-Cycle Defrost Compressor Icon Off Compressor Icon Off Fan Icon Off Fan Icon On Defrost Icon On Defrost Icon Off Table 11 Electric defrost vs.

  • Page 32: Decode Alphabet

    Decode Alphabet F G H C D E L M N I J K O P Q R S T U V W X Y Z Figure 28 Decoding display Alphabet...

  • Page 33: Understanding The Menu System

    Understanding the Menu System Figure 29 Control Menu...

  • Page 34: Defrost Settings

    Defrost Settings Display Cabinet Temperature Press Enter Sensor Submenu Tap lightly two times to unlock. Settings Submenu Enter Technician Passcode Figure 30 Defrost settings...

  • Page 35: Defrost Setpoint

    Defrost Setpoint Defrost Setpoint Defrost Setpoint = Evaporator Coil Press enter to Temperature at Defrost heat view setting. Termination 1. Freezer Setting 2. Refrigerator Setting Figure 31 Defrost setpoint Defrost Mode Defrost Mode Defrost Mode = Determines how defrost is initiated. 1.

  • Page 36: Defrost Interval

    4.10 Defrost Interval Defrost Interval Defrost Interval = Determines how many hours between each defrost. Refrigerator Off-Cycle Defrost Off-Cycle Defrost = Defrost Interval set to h02 for Refrigerators utilizing Off- Cycle Defrost Freezer Electric Defrost Freezer Electric Defrost = Defrost Interval set to h04 for freezers utilizing Electric Defrost Refrigerator Electric Defrost...

  • Page 37: Diagnostic Menu

    4.11 Diagnostic Menu Press Enter Enter Technician Passcode 555...
  • Page 39 Press and hold, the Modify key for 2 seconds. ACt will begin to flash. Press enter to Activate (energize) the compressor and condenser fan motor. Press and hold, Press enter to Deactivate the Modify key (de-energize) the compressor and condenser for 2 seconds.

  • Page 40: Control Cover Removal & Components

    4.12 Control Cover Removal & Components 4.12.1 Removing the Display: Remove bottom louver screws and rotate louver up out of the way. Disconnect cable from the back of the controller. Lastly, squeeze the (4) tabs holding on the back side of the display and push outward to remove the display.

  • Page 41: Accessing The Power Module (Control Board)

    Figure 36: DISPLAY INSTALL 4.12.3 Accessing the Power Module (Control Board): Use a #2 Phillips screwdriver to remove the (3) screws (See Figure 42) and lift on bracket. Figure 37: POWER MODULE ACCESS (Control Board)

  • Page 42: Power Module Connections Overview

    4.13 Power Module Connections Overview Part Number: 950-60509-01 (NOTE: Serial & Model #’s Necessary for Power Module Replacement Due to Programming) Picture below illustrates input/output connection points. OUPUTS INPUTS CABINET LIGHT SENSOR OUTPUT EVAP SENSOR DEFROS SENSOR HEATER EVAP DOOR SWITCH LIGHT SWITC...

  • Page 43: Power Module Led's & Reset Button Overview

    4.14 Power module LED’s & Reset Button Overview: DOOR LIGHTS RESET BUTTON DEFROST FANS LED PROCESSOR STAGE (FLASHES) POWER DOOR HEATER INDICATOR LED (ALWAYS ON) COMPRESSOR USB LED Figure 39: Power Module Led and reset button Overview. NOTE: To reboot the board, press the reset button (See above Figure) for 5 seconds or until all the LED lights flash, shut off and then come back on again.
  • Page 44 Figure 40: Power Module & display schematics...

  • Page 45: Sensor Location

    5. Sensor Location This secition describes about the sensor locations at various locations in the cabinet. Figure 41 Freezer Sensor Location Figure 42 Refrigerator (electric defrost-with heater) Sensor Location.
  • Page 46 Figure 43 Refrigerator (off cycle defrost-no heater) Sensor Location.

  • Page 47: Sensor Control Value Test

    Sensor Control Value Test 1. Submerge sensor Bulb into a 32°F Ice Bath. 2. Follow steps below to view control value. Press Enter Tap lightly two times to unlock Enter Technician Passcode TC = Cabinet Return Air Temperature TE = Evaporator Coil Temperature TLi= Liquid Line Temperature Good Sensor Reading Figure 44 Sensor Control Value Test...

  • Page 48: Sensor Resistance Test

    Sensor Resistance Test Figure 45 Resistance Test curve...

  • Page 49: Troubleshooting

    6. Troubleshooting Condensate Overflow Troubleshooting 6.1.1 Condensate Overflow: The condensate pan generally does not overflow unless there is an excess of ambient air infiltrating the cabinet. Figure 46: Troubleshooting Condensate Pan Overflow • Hump Cover not Sealed Properly. i.e., torn, or missing Foam Tape •...

  • Page 50: Compressor Troubleshooting

    Compressor Troubleshooting 6.2.1 Terminology: • OEM – Original Equipment Manufacturer – Refers to the manufacturer of a piece of equipment or component. • RLA – Rated Load Amps – The OEM test conditions amperage rating (does not necessarily indicate the normal running amperage as conditions and applications can vary from OEM test conditions) •...

  • Page 51: Accessing The Compressor

    6.2.2 Accessing the Compressor: Figure 48: Remove (5) Screws Figure 49: Remove Condenser Housing...

  • Page 52: Compressor Not Running

    Take several measurements to ensure you are consistently getting the same values. If the resistance values are consistent, but do not match the values given below, replace the compressor with OEM replacement 6.2.5 Resistance and Amp Values of G-Series Compressors: Compressor Information Resistance Current Traulsen Part Embraco Copeland Start Number Model Model...

  • Page 53: Measuring For Excessive Voltage Drop

    6.2.7 Measuring for Excessive Voltage Drop: Now that the compressor has cooled down, measure the voltage supplied to the cabinet while the compressor is trying to start. If the voltage drops below 104 volts, you may have a problem with the power supply, try a different circuit.

  • Page 54: Locked Up Compressor

    LRA, this could be indicative of an internal mechanical problem within the compressor. If so, replace the compressor with OEM replacement. See Table 12 for Traulsen part number and OEM model number. 6.2.12 Current Climbs Above RLA: See section on Troubleshooting Run Capacitor first.

  • Page 55: Replacing The Compressor

    (Traulsen Part Number 325-60103-00). Traulsen recommends that you use a nitrogen flow regulator to purge with low pressure nitrogen as you braze all connections. After you have brazed all connections and have checked thoroughly for leaks, change the oil in your vacuum pump before connecting to system with a micron gauge.

  • Page 56: Compressor Wiring Schematics

    6.2.14 Compressor Wiring Schematics: Figure 53: Capacitor Run/ Capacitor Start Compressors...
  • Page 57 Figure 54: Induction Run Capacitor Start Compressors...

  • Page 58: Compressor Short Cycles On Overload Protection

    6.2.15 Compressor Short Cycles on Overload Protection:...

  • Page 59: Compressor Not Trying To Start

    6.2.16 Compressor not Trying to Start: Condenser Fan Runs but Compressor Not Trying to Start Measure Voltage at Compressor Voltage Within ±10% No Voltage Test Overload Test Harness Overload Open, Will Overload Closed Not Close Measure Resistance Replace Overload of Windings Resistance Match Open Windings OEM Specs...

  • Page 60: Evaporator Fan Troubleshooting

    Evaporator Fan Troubleshooting: 6.3.1 Steps for troubleshooting G-series Evaporator Fan 1. First verify fan icon is illuminated on the display indicating a call for the evaporator fan. (Remember the fan will shut off when door is opened so if you want to open the door to physically check to see if fan is running you will need to disconnect white door switch connector from control board.) Figure 55: Evaporator Fan Icon on Display 2.
  • Page 61 Figure 57: Evaporator Fan Assembly Removal Figure 58: C-Frame (Shaded Pole) Fan Motor...
  • Page 62 C-Frame Fan motor: 338-60054-00 DESCRIPTION/ MANUFACTURER SPECIFICATION FASCO INDUSTRIES, INC. BAY MOTOR PRODUCTS, INC. PART No. 7102-2992 5A141-94 AMPS 0.63A 0.5A VOLTAGE 115VAC 115VAC FREQUENCY 60 Hz 60Hz SPEED 3000 RPM 3000 RPM ROTATION Table 15: C-Frame Fan Motor Specs Evaporator Fan Blade: 325-60240-10 EVAPORATOR FAN BLADE SPECIFICATIONS COLOR...
  • Page 63 Figure 60: ECM Fan Motor CW from Lead End ECM Fan Motor: 338-60066-00 DESCRIPTION/ MANUFACTURER SPECIFICATION PART No. EXRi50-154F-B-2400-M01 OUTPUT 8 WATTS AMPS 0.07 VOLTAGE 120/230 VAC FREQUENCY 50/60 Hz SPEED 2400 RPM ROTATION AIR FLOW 168 CFM Table 17: ECM Fan Motor Specs...

  • Page 64: Condenser Fan Troubleshooting

    Condenser Fan Troubleshooting Troubleshooting the Condenser Fan Motor on G-Series: 6.4.1 Figure 61: CFM Assembly View First verify that the Call for Cooling LED on the display is illuminated. Figure 62: LED Display...

  • Page 65: Motor Bearing Failure

    If the compressor is running but not the condenser fan motor, you should measure voltage at the condenser fan motor. If you measure, +/- 10% of rated voltage but motor doesn’t run, replace the fan motor. 6.4.2 Motor Bearing Failure: Problems with motor bearings can be easily overlooked as the motor will run while the cabinet drops in temperature until the motor overheats.
  • Page 66 Step 3: Figure 64: Remove Speed Nut Step 4: Figure 65: Remove Fan Blade...

  • Page 67: Replacing The Condenser Fan Motor

    Troubleshooting Thermostatic Expansion Valve All Traulsen G-Series Refrigerators and Freezers are equipped with a Thermostatic Expansion Valve or TXV. The TXV is a type of metering device that meters liquid refrigerant into the evaporator coil. A TXV is superior to a capillary tube metering device as it can respond to load changes.

  • Page 68: Three Pressures

    TXV on Traulsen equipment as the superheat will be properly adjusted by Traulsen. 6.5.2 Non-Bleed Type The TXV used on Traulsen G-Series Equipment is a non-bleed or hard shut off type of TXV which means that the pressures do not equalize during the off cycle. 6.5.3 Maximum Operating Pressure The TXV used on Traulsen G-Series Equipment is a MOP valve with Maximum Operating Pressure.

  • Page 69: Restrictions

    test. Installing pressure test access valves should be the last resort. Superheat can be measured with two thermometers securely attached to refrigerant lines. (T1) Measure the temperature at the inlet of the evaporator coil after the TXV valve body. (T2) Measure the temperature at the outlet of the evaporator coil after the TXV sensing bulb.

  • Page 70: Removing The Refrigeration System

    Removing the Refrigeration System 6.6.1 Condenser Assembly: Figure 69: Fastener Locations...

  • Page 71: Defrost Troubleshooting

    6.6.2 Defrost Troubleshooting Traulsen uses two different types of defrost on the G-Series Refrigerators. The last cabinet temperature before the defrost started will be displayed throughout the entire defrost cycle. 1. Off-Cyle Defrost- The off-cycle defrost is really an air over defrost. In otherwords we shut off the compressor but continue to run the Evaporator Fan Motor.
  • Page 72 Evaporator coil temperature drops to 30 degrees fahrenheit the Evaporator Fan Motor will be energized. Figure 72:Display During Electric Defrost On G-Series Freezers Traulsen only uses one type of defrost. Electric Defrost- During an electric defrost we shut off the compressor and the Evaporator Fan Motor but energize an electric heating element at which time the melting snowflake is illuminated on the display.

  • Page 73: General Wiring Diagrams

    7. General Wiring Diagrams Refrigerator (Off-Cycle Defrost) 115 Volt Figure 74:Refrigerator Off Cycle Defrost 115V.

  • Page 74: Refrigerator Electric Defrost/ Freezer 115 Volt

    Refrigerator Electric Defrost/ Freezer 115 Volt Figure 75: Refrigerator Electric Defrost/ Freezer 115 Volt...

  • Page 75: Lighting Circuits

    Lighting Circuits Figure 76: Lighting Circuits...

  • Page 76: 3-Section Freezer 208-230/115 Volt

    3-Section Freezer 208-230/115 Volt Figure 77: 3-Section Freezer 208-230/115 Volt...

  • Page 77: Traulsen Equipment Warranty

    Equipment (“Purchaser”) that Traulsen will convey the Equipment free and clear of all liens, security interests, and encumbrances created by, through or under Traulsen. Traulsen further warrants that for a period of three (3) years from the later of either (a) the date of delivery to the common carrier or (b) the date of installation (the “Domestic Warranty Period”) but in no event, shall the Domestic...
  • Page 78 Traulsen HOURS OF OPERATION: 4401 Blue Mound Road Fort Worth, Texas Monday thru Friday 7:30 am - 4:30 pm CST 76106 Phone: (800) - 825 - 8220 TR35731...

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