Traulsen Freezer G12000 User Manual

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. 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.  
A product of TRAULSEN  
Fort Worth, TX 76106-1988  
F25393 (August 2010)  
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G SERIES FREEZER - GENERAL  
GENERAL  
INTRODUCTION  
CLEANING  
Refer to the Operation Manual for specific cleaning  
instructions. The condenser coil must be cleaned  
every six months. This can be done with a vacuum  
cleaner using a fin comb or condenser coil brush.  
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.  
TOOLS  
Standard set of hand tools  
These units aid in preserving food quality, texture  
and nutritional value.  
Clamp meter Part No. 00-541069 Grainger No.  
1ND81 or equivalent  
All of the information, illustrations and specifications  
contained in this manual are based on the latest  
product information available at the time of printing.  
Grounding kit - Static Control Kit Grainger No.  
4KK44  
Micro amp meter  
LOCATION  
VOM with AC current tester (sensitivity of at  
least 20,000 ohms per volt)  
Refer to the Installation Instructions for specific  
location requirements.  
Refrigeration tool kit Part No. 00-913093-15  
OPERATION  
Digital thermometer with quad inputs Model  
DT304 Part No. 00-913093-12  
Refer to the Operation Manual for specific operating  
instructions.  
Inficon D-Tek Select refrigerant leak detector  
Part No. 00-913093-2  
Vacuum Cleaner - Shop Vac  
Fin comb Grainger Part No. 2YJ78 or equivalent  
Condenser coil brush Grainger Part No. 3HHE8  
or equivalent  
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G SERIES FREEZER - GENERAL  
CONTROL PANEL  
SPECIFICATIONS  
DIMENSIONS  
1 Section Cabinet  
2 Section Cabinet  
83- 1/4" (211.46cm)  
52- 1/8" (132.4cm)  
35" (88.8cm)  
3 Section Cabinet  
83- 1/4" (211.46cm)  
76- 5/16" (193.8cm)  
35" (88.8cm)  
Height- overall on casters  
Width  
83-1/4" (211.46cm)  
29- 7/8" (75.9cm)  
35" (88.8cm)  
24.2  
Depth  
Net Capacity cu. ft.  
46.0  
69.1  
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G SERIES FREEZER - GENERAL  
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS  
DATA  
1 Section Cabinet  
115/60/1  
2 Section Cabinet  
115/60/1  
3 Section Cabinet  
115/60/1  
3 Section Cabinet  
208/60/1  
Voltage  
Amps Full Load  
9.5  
11.2  
16.0  
11.0  
OPERATING DATA  
Refrigerant Type  
1 Section Cabinet  
2 Section Cabinet  
3 Section Cabinet  
R-404A  
R-404A  
R-404A  
High Pressure (psi)  
500  
500  
500  
250  
90EF Operating  
Temperature  
Low Pressure (psi)  
250  
250  
90EF Operating  
Temperature  
BTU/HR (HP)  
1930 @ -20EF Evaporator  
Temp. & 90EF Ambient  
2970 @-20EF Evaporator  
Temp. & 90EF Ambient  
4710 @-20EF Evaporator  
Temp. & 90EF Ambient  
(1/2HP)  
(3/4HP)  
(1HP)  
REMOVAL AND REPLACEMENT OF PARTS  
COVERS & PANELS  
Front Panel  
1. Remove lower panel screws from cabinet.  
3. Remove panel from cabinet.  
4. Reverse the procedure to install.  
Condenser / Compressor Cover  
1. Access condenser cover at top of cabinet.  
2. Remove upper panel screws from cabinet.  
2. Remove all screws securing condenser cover to  
cabinet.  
NOTE: Upper panel screws are accessed from the  
back side of front panel.  
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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  
1. Access harness raceway cover at top of  
cabinet.  
2. Remove screws securing cover to raceway  
housing.  
3. Lift cover from cabinet.  
4. Reverse the procedure to install.  
Evaporator Cover  
3. Lift cover up from raceway housing.  
4. Reverse the procedure to install.  
Control Box Cover  
1. Access control box cover at top of cabinet.  
2. Remove screws securing cover to cabinet.  
1. Access evaporator cover at top of cabinet.  
2. Remove bolts securing evaporator cover to  
cabinet.  
3. Lift cover up from control box.  
4. Reverse the procedure to install.  
3. Use of a screw driver to aid in prying up cover  
to break adhesive seal then lift cover from  
cabinet.  
CABINET LAMP  
1. Open cabinet door to gain access to cabinet  
light.  
2. Reach up and carefully squeeze lamp lens  
inward to release lens from mounting tabs.  
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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.  
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.  
NOTE: Use care not to damage lead wires.  
4. Loosen screws securing harness connector to  
Intela-Traul Control.  
5. Disconnect harness connector from Intela-Traul  
Control.  
8. Reverse the procedure to install.  
INTELA-TRAUL RELAY MODULE  
Removal  
1. Remove front panel as outlined under COVERS  
& PANELS.  
2. Access Intela-Traul relay module at top of  
cabinet.  
6. Compress in both sides of mounting clip, while  
sliding clip off Intela-Traul control. Repeat for  
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.  
CABINET AIR SENSOR  
4. Disconnect all lead wire connectors from Intela-  
Traul relay box.  
5. Remove both nuts securing Intela-Traul relay  
module to control box cover.  
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.  
6. Reverse the procedure to install.  
COMPRESSOR RELAY  
4. Remove harness raceway cover as outlined  
under COVERS & PANELS.  
1. Remove front panel as outlined under COVERS  
& PANELS.  
5. Remove control box cover as outlined under  
COVERS & PANELS.  
2. Access compressor relay at top of cabinet.  
3. Remove control box cover as outlined under  
COVERS & PANELS.  
6. Route sensor out from evaporator compartment.  
7. Disconnect sensor lead wire connector.  
4. Disconnect all lead wires from compressor  
relay.  
NOTE: The green insulation lead wire to green  
indicator tape on connector for proper connection.  
5. Remove nuts from compressor relay.  
8. Reverse the procedure to install.  
6. Reverse the procedure to install.  
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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. Access thermal expansion valve at top of  
cabinet.  
2. Remove evaporator cover as outlined under  
COVERS & PANELS.  
2. Remove evaporator cover as outlined under  
COVERS & PANELS.  
3. Pull sensor out from evaporator fins.  
3. Cut wire ties off from refrigerant line insulation.  
4. Remove pipe insulation from refrigerant line.  
5. Remove insulation from refrigerant line.  
NOTE: Sensor location for replacement.  
4. Remove harness raceway cover as outlined  
under COVERS & PANELS.  
5. Remove control box cover as outlined under  
COVERS & PANELS.  
6. Loosen bolts securing sensor from refrigerant  
line.  
6. Route sensor out from evaporator compartment.  
7. Disconnect sensor lead wire connector.  
7. Pull sensor out from mounting bracket.  
NOTE: The blue insulation lead wire to blue indicator  
tape on connector for proper connection.  
8. Remove expansion valve from the liquid line at  
inlet and outlet of valve.  
8. Reverse procedure to install.  
9. Install replacement expansion valve into inlet  
and fasten sensor to suction line.  
10. Recharge unit and check for leaks.  
11. Put system back into operation and check the  
superheat as outlined under CHECK  
REFRIGERANT CHARGE in SERVICE  
PROCEDURES AND ADJUSTMENTS.  
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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.  
7. Remove defrost heater mounting clips from  
evaporator coil to release defrost heater.  
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.  
8. Route heater lead wires out from evaporator  
compartment.  
9. Reverse the procedure to install.  
DOOR GASKET  
5. Remove adhesive tape over refrigeration lines.  
To Remove:  
1. Open cabinet door to gain access to door  
gasket.  
2. Start at one corner of the gasket and pull gasket  
out from the gasket retaining channel.  
A. Continue to pull gasket from door until  
gasket is completely out of gasket retaining  
channel.  
6. Lift evaporator coil up and out from evaporator  
compartment to expose bottom of evaporator  
coil.  
NOTE: Do Not kink refrigeration lines or damage  
lead wires.  
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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  
4. Open cabinet door to gain access to evaporator  
fan housing.  
1. Remove screw from upper door hinge.  
5. Loosen screws securing evaporator air duct to  
cabinet.  
A. Slide evaporator air duct away from right  
side cabinet wall and allow duct to lower  
into cabinet.  
NOTE: Mounting holes in evaporator air duct are  
keyhole slots.  
2. Lift door assembly upward off hinges and set  
door assembly aside.  
3. Reverse the procedure to install.  
NOTE: Install original hinge assemblies onto  
replacement door.  
6. Remove screws securing evaporator fan  
housing to evaporator compartment.  
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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.  
Compressor  
1. Remove condenser / compressor cover as  
outlined under COVERS & PANELS.  
2. Evacuate refrigeration system.  
NOTE: The use of reclaiming equipment is  
mandatory.  
3. Use of screwdriver to lift retaining brace upward  
off junction box cover.  
8. Install new compressor and connect wire leads  
at compressor junction box.  
9. Install new filter drier.  
10. Evacuate refrigeration system.  
11. Charge system and put unit into operation.  
12. Check for proper operation.  
Condenser Fan Assembly  
1. Remove condenser / compressor cover as  
outlined under COVERS & PANELS.  
2. Disconnect lead wires to condenser fan.  
3. Remove screws securing condenser fan  
mounting bracket to cabinet.  
4. Disconnect lead wires from compressor junction  
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G SERIES FREEZER - REMOVAL AND REPLACEMENT OF PARTS  
5. Reverse procedure to install coil, then proceed  
to next step.  
NOTE: It is recommended that the filter drier be  
4. Remove the screws securing mounting bracket  
to condenser fan.  
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  
1. Remove condenser / compressor cover as  
outlined under COVERS & PANELS.  
2. Remove filter drier from liquid lines.  
3. Install a new filter direr.  
4. Evacuate refrigeration system.  
NOTE: The use of reclaiming equipment is  
5. Reverse the procedure to install.  
mandatory.  
Condenser Coil  
5. Charge system and put unit into operation.  
HOT GAS CONDENSATE PAN  
1. Evacuate refrigeration system.  
NOTE: The use of reclaiming equipment is  
mandatory.  
1. Remove condenser / compressor cover as  
outlined under COVERS & PANELS.  
2. Remove condenser / compressor cover as  
outlined under COVERS & PANELS.  
2. Remove screw securing hot gas coil retaining  
bracket to the cabinet.  
3. Disconnect inlet and outlet lines at the soldered  
connections nearest the condenser coil.  
NOTE: Do not damage the coil during removal.  
4. Remove screws securing coil to mounting plate.  
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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.  
Helpful Hints  
7 degrees F is a desirable superheat at coil  
outlet, but superheat for the TXV's are set at the  
factory.  
Procedure  
1. Superheat Temperature  
2. Connect a temperature probe thermocouple to  
the evaporator coil outlet (D).  
A. Install a piece of pipe insulation around the  
thermocouple probe.  
3. Connect a temperature probe thermocouple to  
the evaporator coil inlet (C).  
A. Install a piece of pipe insulation around the  
thermocouple probe.  
4. If applicable, install all evaporator box covers  
over evaporator.  
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS  
5. Let refrigerant system run. Temperature  
B. To obtain a split temperature reading: add  
condenser coil inlet (A) & condenser coil  
outlet (B) readings divide by 2 and then  
subtract ambient temperature reading.  
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. Subtract temperature reading of evaporator  
coil outlet temperature (D) to the  
6. If split temperature reading is out of spec, call  
Refrigeration Service Support.  
evaporator coil inlet temperature (C)  
7. Remove thermocouples and install all covers &  
panels.  
reading to obtain a superheat temperature.  
Example: evaporator outlet temp. (D) - evaporator  
inlet temp. (C) = superheat temp.  
CHECKING FOR LEAKS  
NOTE: TXV superheat is set at the factory and is not  
adjustable.  
B. If superheat temperature reading is out of  
spec, call Refrigeration Service Support.  
7. Remove thermocouples and install all covers &  
panels.  
Sub Cooling & Split Temperatures  
1. Access the refrigeration system.  
2. Connect the low (blue) side of gauge manifold  
to schrader valve.  
3. Connect refrigerant bottle to center of gauge  
manifold and open valve on bottle.  
4. Open valve on low side of gauge manifold and  
charge system with a small amount of  
refrigerant (1 to 2 ounces).  
5. Close bottle valve and gauge valve.  
1. Connect a temperature probe thermocouple to  
the condenser coil inlet (A).  
6. Disconnect refrigerant bottle and connect  
nitrogen bottle.  
A. Install a piece of pipe insulation around the  
thermocouple probe.  
7. Set output valve on nitrogen bottle to 120 psi.  
2. Connect a temperature probe thermocouple to  
the condenser coil outlet (B).  
8. Open nitrogen bottle valve and gauge manifold  
valve (low side) and allow pressure to equalize.  
A. Install a piece of pipe insulation around the  
thermocouple probe.  
9. Shut off both valves and disconnect the nitrogen  
bottle.  
3. If applicable, install all evaporator box covers  
over evaporator.  
10. Using a leak detector or a thick soapy solution,  
check for leaks at all tubing connections.  
4. Let refrigerant system run for approximately 3 to  
5 minutes before taking temperature readings.  
A. If any leaks are detected, repair the leak  
and recheck.  
5. Take readings of condenser coil inlet (A) &  
condenser coil outlet (B) lines.  
B. If no leaks are discovered, evacuate  
system as outlined under EVACUATING  
SYSTEM.  
A. To obtain a sub cooling temperature  
reading: add condenser coil inlet (A) &  
condenser coil outlet (B) readings divide by  
2 and then subtract condenser coil outlet  
(B) reading.  
11. Charge system as outlined under CHARGING  
SYSTEM.  
Example: [(condenser inlet (A) + condenser outlet  
temp. (B)) / 2] !condenser outlet (B) = sub cooling  
temperature.  
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS  
7. Repeat steps 5 and 6 once.  
EVACUATING SYSTEM  
8. Pull vacuum to 500 microns.  
Introduction  
9. Charge system and check for proper operation.  
Refrigeration reclaiming equipment is required.  
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. Because of this,  
guidelines and methods must be developed and  
adhered to ensuring only harmless amounts of  
contaminants remain in the system.  
Guidelines  
Use only a two stage vacuum pump (2 CFM or  
greater) and electronic micron gauge integrated  
into a refrigeration reclaiming system.  
1. Access the refrigeration system.  
2. Be sure system is properly leak checked and  
evacuated before charging as outlined under  
LEAK CHECK and EVACUATING SYSTEM.  
Evacuate from high to low sides of system.  
No chemical additives or alcohols are to be  
used to Dry Up a system.  
3. Connect high side of gauge manifold to the  
receiver valve. Make certain both valves are  
closed on the gauge manifold.  
No Flushing with solvents or any type of Freon  
alien to system. Blow down of system with DRY  
NITROGEN prior to evacuation is acceptable  
and many times desirable. See SYSTEM  
CLEAN UP.  
NOTE: Charge the system through the high side to  
prevent liquid refrigerant from reaching the  
compressor.  
Evacuate to 500 microns of mercury.  
4. Connect refrigerant bottle to center connection  
of gauge manifold.  
Procedure  
5. Turn the refrigerant bottle upside down.  
6. Open valves on bottle, gauge manifold and  
receiver.  
7. Allow the proper amount of refrigerant to enter  
the system, then shut the gauge and bottle  
valves.  
8. Disconnect the hose from the receiver valve.  
9. Reconnect power to the unit and check for  
proper operation and high pressure leaks.  
10. Disconnect power to the unit and replace any  
covers removed.  
11. Reconnect power to the unit.  
SYSTEM CLEAN UP  
1. Access the refrigeration system.  
2. Connect low (blue) side of gauge manifold to  
schrader valve on compressor access line and  
high (red) side of gauge manifold to schrader  
valve on filter drier line.  
3. Connect center line of gauge manifold to  
vacuum pump.  
4. Turn vacuum pump on and open both sides of  
gauge manifold.  
Introduction  
When a compressor burn-out is encountered, the  
service person must make the determination as to  
the degree of system contamination.  
5. Pull a vacuum to 500 microns.  
6. Break the vacuum with 3 psig of operating  
refrigerant. On remote systems DRY  
NITROGEN may be preferred.  
Normally a compressor burn-out will fit in one of  
three categories:  
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G SERIES FREEZER - SERVICE PROCEDURES AND ADJUSTMENTS  
Contained - compressor oil not acidic, no oil  
SOFTWARE VERSION  
discoloration.  
The control program software version can be  
determined by:  
Contaminated compressor - oil acidic,  
discoloration of oil, contamination limited to  
compressor.  
1. Turn power on to the Intela-Traul control.  
Massive contamination - contaminated oil and /  
or refrigerant pumped into system.  
2. While control powers up the control display will  
show the software version for a second (C32  
and above).  
Contained  
1. Replacement of liquid line drier.  
2. Install suction line filter drier.  
3. Replacement of compressor.  
4. Evacuation (to 500 microns).  
5. Charge by weight.  
CONTROL CALIBRATION  
Certain components in this system are  
subject to damage by electrostatic discharge during  
field repairs. A field service grounding kit is available  
to prevent damage. The field service grounding kit  
must be used anytime the control board is handled.  
Contaminated Compressor  
1. Verify that the cabinet air sensor is functioning  
properly as outlined under CABINET AIR, &  
CABINET COIL, SENSOR TEST.  
The Contaminated Compressor requires the same  
procedure as the Contained Burn-Out. Plus, the  
system must be flushed after the compressor and  
drier have been removed.  
2. Place a thermocouple of a temperature tester in  
the center of right incoming air slot of the  
cabinet.  
Massive Contamination  
A. Route thermocouple through hinge side of  
door to the outside of the cabinet and close  
the door(s).  
The replacement compressor MUST NOT be  
installed until after system clean-up procedures have  
been completed.  
3. Set the control temperature to 0EF.  
1. Remove the burned-out compressor as outlined  
under COMPRESSOR in REMOVAL AND  
REPLACEMENT OF PARTS.  
4. Allow the cabinet temperature to stabilize  
(minimum 3 cycles).  
2. Remove any of the in-line refrigerant controls.  
5. Note temperature reading on temperature tester  
and control display at the exact time the  
refrigeration system turns off.  
3. Flush high and low sides of system until acidic  
oil has been removed from the remaining  
components of the system.  
6. If the temperature difference between the two  
readings is greater than ±2EF or ±1EC, adjust if:  
4. Reassemble refrigeration system.  
A. If temperature test shows a temperature  
higher than control, increase.  
5. Evacuate refrigeration system as outlined under  
EVACUATING SYSTEM.  
B. If temperature test shows a temperature  
lower than control, decrease.  
6. Charge system as outlined under CHARGING  
SYSTEM.  
C. If temperature difference is greater than  
the range of the control, replace controller  
(range ±50EF. or ±10EC.).  
7. Reconnect power and check for proper  
operation.  
8. Disconnect power and install any panels  
removed.  
7. Check for proper operation.  
8. Remove temperature tester thermocouple from  
the cabinet.  
9. Reconnect power. After 24 hours of operation  
check system for acid and proper operation.  
10. Once the system is determined clean, remove  
the suction line drier.  
F25393 (August 2010)  
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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). To save settings & exit customer access mode, press the alarm cancel keypad or not pressing  
any keypads for 30 seconds.  
To Access Customer Level  
1. Use security code 0A1 by:  
2. Pressing the Set keypad until CUS is displayed.  
3. Press the Set keypad until left zero is flashing with three zeros displayed.  
4. Press the Set keypad until center zero is flashing with three zeros displayed.  
5. Press the Down Arrow until A is shown in center display.  
6. Press Set keypad until right zero is flashing with 0A0 displayed.  
7. Press the Up Arrow until 1 is flashing in right display.  
8. Press the Set keypad. Display should read SP (Thermostat Set Point) indicating controller is in Customer  
Access Mode.  
To Access Engineering Level  
1. Press the Set keypad until CUS is displayed.  
2. Press the DOWN ARROW keypad until ENG is displayed.  
3. Press the Set keypad until 000 is displayed with the left digit flashing.  
4. Press the DOWN ARROW keypad until left digit displays 9.  
5. Press the Set keypad until the center digit flashes.  
6. Press the DOWN ARROW keypad until center digit displays 9.  
7. Press the Set keypad until the right digit flashes.  
8. Press the DOWN ARROW keypad until the right digit displays E.  
9. Press SET keypad then the DOWN ARROW keypad until FOC is displayed.  
NOTE: Hex File GF1 (Standard) and GF3 (-10 EF Freezer).  
10. Use the DOWN ARROW keypad to scroll through control parameters.  
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  
SPH  
software ver. C28  
Temperature set point  
high / Cus. level  
SHH to SHL  
SLH to SLL  
0 EF  
-5.0EF  
SPL  
Temperature set point  
low / Cuc. level  
-4.0EF  
-10.0EF  
software ver. C28  
SP  
Set point cut out  
temperature  
-3.0 EF  
-10.0 EF  
software ver. C32  
& above  
SPD  
Set point differential  
SP TO SPD  
2.0 EF  
-2.0 EF  
2.0 EF  
4.0 EF  
software ver. C32  
& above  
SHL  
Set point high-low /  
Eng. level  
-40EF. up to current  
setting for SHH  
-8.0 EF  
software ver. C28  
From current setting  
for SHL up to  
266EF.  
SHH  
software ver. C28  
Set point high-high /  
Eng. level  
-5.0 EF  
Page 19 of 32  
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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  
Set point low-low/ Eng.  
level  
-40EF. up to current  
-6.0 EF  
-13.0 EF  
setting for SLH  
software ver. C28  
SLH  
Set point low-high/ Eng.  
level  
from current setting  
for SLL up to 266 EF  
-2.5 EF  
-10 EF  
software ver. C28  
Room ambient offset /  
Cuc. level  
±3EF. in 1/2EF.  
RO  
HI  
0 EF  
10.0EF  
-15.0 EF  
EF  
0 EF  
5.0 EF  
-15.0 EF  
EF  
increments  
Upper temperature limit  
/ Eng. level  
-40 EF. to 266EF.  
-40 EF. to 266EF.  
EF. or EC.  
Lower temperature limit  
/ Eng. level  
LO  
Temperature scale EF  
SCL  
AC  
or EC / Cuc. level  
Anti-cycling- minute /  
Eng. level  
1-10 min. in 1 min.  
increments  
3
3
Defrost type- ele., gas,  
none, off cycle / Eng.  
level  
ELE, GAS, NONE or  
OFF  
DEF  
IBD  
ELE  
4.0  
ELE  
4.0  
Intervals between  
defrosts- hours / Eng.  
level  
1-9 hrs. in 1 hr.  
increments  
Maximum defrost  
duration- minute / Eng.  
level  
0-30 min. in 5 min.  
increments  
DDC  
CDE  
DDE  
30  
30  
Coil temperature at end  
of defrost cycle / Eng.  
level  
40 EF. to 80 EF. in 5  
45 EF  
4
45 EF  
4
EF. increments  
Drip time at end of  
defrost cycle- minute /  
Eng. level  
1-5 min. in 1 min.  
increments  
Blower delay at drip  
0-5 min. in 1 min.  
increments  
BDD  
BSD  
6
7
time-minute / Eng. level  
BSD after defrost end /  
Eng. level  
30 EF. to 40 EF. in 1  
20.0 EF  
10.0 EF  
EF. increments  
Display hold after  
defrost-minute / Eng.  
level  
0-30 min. in 5 min.  
increments  
ODD  
SD  
10  
10  
Start-Stop defrost /  
Cus. level  
Start a new defrost cycle at any time or stops  
a current defrost cycle.  
YES / NO  
00:00 to 23:59  
Setting for 12hr. or  
24 hr. time  
(H=hours, N=min.,  
S=sec.)  
Set the clock time /  
Cus. level  
Set the clock for standard time or military  
time.  
CL  
F25393 (August 2010)  
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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  
(Y=year, N=month,  
E=day # in week  
example: Sun=1  
Sat=7)  
Set the clock date /  
Cus. level  
Set the year, month, day of the month and  
day of the week.  
DAY  
Daylight Savings / Cus.  
level  
DS  
ON / OFF  
ON  
ON  
2:00 to 8:00 in. 30  
min. increments &  
OFF  
Defrost lockout 1 / Cus.  
level  
DL1  
OFF  
OFF  
14:00 to 20:00 in. 30  
min. increments &  
OFF  
Defrost lockout 3 / Cus.  
level  
DL3  
DL4  
OFF  
OFF  
2:00 to 20:00 in. 30  
min. increments &  
OFF  
Defrost lockout 4 / Cus.  
level  
OFF  
100  
OFF  
100  
DCF  
software ver. C28  
Dewpoint correction  
factor / Cus. level  
0 to 100  
Compressor default On  
time / Eng. level  
5-30 min. in 1 min.  
increments  
CON  
COF  
20  
5
20  
5
Compressor Off time /  
Eng. level  
5-30 min. in 1 min.  
increments  
Evaporator coil  
temperature / Cus.  
level  
Displays evaporator coil temperature in real  
time every time an arrow keypad is pressed.  
EL  
n/a  
Cabinet air temperature  
/ Cus. level  
Displays cabinet air temperature in real time  
every time an arrow keypad is pressed.  
CB  
n/a  
n/a  
PLn  
Display line voltage /  
Eng. level  
Displays power line voltage in real time every  
time an arrow keypad is pressed.  
software ver. C28  
Cycle compressor relay  
/ Eng. level  
Turns On/Off the compressor relay for 10  
seconds or until an arrow keypad is pressed.  
RCO  
RdF  
RFA  
RDH  
CEP  
n/a  
n/a  
n/a  
n/a  
n/a  
Cycle defrost relay /  
Eng. level  
Turns On/Off the defrost relay for 10  
seconds or until an arrow keypad is pressed.  
Cycle fan relay / Eng.  
level  
Turns On/Off the blower relay for 10 seconds  
or until an arrow keypad is pressed.  
Cycle door heater relay  
/ Eng. level  
Turns On/Off the door heater for 10 seconds  
or until an arrow keypad is pressed.  
Clear EPROM & load  
defaults / Eng. level  
Clear all control memories and reloads the  
factory default parameters.  
Firmware revision in the format X9.9  
(X=version, 9=major revision, .9= minor  
revision).  
Software version,  
Ref  
Sn  
n/a  
n/a  
revision, step / n/a level  
Cabinet serial number /  
Cus. level  
n/a  
11. To exit, press the alarm cancel keypad or not pressing any keypads for 30 seconds.  
Page 21 of 32  
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G SERIES FREEZER - ELECTRICAL OPERATION  
4. Verify multi meter reading to the temperature  
conversion chart as follows.  
EVAPORATOR COIL SENSOR  
TEST  
Temperature  
Ohm Reading  
K Ohms  
Temperature  
EF  
EC  
1. Access the customer level by pressing the Set  
keypad until CUS is displayed.  
-5.0  
0
99.9  
85.2  
72.9  
62.4  
53.7  
46.2  
39.9  
34.6  
32.7  
30.1  
26.1  
22.8  
19.9  
17.4  
15.3  
13.5  
11.9  
-20.5  
-17.7  
-15.0  
-12.2  
-9.4  
-6.7  
-3.9  
-1.1  
0.0  
2. Press the Set keypad until left zero is flashing  
with three zeros displayed.  
3. Press the Set keypad until center zero is  
flashing with three zeros displayed.  
5.0  
4. Press the Down Arrow until A is shown in center  
display.  
10.0  
15.0  
20.0  
25.0  
30.0  
32.0  
35.0  
40.0  
45.0  
50.0  
55.0  
60.0  
65.0  
70.0  
5. Press Set keypad until right zero is flashing with  
0A0 displayed.  
6. Press the Up Arrow until 1 is flashing in right  
display.  
7. Press Up Arrow until EL is displayed then press  
Set keypad.  
A. If display shows -40 check for loose wire  
connections and retest.  
1.7  
B. If display shows 266 OR higher replace the  
evaporator coil sensor.  
4.4  
NOTE: Erratic display readings indicate an open or  
short in the control.  
7.2  
CABINET AIR SENSOR TEST  
10.0  
12.8  
15.6  
18.3  
21.1  
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.  
3. Press the Set keypad until center zero is  
flashing with three zeros displayed.  
4. Press the Down Arrow until A is shown in center  
display.  
5. If multi meter reading indicates an open or is  
outside the ohm range ±10%, replace the  
sensor.  
5. Press Set keypad until right zero is flashing with  
0A0 displayed.  
COMPRESSOR RELAY TEST  
6. Press the Up Arrow until 1 is flashing in right  
display.  
1. Turn supply power Off.  
7. Press Up Arrow until AA is displayed then press  
Set keypad.  
2. Gain access to the compressor relay.  
3. Disconnect N.O. & COM lead wires from relay.  
A. If display shows 111 check for loose wire  
connections and retest.  
4. Set the multi meter to ohm scale and connect  
leads to relay N.O. & COM terminals .  
B. If display shows 32.0 correct inadequate  
air flow through the condenser, replace the  
cabinet air sensor, or condenser fan  
assembly.  
5. Verify the multi meter reading indicates an open  
circuit. If not, replaced the relay .  
DOOR SWITCH TEST  
NOTE: Erratic display readings indicate an open or  
short in the control.  
1. Turn supply power Off.  
2. Open the cabinet doors.  
CABINET AIR, CABINET COIL,  
& SENSOR RESISTANCE TEST  
3. Gain access to the door switch.  
4. Disconnect lead wires from switch.  
1. Gain access to the sensor.  
5. Set the multi meter to ohm scale and connect  
leads to switch terminals .  
2. Disconnect sensor lead wires from connector.  
3. Set the multi meter to ohm scale and connect  
leads to sensor lead wires.  
6. Verify the multi meter reading indicates an open  
circuit. If not, replaced the switch.  
F25393 (August 2010)  
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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 . . . . . . . . . . . . . . Pumps refrigerant through refrigeration system lines and components.  
Start Capacitor . . . . . . . . . . . . Wired in series with the start windings to help start compressor motor.  
Run Capacitor . . . . . . . . . . . . . Continually in circuit to help compressor motor during operation.  
Compressor Relay . . . . . . . . . Senses current of run winding of compressor motor. Normally open contacts  
close when the run winding draws a high amperage at start and brings the start  
capacitor and start windings into the circuit. As the motor reaches operating  
speed (less amperage through run winding), the normally open contacts open  
and removes the start capacitor and start windings from the circuit.  
Evaporator Fan . . . . . . . . . . . Draws air from the cabinet and moves the air through the evaporator coil back  
into cabinet.  
Condenser Fan . . . . . . . . . . . Draws air across condenser coil to aid in removing heat from the refrigerant and  
move air across compressor to aid in cooling the compressor.  
Defrost Heater . . . . . . . . . . . . . Defrosts evaporator coil and prevents water droplets from evaporator coil to  
freeze before they can drain to the condensate pan. Operates only during defrost  
cycle.  
Cabinet Air Sensor . . . . . . . . Monitors air temperature inside cabinet.  
Cabinet Coil Sensor . . . . . . . Monitors the evaporator coil while the cabinet is powered.  
. . . . . . . . . . .  
Door Switch . . . . . . . . . . . . . . Monitors door for open or closed position. Evaporator fans stop when door is  
open.  
Solenoid Valve . . . . . . . . . . . . Normally closed when energized, allows refrigerant to flow from receiver to  
evaporator coil.  
Door Perimeter Heater . . . . . . Prevents condensate from forming on door frame.  
Intela-Traul Relay Module . . . Controls power to the following components:  
A. Evaporator fan(s).  
B. Door heater.  
C. Defrost heater.  
D. Compressor relay.  
E. Solenoid valve.  
Main Switch . . . . . . . . . . . . . . . Controls power to intela-traul relay box, compressor relay, door switch, &  
auxiliary components. Removes power from listed components.  
Heated Glass Doors . . . . . . . . Auxiliary component, prevents condensate from forming on glass door.  
Condensate Evaporator . . . . . Auxiliary component, when energized dissipates condensate in the evaporator  
pan.  
Page 23 of 32  
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G SERIES FREEZER - ELECTRICAL OPERATION  
SEQUENCE OF OPERATION  
Refrigeration System  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
The control must be powered on.  
The control monitors cabinet air temperature and senses a need for cooling.  
The compressor motor is energized and refrigerant is pumped through the system.  
The TXV monitors the evaporator superheat and meters the amount of refrigerant entering the evaporator.  
The control senses the cabinet air temperature requirements have been met.  
Compressor motor de-energized by the compressor relay.  
System is cycled by control.  
Freezer Mode  
1.  
Main switch closed.  
A. Relay module energized.  
B. Control energized.  
C. Compressor relay.  
D. Condenser fan(s) energized.  
E. Compressor motor energized.  
2.  
3.  
4.  
Control displays software revision & then cabinet temperature.  
After 2-1/2 minutes evaporator fan(s) energized.  
The refrigeration system will cycle on the air temperature of the cabinet.  
A. On at the high set point (SP + D) temperature.  
B. Off at the low set point (SP) temperature.  
NOTE: Set points are selected in the parameter menu.  
NOTE: If the cabinet door is opened during operation, the evaporator fan(s) will shut Off.  
5.  
6.  
Evaporator fan(s) cycled on time and or temperature.  
Unit is cycled by control.  
Defrost Mode  
1.  
2.  
The defrost mode can be entered manually or run automatically.  
When control initiates a defrost cycle, the control snowflake is illuminated.  
A. Defrost heater energized.  
B. Compressor motor de-energized.  
C. Evaporator fan(s) de-energized.  
3.  
4.  
Defrost cycle operates until the EL temperature setting is reached or the maximum DDC time setting has  
elapsed.  
Defrost mode cycled by control.  
F25393 (August 2010)  
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G SERIES FREEZER - ELECTRICAL OPERATION  
COMPONENT LOCATION  
Page 25 of 32  
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G SERIES FREEZER - ELECTRICAL OPERATION  
WIRING DIAGRAMS  
115V/60HZ/1PH  
F25393 (August 2010)  
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G SERIES FREEZER - ELECTRICAL OPERATION  
220V/50-60HZ/1PH  
Page 27 of 32  
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G SERIES FREEZER - TROUBLESHOOTING  
TROUBLESHOOTING  
SYMPTOM  
Nothing runs, blank control.  
POSSIBLE CAUSES  
1.  
2.  
3.  
Main circuit breaker open.  
Main on/off switch off.  
Power cord unplugged.  
Compressor will not run, no current draw.  
1.  
2.  
Cabinet temperature satisfied.  
Door open or malfunction door switch, with display on  
control.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
Incorrect wiring.  
Cabinet air sensor malfunctioned.  
Start component malfunctioned.  
Compressor motor windings open.  
Control malfunctioned.  
Compressor relay malfunctioned.  
Relay module malfunctioned.  
Compressor will not run, current draw and trips  
breaker.  
1.  
2.  
3.  
Start component malfunctioned.  
Compressor motor windings shorted.  
Locked rotor.  
Defrost time too long.  
1.  
2.  
3.  
4.  
Evaporator coil sensor malfunctioned.  
Incorrect wiring.  
Control malfunctioned.  
Defrost heater malfunctioned.  
Compressor short cycles.  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
Improper air flow over evaporator coil.  
Expansion valve malfunctioned.  
Low ambient conditions.  
Evaporator fan(s) malfunctioned.  
Cabinet air sensor malfunctioned.  
Evaporator coil sensor malfunctioned.  
Control malfunctioned.  
Compressor run time lengthy.  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
Partial loss of refrigerant.  
High ambient conditions.  
Improper air flow over condenser coil.  
Excessive product load.  
Excessive door openings.  
Door gasket(s) need replaced.  
Condenser fan(s) malfunctioned.  
Cabinet air sensor malfunctioned.  
Cabinet coil sensor malfunctioned.  
10. Contaminates in refrigeration system.  
11. Control malfunctioned.  
12. Relay module malfunctioned.  
Continuous compressor operation.  
1.  
2.  
3.  
4.  
Loss of refrigerant.  
Excessive door openings.  
Cabinet air sensor malfunction.  
Control malfunctioned.  
Low suction pressure.  
High head pressure.  
1.  
2.  
3.  
Restriction in refrigeration system.  
Loss of refrigerant.  
Expansion valve blocked.  
1.  
2.  
3.  
4.  
5.  
Improper air flow across condenser.  
Extreme ambient conditions.  
Overcharge of refrigerant.  
Air in refrigerant system.  
Condenser fan(s) malfunctioned.  
F25393 (August 2010)  
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G SERIES FREEZER - TROUBLESHOOTING  
POSSIBLE CAUSES  
SYMPTOM  
Iced Evaporator coil.  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
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.  
Will not defrost.  
1.  
2.  
3.  
4.  
5.  
Defrost heater(s) malfunction.  
Incorrect wiring.  
Compressor relay malfunctioned.  
Evaporator coil sensor malfunctioned.  
Control malfunctioned.  
Control display blank.  
1.  
2.  
3.  
4.  
Main power supply.  
Relay module malfunctioned.  
On/off switch malfunctioned.  
Control malfunctioned.  
Page 29 of 32  
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G SERIES FREEZER - TROUBLESHOOTING  
-NOTES-  
F25393 (August 2010)  
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G SERIES FREEZER - TROUBLESHOOTING  
-NOTES-  
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G SERIES FREEZER - TROUBLESHOOTING  
-NOTES-  
F25393 (August 2010)  
Printed in U.S.A.  
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