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Norcold 1200 Series User Manual

Norcold 1200 Series
67 pages
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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.
Service Manual
Publication No. 618968B (02-18-05)
© 2005 THETFORD CORP., NORCOLD, INC. All rights reserved.
INC.
!
WARNING
Gas/Electric Refrigerators
120X-IMXX
1200XX
MODELS

Table of Contents

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Norcold 1200 Series Specifications

General IconGeneral
TypeAbsorption Refrigerator
Interior LightYes
RefrigerantAmmonia
Power SourceAC, DC, LP Gas
Capacity12 cubic feet

Summary

Introduction to Norcold Refrigerators

About this Manual

Provides maintenance, diagnostic, and repair information for Norcold refrigerators.

Model Identification

Explains the 2-way refrigerator models and factory-installed accessories.

Information Label Location

Details the location and content of the refrigerator's information label.

Cooling Unit Serial Number

Specifies the location of the cooling unit's unique serial number.

Certification and Code Requirements

Lists relevant standards and certifications for the refrigerators.

Installation Guidelines

Outlines requirements for proper refrigerator installation.

Replacement Parts

Recommends using only authorized Norcold replacement parts for safety.

Technical Assistance

Provides contact information for technical support.

Safety Awareness for Norcold Refrigerators

Safety Notice

General safety precautions and disclaimer for servicing.

Attention Statements

Explanation of warning and caution alert symbols.

Safety Statements

Critical safety warnings regarding LP gas, electrical, and unit operation.

Specifications for 1200XX/120X-IMXX Models

Storage Volume

Details freezer and fresh food compartment capacities.

Rough Opening Dimensions

Provides installation dimensions for the refrigerator enclosure.

Decorative Panels Dimensions

Specifies dimensions for decorative door panels.

Controls Specifications

Details control type, temperature settings, and sensor.

Off-level Operating Limits

Maximum tilt angles permitted for side-to-side and front-to-back operation.

DC Power Specifications

Covers operating voltage, fuse, and amp draws.

AC Power Specifications

Details operating voltage, fuse, and power rating.

LP Gas (Propane) Specifications

Includes operating pressure, heat input, and orifice details.

Troubleshooting – Quick Reference Guide

Refrigerator Does Not Turn ON

Troubleshooting steps for the refrigerator failing to power on.

Refrigerator Does Not Cool on AC Power

Troubleshooting guide for cooling issues when on AC power.

Refrigerator Does Not Cool Efficiently on AC Power

Steps to diagnose inefficient cooling on AC power.

Refrigerator Does Not Operate on LP Gas

Troubleshooting for problems with LP gas operation.

Refrigerator Does Not Cool Efficiently on LP Gas

Steps to diagnose inefficient cooling on LP gas.

"No" "co" Fault Code

Troubleshooting flowchart for the 'no co' fault code.

Displayed Fault Codes: S/N 832170 and Lower

LEDs Off Fault

Troubleshooting for 'LEDs off' fault code indicating unit off or no power.

"no" Flashing Fault

Troubleshooting for 'no' flashing fault code (burner failure).

"FS" and "Sr" Flashing Fault

Troubleshooting for flame sense circuit failure.

"dc" and "LO" Flashing Fault

Troubleshooting for low DC voltage fault.

"dc" and "HI" Flashing Fault

Troubleshooting for high DC voltage fault.

"no" Flashing (AC LED Flashing) Fault

Troubleshooting for 'no AC' fault code.

Displayed Fault Codes: S/N 832170 and Lower (Continued)

"Sr" and "CL" Flashing Fault

Troubleshooting for AC relay stuck closed fault.

"LO" Flashing Fault

Troubleshooting for AC voltage low fault.

"HI" Flashing Fault

Troubleshooting for AC voltage high fault.

"Sr" and "OP" Flashing Fault

Troubleshooting for AC heater failed open fault.

"dr" Flashing Fault

Troubleshooting for door open fault.

Temperature LED Flashing Fault

Troubleshooting for backup operating system mode.

Displayed Fault Codes: S/N 832171 and Higher

Blank Display Screen Fault

Troubleshooting for blank display, unit off or no power.

no.FL Fault

Troubleshooting for burner failure to ignite or reignite.

Sr. Fault

Troubleshooting for flame sense circuit failure.

dc.LO. Fault

Troubleshooting for low DC voltage.

dc.HI. Fault

Troubleshooting for high DC voltage.

no.AC. Fault

Troubleshooting for no AC power available.

AC.FE. Fault

Troubleshooting for AC relay stuck closed.

AC.LO. Fault

Troubleshooting for AC voltage low.

AC.HI. Fault

Troubleshooting for AC voltage high.

AC.HE. Fault

Troubleshooting for AC heater failed open.

dr. Fault

Troubleshooting for door open for more than 2 minutes.

Flashing Temp Setting Fault

Troubleshooting for backup operating system.

no.co Fault

Troubleshooting for no cooling detected by controls.

Troubleshooting Flowcharts

Blank Display – Refrigerator Does Not Turn On

Flowchart to diagnose refrigerator not turning on.

Troubleshooting Flowcharts (Continued)

No LP - No FL Fault Code – Burner Failed to Ignite or Reignite

Flowchart for burner ignition or reignition failure.

Displayed Fault Codes (Continued)

Sr FS - Sr Fault Code - Flame Sense Circuit Failure

Troubleshooting for flame sense circuit failure.

dc LO Fault Code – Low DC Voltage

Troubleshooting steps for low DC voltage.

Displayed Fault Codes (Continued)

dc HI Fault Code – DC Voltage High

Troubleshooting steps for high DC voltage.

Sr CL - AC rE Fault Code – AC Relay Stuck Closed

Troubleshooting for AC relay stuck closed fault.

Displayed Fault Codes (Continued)

no AC Fault Code – No AC Power Available

Troubleshooting guide for lack of AC power.

Displayed Fault Codes (Continued)

AC LO Fault Code – AC Voltage Low

Troubleshooting steps for low AC voltage.

AC HI Fault Code – AC Voltage High

Troubleshooting steps for high AC voltage.

Displayed Fault Codes (Continued)

AC HE Fault Code – AC Heater Failed Open

Troubleshooting for AC heater failure.

Displayed Fault Codes (Continued)

dr Fault Code – Door Open for More Than 2 Minutes

Troubleshooting for door open fault.

Thermistor Failure Fault

Controls in Backup Operating System Mode

Explanation of the Backup Operating System (BOS) function.

no co Fault Code

Power Board Resetting Procedure

Step-by-step guide to reset the power board.

VENTILATION

Roof Exhaust Venting

Guidelines for roof exhaust vent installation.

Air Intake Vent

Description of the air intake vent for combustion and ventilation.

Roof Exhaust Vent

Details of the roof exhaust vent system.

VENTILATION (Continued)

Baffles

Information on minimum and maximum clearances for baffles.

Vertical Angled Baffles

Requirements for angled baffles in specific installations.

Double Sidewall Venting

Air Intake Vent

Air intake vent description for slide-out applications.

Sidewall Exhaust Vent

Sidewall exhaust vent description for slide-out applications.

LP GAS SYSTEM

Pressure Requirements

Details LP gas pressure requirements and warnings.

Testing for LP Gas Leaks

Solenoid Gas Valve

Description and operation of the solenoid gas valve.

Solenoid Gas Valve Connections

Specifies inlet and outlet fitting sizes for the solenoid valve.

Replacing Old Style Gas Valve

Information on using conversion kits for old style valves.

Orifice

Burner

Burner Tube

Flue System Components

Flue

Description of the flue, baffle, and cap.

Flue Cap

Function of the flue cap in deflecting gases and preventing debris.

Flue Baffle

Description and maintenance of the flue baffle.

Flame Appearance

Description of correct and incorrect flame appearance.

Burner Cleaning Procedure

Warning

Safety warning regarding burn hazards during cleaning.

Caution

Precautionary note about gas leaks and burner tube damage.

Note

Important note on cleaning burner slots.

ELECTRICAL REQUIREMENTS AND COMPONENTS

DC Voltage Requirements and Polarity

Specifies DC voltage range and terminal connections.

Power Board DC Fuse

Information on the DC fuse location and rating.

DC Power Wiring Requirements

Guidance on wire gauge and fuse size for DC power.

AC/DC Converter as Power Source

Requirements for AC/DC converters used as a power source.

Lamp/Thermistor Assembly

Description of the fresh food compartment lamp and thermistor.

Divider Heater

Description of the permanently installed divider heater.

AC Power Requirements

AC Heaters

Details on the two cartridge-type AC heaters.

AC Heater Circuit Fuse

Specifies the AC heater circuit fuse type and rating.

Power Board AC Power Cord

Information regarding the AC power cord and grounding.

Ice Maker Power Cord

12 Vdc Ventilation Fans

COOLING UNIT

Description

Overview of the self-contained gravity flow absorption refrigeration system.

Heat Absorption

Explanation of how heat is absorbed and airflow is created.

Leveled Operation

Importance of operating the refrigerator level to avoid damage.

Gradual Decrease in Cooling Efficiency

Factors that can cause a gradual decrease in cooling efficiency.

Cooling Performance Monitoring Control

Details the control for serial numbers 832171 and higher.

Cooling Unit Monitoring Control Operation

First "no co" Fault Code

Refrigerant Leakage

Disposal of Cooling Unit

Cooling System Diagnostic Flowchart

Warning

Caution against bypassing controls or wiring heater directly.

Cooling System Diagnostic Flowchart (Continued)

Warning

Warning not to operate if cooling unit is leaking.

Replacing the Cooling Unit

Note

Important note on saving screws during replacement.

Ice Maker and/or Dispenser Models

Specific steps for models with ice maker or dispenser.

Removing the Refrigerator and Cooling Unit

Procedure for removing the refrigerator and cooling unit.

Removing Cooling Unit

Ice Maker and/or Dispenser Models

Specific steps for ice maker/dispenser models.

Installation of Replacement Cooling Unit

Steps for installing a new cooling unit.

Caution

Warning against using non-approved sealants.

Note

Guidance on correct sealant application.

Installation of Replacement Cooling Unit (Continued)

Note

Important note regarding sealant application for optimal performance.

Reinstallation of Refrigerator into Enclosure

Warning

Warning about damaged combustion seals and LP gas exhaust.

Ice Maker and/or Dispenser Models

Specific steps for ice maker/dispenser models during reinstallation.

ELECTRONIC COMPONENTS

Power Board

Description and location of the power board.

Removal-Power Board

Step-by-step procedure for removing the power board.

Installation-Power Board

Step-by-step procedure for installing the power board.

Note

Important note regarding AC heater wire connections.

Ice Maker and/or Water Dispenser Units

Specific steps for ice maker/dispenser units during power board service.

CONTROLS

TEMP SET Switch

Function of the temperature setting switch.

Two 7-Segment LED Display

Description of the display showing mode, faults, and info.

Power Switch

Function of the power switch for turning the unit on/off.

MODE Switch

Function of the mode switch for selecting operation modes.

Optical Control Assembly

Description of the control assembly interface.

Replacing Optical Control Assembly

Procedure for replacing the optical control assembly.

Modes of Operation, S/N 832170 and Lower

AUTO Mode

Explanation of the AUTO mode's heat source selection.

AUTO AC Operation

Details on how AUTO AC operation works.

Note 1

Information on momentarily displaying the heat source in use.

AUTO LP Operation

Details on how AUTO LP operation works when AC is unavailable.

Shift from AUTO LP GAS to AUTO AC

How the controls shift from LP to AC mode.

No AC Power and No Flame

Troubleshooting steps for no AC power and no flame.

Note 2

Information on 'gas lock-out' clearing.

Troubleshooting No Flame and No AC Faults

References for correcting ignition and 'no AC' faults.

AC Manual Mode

LP Manual Mode

No AC Power or Loss of AC Power

AC Power Restored

Troubleshooting "no AC" Fault

Flame Fails to Ignite or Flame Goes Out

Modes of Operation, S/N 832171 and Higher

AUTO Mode

Explanation of the AUTO mode's heat source selection.

AUTO AC Operation

Details on how AUTO AC operation works.

Note 4

Information on momentarily displaying the heat source in use.

AUTO LP Operation

Details on how AUTO LP operation works when AC is unavailable.

Shift from AUTO LP GAS to AUTO AC

How the controls shift from LP to AC mode.

No AC Power and No Flame

Troubleshooting steps for no AC power and no flame.

Note 5

Information on 'gas lock-out' clearing.

Troubleshooting No Flame and No AC Faults

References for correcting ignition and 'no AC' faults.

AC Manual Mode

LP Manual Mode

No AC Power or Loss of AC Power

AC Power Restored

Troubleshooting "no AC" Fault

Flame Fails to Ignite or Flame Goes Out

DIAGNOSTIC MODE - UNITS S/N 832171 AND ABOVE

Accessing the Diagnostic Mode

Procedure to access the diagnostic mode.

Changing Screens

Instructions on how to navigate through diagnostic screens.

Exiting the Diagnostic Mode

Procedure to exit the diagnostic mode.

Screens and Diagnostic LEDs Information, Units with S/N 832170 and Lower

Screen 1, LED Segments Reliability Check

Verifies LED screen and light operational status.

Screen 2, LED Segments Reliability Check

Confirms reliability of display segments and lights.

Screen 3, Inputs and Outputs

Displays real-time activity of the refrigerator.

Screen 4, Inputs and Outputs

Displays real-time activity of the refrigerator.

Screen 5, Stored Fault History

Shows stored fault history using LED lights.

Screen 6, Stored Fault History

Shows stored fault history using LED lights.

Screens and Diagnostic Information

Screen 7, Fin Temperature

Displays actual fin temperature sensed by the thermistor.

Screen 9, AC Heater Current

Shows AC heater current measured by the controls.

Screen 8, AC Input Voltage

Displays AC input voltage measured by the controls.

Screen 0, DC Input Voltage

Displays DC voltage measured by the controls.

DIAGNOSTIC MODE - UNITS S/N 832171 AND ABOVE

Accessing the Diagnostic Mode

Procedure to access the diagnostic mode.

Changing Screens

Instructions on how to navigate through diagnostic screens.

Exiting the Diagnostic Mode

Procedure to exit the diagnostic mode.

Screens and Diagnostic Segments Information

Screen 1 Diagnostic Mode Active

Confirms diagnostic mode is active and LEDs are lit.

Screen 2 LED Segments Reliability Check

Checks reliability of display segments; lights should be off.

Screen 3 Thermistor Fin Temperature

Displays fin temperature sensed by the thermistor.

Screen 4 Stored Fault History

Shows stored fault history using LED segments.

Screen 5 Stored Fault History

Shows stored fault history using LED segments.

Screen 6 Erase Fault History

Procedure to erase fault history from memory.

Screens and Diagnostic Information (Continued)

Screen Power Board Inputs

Displays live power board inputs using LED segments.

Screen Power Board DC Voltage Status

Shows DC voltage status and assigned LED segments.

Screen Power Board Outputs

Displays live power board outputs using LED segments.

Screen Power Board AC Voltage Status

Shows AC voltage status and assigned LED segments.

WIRING PICTORIALS AND DIAGRAMS - SN 832170 AND BELOW

WIRING PICTORIALS AND DIAGRAMS - SN 832170 AND BELOW (Continued)

WIRING PICTORIALS AND DIAGRAMS - SN 832171 AND ABOVE

WIRING PICTORIALS AND DIAGRAMS - SN 832171 AND ABOVE (Continued)

ICE MAKER COMPONENTS AND SERVICE

Specifications

Details ice maker cycle, capacity, and electrical ratings.

Wire Harness

Description of the ice maker wire harness connections.

Replacing Ice Maker

Note

Note on saving screws and components during replacement.

Installation of Replacement Ice Maker

Procedure for installing a replacement ice maker.

Cycle Testing Ice Maker

Checking Water Valve Operation

Ice Maker Troubleshooting Chart

Water Valve Service (Models without Water Dispenser)

Checking Mold Heater Resistance

Checking Voltage to Motor

Winterization

Water Fill Adjustment

Caution!

Warning about turning the water fill adjustment screw.

Checking Water Valve Solenoid Resistance

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