Service Manual. Solar Direct Drive Vaccine Refrigerator / Freezer. Model :HTC-40/110; HTCD-90 Pictures :

Transcription

1 Internal training document for Haier service providers. External disclosure is forbidden Service Manual Solar Direct Drive Vaccine Refrigerator / Freezer Model :HTC-40/110; HTCD-90 Pictures : HTC-40/110 HTCD-90

2 Contents After-sales service manual of HTC-40/110 and HTCD-90 solar refrigerator I. Product model coding explanation... 3 II. Product appearance and components... 3 III. Unit description... 5 IV. Electric parts and wiring diagram... 5 V. Parameter of refrigerating system and spare parts... 7 VI. Parts layout... 9 VII. Operation guide VIII. Indications and alarm functions IX. Precautions for installation and commissioning X. Replacement guide for key components XI. Transportation conditions, installation environment and package disassembly XII. Test curve

3 I. Product model coding explanation H(Haier)T(solar)C(refrigerator)D(freezer)-90(volume: about 90L) II. Product appearance and components HTC-40/110: Handle Door Water tank cover Inner door Basket Lifting handle Grilling Temperature displayer Hinge Electric cabinet Power switch Fan Compressor Temperature controller Condenser 3

4 HTCD-90 Inner door for refrigerator Door handle Refrigerating chamber Water tank cover Door Inner door for freezer Basket Grilling Freezing chamber Lifting handle Temperature displayer Hinge Fan Electric cabinet temperature controller Compressor for freezer Condenser for refrigerator Compressor refrigerator for Condenser for freezer 4

5 III. Unit description After-sales service manual of HTC-40/110 and HTCD-90 solar refrigerator Parameter HTC-40 HTC-110 HTCD-90 Ambient temperature ( ) +5~+43 +5~+43 +5~+43 Temperature range of refrigerator ( ) +2~+8 +2~+8 +2~+8 Temperature range of freezer ( ) - <-5 <-5 Gross volume(l) Effective volume of vaccine (L) (without basket) (with basket) Freezing volume for ice pack (L) Freezing capacity for ice pack (kg/24h) Storage volume for ice pack (kg) Refrigerant R600a(g) x45 Voltage(DCV) Rated power(w) Auxiliary (Available/Unavailable) battery Exterior dimension(w D H)( mm ) Unavailable Unavailable Unavailable 788*654* *654* *654*875 Weight(kg) Power of solar panel(w) 2*180 2*180 4*180 IV. Electric parts and wiring diagram HTC-40/110,HTCD-90: No Material number Description Quantity Main technical parameter Remark Condensation fan Heater wire Electric temperature controller 1 DC 10V~DC 56V, DC power supply DC 10V~DC 56V, rated Power: 2.6W, revolving speed Rated working voltage:30v, power :28W Working voltage range: DC 10V-DC 45V Working power range:3.1w-63.3w 1 Working voltage: DC 8V-DC 60V Switch 1 AC 240V/DC 60V,50/60HZ,20A Rated specification: AC 240V/DC 60V, 50/60HZ, 20A 5

6 Fuse holder 1 DC 32V/40A Rated voltage/current: DC 32V/40A DC 8V~DC 45V Working voltage range: DC 8V-DC 45V Temperature displayer 1 Temperature range:-50.0 to 70.0, resolution: 0.1 and electric current: less than 0.2A HTCD-90 Two for HTCD-90 HTC-40 HTC-110: Temperature sensor Refrigerating sensor Ice layer sensor Refrigerating compressor Heating Fan Electronic double-way temperature controller Fuse Capacitor Power module Heater strip Double-thro w switch PV input (+) PV output (-) HTCD-90: 6

7 Temperature sensor Freezing sensor Refrigerating sensor Ice layer sensor Freezing compressor Heating Electronic double-way temperature controller Refrigerating compressor Fuse Capacitor Fan Power module Double-thr ow switch PV input (+) PV output (-) Heater strip V. Parameter of refrigerating system and spare parts HTC-40: No Material number Compressor Evaporator Description Quantity Main technical parameter Wire and tube condenser 1 BD-35K (accessories: 101N0400, 10-45Vdc) 1 Blow-up type, flow rate of capillary: 5L/min 1 +Φ1.5 electrophoresis and rust-resistance steel wire of Φ steel tube Dry filter 1 10g Refrigerant 45g R600a Remark Heat pipe 2*18g R134a refrigerant 18g Upper layer A Heat pipe 2*18g R134a refrigerant 18g Lower layer 7

8 HTC-110: After-sales service manual of HTC-40/110 and HTCD-90 solar refrigerator No Material number Compressor Evaporator Description Quantity Main technical parameter Remark Wire and tube condenser 1 BD-35K ( accessories: 101N0400, 10-45Vdc) 1 Blow-up type, flow rate of capillary: 5L/min 1 +Φ1.5 electrophoresis and rust-resistance steel wire of Φ steel tube Dry filter 1 10g Refrigerant 45g R600a HTCD-90: No A Material number Heat pipe Heat pipe Heat pipe Heat pipe Compressor Evaporator Ⅰ Evaporator Ⅱ A 1 R134a refrigerant 20g Left center 1 R134a refrigerant 20g Right center 2 R134a refrigerant 20g Lower layer 2 R134a refrigerant 20g Upper layer Description Quantity Main technical parameter Remark Wire and tube condenser Wire and tube condenser 2 BD-35K ( accessories: 101N0400, 10-45Vdc) 1 Blow-up type, flow rate of capillary: 5L/min 1 Φ6 0.75TP2M 10500mm, 5L/min Dry filter 2 10g 1 +Φ1.5 electrophoresis and rust-resistance steel wire of Φ steel tube 1 +Φ1.5 electrophoresis and rust-resistance steel wire of Φ steel tube Refrigerant 45g R600a Refrigerator Freezer Heat pipe 2 R134a refrigerant 18g Upper layer A Heat pipe 2 R134a refrigerant 18g Lower layer 8

9 Refrigerating schematic diagram After-sales service manual of HTC-40/110 and HTCD-90 solar refrigerator Evaporator 蒸发器 Condenser 冷凝器 Dry 干燥过滤器 filter Capillary 毛细管 Muffler 回气管 Compre 压缩机 ssor Compre 压机油 ssor oil Exhaust pipe 排气管 VI. Parts layout 1. HTC-40 explosive view: 9

10 Refrigerator sensor Ice layer sensor Including the refrigerating control sensor and the display sensor Details of explosive view: 序号 专用号 名称 备注 No. Material number Description Remark 太阳能显示屏 Solar screen 把手总成 Handle assembly B 冷藏内门 Inner door of refrigerator 蒸发器 Evaporator 铰链组装 - 组件 Hinge assembly-component 后背冷凝器 Back condenser 保险丝座 Fuse holder C 太阳能输入线 Solar energy input wire 10

11 电源开关 Power switch A 温控器 Temperature controller 电解电容 Electrolytic capacitor 干燥过滤器 Dry filter 压缩机 Compressor 风机 Fan 风机罩 Fan shield D 筐 Basket 上层热管 Upper heat pipe A 下层热管 Lower heat pipe 蓄热水盒 Hot water tank 加热丝 Heater strip 冷藏室传感器 Refrigerator sensor 冰层传感器 Ice layer sensor 2 HTC-110 explosive view: 11

12 Refrigerator sensor Including the refrigerating control sensor and the display sensor Ice layer sensor Details of explosive view: 序号 专用号 名称 备注 No. Material number Description Remark 太阳能显示屏 Solar screen 12

13 A 把手总成 Handle assembly 铰链组装 - 组件 Hinge assembly-component 冷藏区内门 Inner door of refrigerator 蒸发器 Evaporator 冷凝器 Condenser 保险丝座 Fuse holder C 太阳能输入线 Solar energy input wire 电源开关 Power switch 温控器 Temperature controller 干燥过滤器 Dry filter 电解电容 A A 压缩机 Compressor 风机 Fan 风机罩 Fan shield 热管 Heat pipe 热管 Heat pipe 热管 Heat pipe 热管 Heat pipe 左侧中间 Left center 右侧中间 Right center 下层 Lower layer 上层 Upper layer 蓄热水盒 Hot water tank C 加热丝 Heater strip 大筐 Large basket 13

14 冷藏室传感器 Refrigerator sensor 冰层传感器 Ice layer sensor 3. HTCD-90 explosive view: Refrigerator sensor Freezing chamber sensor Ice layer sensor Including the refrigerating control sensor and the display sensor Including the freezing control sensor and the display sensor Details of explosive view: 序号 专用号 名称 备注 No. Material number Description Remark 14

15 太阳能显示屏 Solar screen 把手总成 Handle assembly 冷冻内门组装 Inner door of freezer 冷藏内门组装 Inner door of refrigerator 铰链组装 - 组件 Hinge assembly-component A 冷凝器 Condenser 冷凝器 Condenser 远压机 Far-end compressor 近压机 Near-end compressor 蒸发器 Evaporator C 太阳能输入线 Solar energy input wire 电源开关 Power switch 温控器 Temperature controller 保险丝座 Fuse holder 干燥过滤器 Dry filter 电解电容 Electrolytic capacitor A 压缩机 Compressor 风机 Fan 风机罩 Fan shield 热管 Heat pipe A 热管 Heat pipe 上层 Upper layer 下层 Lower layer C 筐 Basket 15

16 蓄热水盒 Hot water tank 加热丝 Heater strip 冷藏室传感器 Refrigerator sensor A 冷冻室传感器 Freezer sensor 冰层传感器 Ice layer sensor VII. Operation guide Temperature controller (in the electric cabinet of the product) 1. Ice layer sensor: control the startup and shutdown of refrigerator compressor. The parameter setting is SP1, which can be automatically adjusted as per the environment and cannot be manually adjusted. 2. Refrigerator sensor: control the heating, startup and shutdown of the heat storage module. The parameter setting is SP2, which can be manually adjusted. 3. Freezing sensor: control the startup and shutdown of freezing compressor. The parameter setting is SP3, which can be manually adjusted. 4. Ambient temperature sensor: have no display or control function 5. Sensor of refrigerator temperature displayer: have the display function rather than the control function 6. Sensor of freezer temperature displayer: have the display function rather than the control function 参数 描述 最小值 最大值 单位 默认值 Parameter Description Minimum value Maximum value Unit Default SP1 控制温度 1 r1 r0 o C 0 Control temperature 1 SP2 控制温度 2 Control temperature 2 r1 r0 o C 4 SP3 控制温度 3 Control temperature 3 r3 r2 o C -12 r0 SP1/SP2 可设置温度最大值 r o C

17 r1 r2 r3 After-sales service manual of HTC-40/110 and HTCD-90 solar refrigerator SP1/SP2: able to set the maximum temperature SP1/SP2 可设置温度最小值 SP1/SP2: able to set the minimum temperature SP3 可设置温度最大值 SP3: able to set the maximum temperature SP3 可设置温度最小值 SP3: able to set the minimum temperature r0 r r2 o C 2.0 o C 0.0 o C The controller will be locked automatically and the buzzer will be run for about 0.5s when the temperature controller setting is made and no operation is made via any key within 3min. Please press the and the key for 5 seconds to unlock or lock the controller. At the same time, the buzzer will be run for about 0.5s. When the controller is locked, no operation is allowed. The operation can only initialize when unlocking the controller. Press and hold the key for 5s in the unlocking state. Then, the ice layer display window will flash and display SP1 and the freezer display window will flash and display the target value of ice layer (corresponding value +CA0 can be worked out according to the ambient temperature table). Such target value cannot be set, but can be modified via CA0. Press and hold the key for 5s in the unlocking state. Then, the ice layer display window will flash and display SP3 and the freezer display window will flash and display the freezer target value. The parameter value can be adjusted via the or the. Press and hold the for 5s to save the data once the parameter value is set. Press and hold the key for 3s in the unlocking state. Then, the ice layer display window will flash and display SP3 and the freezer display window will flash and display the refrigerator target value. The parameter value can be adjusted via the or the. Press and hold the for 5s to save the data once the parameter value is set. Note: the buzzer of this product model is turned off by default when being delivered and only the alarm code is displayed! II. Parameter setting of general menu 1. Press the key for more than 5S to display the parameter code PS (password) on the screen; 2. Roll the parameters (PS, AH1,AL1,AH2,AL2,AH3,AL3) with the and the key; 3. Press the key to confirm the parameter and display the parameter value; 4. Increase or decrease the parameter value with the or the key; 5. Press the key to store the modified parameter value temporarily and to return to displayed parameter; 6. Repeat the step 3 to 5 to modify other parameters; 7. Press the key for more than 5s to save the modified parameter and return to the normal condition. The controller parameters are covered in the general menu and the management menu. General menu 17

18 参数 Parameter PS AH1 AL1 AH2 AL2 AH3 AL3 描述 Description 访问管理菜单的密码 Access password of management menu 冰层高温报警温度 High temperature alarm of ice layer 冰层低温报警温度 Low temperature alarm of ice layer 冷藏室高温报警温度 High temperature alarm of refrigerator 冷藏室低温报警温度 Low temperature alarm of refrigerator 冷冻室高温报警温度 High temperature alarm of freezer 冷冻室低温报警温度 Low temperature alarm of freezer 最小值 Minimum value 最大值 Maximum value 单位 Unit 默认值 Default AL oc AH1-0.1 oc AL oc AH2-0.1 oc 2.0 AL oc AH3-0.1 oc III. Alarm description 显示符号 Displayed symbol Er1 Er2 Er3 Er4 AH1 AL1 AH2 AL2 AH3 符号说明 Symbol description 蓄冰传感器故障 Ice storage sensor failure 冷藏传感器故障 Refrigerating sensor failure 冷冻传感器故障 Freezing sensor failure 环温传感器故障 Ambient temperature sensor failure 冰层高温报警 High temperature alarm of ice layer 冰层低温报警 Low temperature alarm of ice layer 冷藏高温报警 High temperature refrigerating alarm 冷藏低温报警 Low temperature refrigerating alarm 冷冻高温报警 18

19 AL3 IV. After-sales service manual of HTC-40/110 and HTCD-90 solar refrigerator High temperature freezing alarm 冷冻低温报警 Low temperature freezing alarm Schematic diagram for connection Ice layer Refrigeratin g Freezing Heater strip Power supply Ice layer Refrigera Freezing Ambient ting temperatur e 1. Please confirm if the voltage of the power supply can meet the power supply requirements for controller. Otherwise, the instrument may fail to be run normally or be burned. 2. Color of sensor terminal: Ice layer sensor: blue Refrigerating sensor: red Freezing sensor: yellow Ambient temperature sensor: white Introduction to temperature displayer (on the product door): 温度显示区 Temperature display area 太阳能接收区 solar energy receiving area 温度显示区 temperature display area 太阳能接收区 solar energy receiving area Note: one temperature displayer is shared by HTC-40 and HTC-110; Two temperature displayers are applicable to HTCD-90. REFRIGERATOR---display the temperature of the refrigerator. FREEZER---display the temperature of the freezer. This displayer has the solar energy power supply function that the additional circuit connection is not required. This displayer only indicates the internal temperature and is unable to control any refrigerating system and others of the product. In the operation process, do not shield the solar energy receiving area. Otherwise, the temperature display area may fail to run. 19

20 VIII. Indications and alarm functions Alarm function of temperature controller: The parameters have been set before the delivery, which cannot be changed by the user. Displayed symbol Symbol description Alarm mode Alarm reset mode Er1 续冰传感器故障 Ice storage sensor failure 代码闪烁 Blinking codes 检修蓄冰传感器 Maintenance of ice storage sensor Er2 冷藏传感器故障 Refrigerating sensor failure 代码闪烁 Blinking codes 检修冷藏传感器 Maintenance of refrigerating sensor Er3 冷冻传感器故障 Freezing failure sensor 代码闪烁 Blinking codes 检修冷冻传感器 Maintenance of freezing sensor Er4 环温传感器故障 Ambient temperature sensor failure 代码闪烁 Blinking codes 检修环温传感器 Maintenance of ambient temperature sensor AH1 冰层高温报警 High temperature alarm of ice layer 代码闪烁 Blinking codes 温高降温后自动解除或者检修传感器 Automatic recover when the high temperature is dropped or maintenance of sensor AL1 冰层低温报警 Low temperature alarm of ice layer 代码闪烁 Blinking codes 环温过低导致水箱过冷冻 Over-freezing of water tank due to excessively-low ambient temperature AH2 冷藏高温报警 High temperature refrigerating alarm 代码闪烁 Blinking codes 温高降温后自动解除或者检修传感器 Automatic recover when the high temperature is dropped or maintenance of sensor AL2 冷藏低温报警 Low temperature refrigerating alarm 代码闪烁 Blinking codes 检查加热功能, 检修传感器 Check of sensor heating function and maintenance of AH3 冷冻高温报警 High temperature freezing alarm 代码闪烁 Blinking codes 温高降温后自动解除或者检修传感器 Automatic recover when the high temperature is dropped or maintenance of sensor AL3 冷冻低温报警 Low temperature freezing alarm 代码闪烁 Blinking codes 检查环温是否过低, 导致箱内温度过低, 或检修传感器 Check if the low inner temperature is caused by the ambient temperature or maintain the sensor. 20

21 IX. Precautions for installation and commissioning Precautions for product installation: 1. The equipment shall be installed in a sunny day with sufficient daylight. Please carefully go through this instruction before the installation. 2. Before installing the solar panel, please carefully learn the accompanying installation video. 3. Confirm if the solar panel is installed on the solid ground. The open space which is not easily to be shielded and is easy to be scrubbed is recommended. 4. Select the installation angle matching with the local lighting conditions. 1) The solar panel shall face to the equator. Namely, it shall face toward the south direction in the Northern Hemisphere and toward the north in the Southern Hemisphere. 2) The dip angle of the solar panel is subject to the terrestrial latitude of the installation location. The general dip angle of the solar panel is as shown in the figure below. 3) For the user near the equator, the installation angle of the solar panel shall not be too small, to ensure that the rainwater can smoothly flow down. 5. The ground rod shall be inserted into the ground at the depth of 1.5m and be spaced to those of other products by 2m at least. The ground lead shall be firmly fixed. 6. The refrigerator shall be placed in the cool and well-ventilated location and be kept away from the direct solar radiation. The ground shall be flat. The refrigerator shall be installed in such a way that each side shall be distanced by 15cm from the wall at least, to guarantee the good radiation. The ground shall be kept clean, to avoid the blockage of the front and rear cabin. 7. Precautions for water feeding of water tank: 1) Please go through the stickers on the water tank before feeding water. 2) Pour the corrosion inhibitor into the water tank first and then add the purified water until reaching the water level. 3) Install the water injection plug in place again after feeding the water. 4) Please keep the corrosion inhibitor away from the children and appropriately dispose the empty bottle. 8. This product is supplied without the truckle. Please lift the box body via the lifting handle on both sides in the process of transferring. Do not drag the product by force. Introduce the usage to the user: when the solar panel and the refrigerator are installed in place, please correctly connect the connecting line of the solar panel system as per the requirements. Test the solar connecting line with a multimeter to confirm the anode and the cathode. 21

22 9. Connect the solar power supply line to the plug of the refrigerator. 10. Open the front shield of the refrigerator cabin, correctly connect the wire, power on the temperature controller and display the current temperature. If no display is given, please immediately cut off the power supply and check the power supply polarity. The water tank temperature is displayed on the upper display, while the freezer temperature is displayed on the lower display. The water tank temperature is displayed on the upper display, while the freezer temperature is displayed on the lower display. Note: for HTC-40 and HTC-110, only the upper screen is applicable. For HTCD-90, the two screens are applicable. X. Replacement guide for key components 10.1 Precautions for disassembly and installation Be sure to disconnect the power plug in the disassembly and installation process; Please install the product in reverse order. Any component must be assembled in its specified locations in the process of installation Disassembly and installation guide for key components Replacement of compressor E-box Fixing bolt x4 Muffler of compressor Exhaust pipe of compressor Process pipe 22

23 When the compressor fails and the replacement is required, please follow the steps below: 1. Disconnect the plug on the compressor accessories (E-box); 2. Discharge the refrigerant from the refrigerating system via the process pipe (be sure to stay away from the fire); 3. Burn off the exhaust pipe of return-gas box after emptying the refrigerant from the system (rinse the system with nitrogen and burn the pipeline with the welding gun, if possible); 4. Remove the compressor fixing screws (4) with a 10mm open spanner; 5. Replace the compressor with a new one, fix and connect the pipeline as per the original; 6. Replace the process pipe with a new one, pump off the system (until the pressure is below 3p) and re-fill 45g of 600a refrigerant (±1g). 7. Seal the process pipe. Precaution: 1. As the moisture requirement for the system is very strict, the machine pipeline shall be immediately sealed after being opened, to avoid the moisture invade from the air. It is required that each opened pipelined shall be welded within 10min. 2. Before welding the pipeline, be sure to empty the refrigerant in the system. Especially, when spraying the oil mist, the open air shall be avoided, to avoid the fire disaster and the fire blast. As the inflammable and explosive R600a refrigerant is used by the product, be sure to provide the good ventilation in the working environment. Replacement of 15A fuse (in the electric cabinet) The rated current of this fuse is 15A. The fuse is located in the electric cabinet of the refrigerator, which shall be replaced according to the steps below: Fuse size Appearance of fuse 1. Open the rear cover of electric control box; 2. Take out the protective shell of fuse holder; Replacement of fan: When the fan fails and the compressor fails and the replacement is required, please follow the steps below: 1. Disconnect the fan connecting plug on the compressor accessories (E-box); 2. Carefully spread the plastic claws (4 pcs) for clamping the fan and take out the fan. 3. Install a new fan and mind the wind direction of the fan (by blowing to the compressor). 4. Connect the fan connection terminal and mind the cathode and the anode (the red wire is the cathode). 23

24 Connect the fan terminal on the compressor accessory. The 3rd and 4th terminals are the fan connection terminals. Fig.1 Disassembly of rear cabin grilling 卡爪 Claws Fig.2 Carefully spread claws (4 PCS) Replacement of electric temperature controller: When the electric temperature controller fails and the compressor fails to be started normally, please replace the electric temperature controller according to the steps below: 1. Open the electric cabinet on the back; 2. Take out the connection wire of the temperature controller to be replaced; 3. Replace the failed temperature controller with a new one. 4. Connect to the power supply and select the temperature controller as per the equipment model. Fig.1 Removing electric cabinet cover Fig.2 Taking out and replacing temperature controller Note: please connect the temperature controller to the power supply after the replacement and 24

25 adjust the PCH value according to the aforesaid adjustment method. PCH product model options 1:HTCD-160 2:HTC-60H- 3:HTC-40 4:HTCD-90 5:HTC-110 6:HTD-60 7:HTC-200 XI. Transportation conditions, installation environment and package disassembly 1. Transportation and transferring conditions (1) The inclination angle of refrigerating shall not be greater than 45 in the process of transferring. (2) Please note that the refrigerator must be transferred with a dedicated dumper or a forklift. It is forbidden to slide or throw the refrigerator from the high place. (3) To avoid the personal injury or the refrigerator damage, mind you step when transferring the refrigerator. (4) Do not try to lift or transfer the equipment via the door handle, to avoid refrigerator damage or personal injury. 2. Installation environment (1) The ambient temperature: is 5 to 43 and the optimal temperature is18 to 32. Use the air conditioning system in the extreme weather. (2) Ambient humidity: less than 85%Rh (3) Do not install the refrigerator (freezer) in the dusty condition. (4) Take measures to avoid the rock or vibration. (5) Altitude of refrigerator: less than 2000m (6) Please locate the refrigerator in the bright location without direct solar radiation. 3. Package disassembly (1) Open the package by lifting the carton box with several hands. (2) Open the package by lifting the carton box with several hands. (3) Take down the cork base. Note: the inclination angle of the refrigeration shall not be greater than 45 in the above process. Please attach importance to the safety in this process, to avoid unnecessary personal injury. 25

26 XII. Test curve HTC-40 curves: Description 1. This test curve is made at the ambient temperature of 43 ; 2. When the product is normally connected to the power supply by the user, the inner temperature of the box can reach 2-8 for about 4 days when the light is sufficient. HTC-110 curves: Description 1. This test curve is made at the ambient temperature of 43 ; 2. When the product is normally connected to the power supply by the user, the inner temperature of the box can reach 2-8 for about 4 days when the light is sufficient. HTCD-90 curves: 26

27 Description: 1. This test curve is made at the ambient temperature of 43 ; 2. When the product is normally connected to the power supply by the user, the inner temperature of the box can reach 2-8 for about 4 days when the light is sufficient; 3. The freezer is applicable only when the inner temperature is below-5. 27

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