Service Manual. Solar Direct Drive Vaccine refrigerator. Haier Medical and Laboratory Products Co,.Ltd. Model:HTC-60H & HTCD-160.

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1 No.: HMRSM Service Manual Solar Direct Drive Vaccine refrigerator Model:HTC-60H & HTCD-160 Pictures: HTC-60H HTCD-160 Haier Medical and Laboratory Products Co,.Ltd

2 Contents 1. Model definition Features and improvement Specification Appearance and part name Dimension of products Operating instructions of controller Electrical principle diagram Maintenance Troubleshooting Explosive view &Spare part list

3 1. Model definition H T C 60 H The first letter of Hot (for tropical climate) The gross volume The first letter of Chinese word-cang The first letter of Chinese word -Tai The first letter of Haier H T C D-160 The gross volume of refrigerator and freezer The first letter of Chinese word -Dong The first letter of Chinese word -Cang The first letter of Chinese word -Tai The first letter of Haier 2. Features and improvement 2.1 The function a. Use solar panels or battery to drive the refrigerator & freezer. 2

4 than -5 ) b. The temperature of cabinet always keeps within 2 to 8 (The freeze space of HTCD-160 is no higher c. Long holding time d. Adapt high ambient temperature from +5 to +43 3

5 e. Overheat and low temperature protection, Make sure the temperature is within 2 to 8 f. PCM Thermal storage material, Ensure uniformity g. Patent technology for conduction, better unigormity. 2.2Improvement 4

6 a. The improved model: HTC-60H can adapt to a wider range of ambient temperature radiation. b. The old model HTC-60 has the inner condenser, but the new one has the back condenser which is better for heat c. The cable from solar panel is connected with the main switch through the conductor-terminal in the model HTC-60, which can t avoid error. The new model HTC-60H has the fast plugs which can be connected with the wires from solar panel d. There are VIP in the insulation foaming layer, which can extend the holding time e. Thermal storage material fixed with heater to avoid higher temperature in the cabinet f. HTCD is a new designed product, upright, chill and freeze combined refrigerator. 5

7 3. Specification MODEL HTC-60H HTCD-160 Ambient temperature( ) +5~+43 +5~+43 The chill space temperature( ) +2~+8 +2~+8 The freeze space temperature( ) - <-5 Gross volume of chill space(l) Vaccine storage capacity(l) Gross volume of freeze space(l) - 40 Icepack freeze capacity(kg/24h) Icepack storage capacity(kg) Refrigerant(g) 45 3x45 Rated voltage(dc.v) Rated power(w) Auxiliary battery(y/n) Y N Dimensions(W*D*H)mm 788x693x x825x1695 Weight(kg) (No water in water box) Solar panel power(w)

8 4. Appearance and part name HTC-60H: Knob Door Condenser Upper Cold Storage box Basket Cover Hinging Ice pack Lower Cold storage box Evaporator Drain port Thermostat HTCD-160 Upper door Temperature display panel Hinging Handle Cable cover Lock Cabin Castor Foot 7

9 Water inlet Water level gauge Water tank Inner door-chill space Inner handle Freeze space Sensor Sensor Shelf Energy storage module Hot pipe cover Controller Capacitor Fan Electric control box Condenser Compressor Water collect box 8

10 5. Dimension of products HTC-60H: HTCD-160: 9

11 6. Operating instructions of controller HTC-60H controller: 6.1 Lock and unlock a. Unlock Press and button for 3 s, the controller will be unlocked. b. Lock If no button operation in 3 minutes, the controller will be locked automatically, and the buzzer sounds for about 0.5 s. When the controller is locked, no operation can be done. 6.2 Function declaration The display screen can show 3digit bits, one - symbol and 5 symbols (cool, power, lock, alarm, defrost) 1 Cooling: Cool /heat symbol, when cooling,the mark will show, when heating, the mark will twinkle. 2 Power : When the voltage of power is higher than 8.9v, the symbol will be lighted, when it is lower than 8.5v and the keep time is longer than Ad value, it will twinkle. 3 Lock status: 10

12 When the controller is locked, the symbol will be lighted. 4 Alarm: When the controller is in alarm condition, this symbol will twinkle. 5 Defrosting: When the controller is in alarm condition, this symbol will twinkle. 6.3 The method of controller setting Parameter settings of the regular menu 1. Press and hold for more than 3s till the parameter code PS (password) is shown on the display; 2. Adjust parameters with and (PS, AH1, AL1, AH2, AL2); 3. Press to confirm the parameter and the value of the parameter will be displayed; 4. Increase or decrease the value of this parameter with and ; 5. Press to temporarily store the modified parameters and return to the parameter display; 6. Repeat steps 3 to 5 to modify other parameter values (if required); 7. Press and hold for more than 3 seconds to store the modified parameter values and return to normal state. Note: The system will exit the settings automatically without saving the parameters and the controller will be locked if there is no button operation in 3 minutes. Regular Menu Parameter Description Min. Value Max. Value Unit Default Value PS Password of access to the management menu AH1 High temperature alarm temperature AL AL1 Low temperature alarm temperature AH1-0.1 AH2 High temperature alarm temperature AL AL2 Low temperature alarm temperature AH2-0.1 o C 80 o C -45 o C 8.0 o C -45 PS - Password of access to the management menu When accessing management parameters, parameters of the management menu can only be modified by inputting the correct password. If the input is incorrect, the system will exit parameter settings. Note: the correct password is -15. AH1 - High temperature alarm temperature for sensor 1 (RT1) When the measured temperature is higher than the set value of AH1, the high temperature alarm is on. AL1 - Low temperature alarm temperature for sensor 1 (RT1) - 11

13 When the measured temperature is lower than the set value of AH1, the low temperature alarm is on. AH2 - High temperature alarm temperature for sensor 2 (RT2) When the measured temperature is higher than the set value of AH2, the high temperature alarm is on. AL2 - Low temperature alarm temperature for sensor 2 (RT2) When the measured temperature is lower than the set value of AH2, the low temperature alarm is on. Note: when r4 = 0, parameters AH2 and AL2 are invalid. 6.5 Alarm description Alarm Code Description Er1 Sensor 1 fault Er2 Sensor 2 fault EH1 Temperature measured by sensor 1 is higher than 85 EL1 Temperature measured by sensor 1 is lower than -45 EH2 Temperature measured by sensor 2 is higher than 85 EL2 Temperature measured by sensor 2 is lower than -45 AH1 High temperature alarm of sensor 1 AL1 Low temperature alarm of sensor 1 AH2 High temperature alarm of sensor 2 AL2 Low temperature alarm of sensor 2 The buzzer will ring if any of the above symbols occurs. Press any button and the buzzer will no longer ring for this alarming; if any other alarm symbol occurs, the buzzer will start to ring again. 6.6 Wiring diagram Note: Please check whether the power supply voltage can meet the requirements of the controller before use, other wise, the instruments may not work properly, and even burn out. Note: Sensor 2 (RT2) mentioned in this specification for the electronic controller is not used in solar refrigerator HTC 60H. HTC-160 controller: 12

14 Display: Two LED windows, the left one is for refrigerator (chill space), the right one is for freezer (freeze space). The icebox sensor: It is used to control the compressor, the code is SP1. The sensor is adjusted automatically, and can t be adjusted by manual. The refrigerator sensor: It is used to control the pcm heating module, the code is SP2. The sensor can be adjusted by manual. The refrigerator monitor sensor: It can only show the temp, and can t control anything The freezer monitor sensor: It can only show the temp, and can t control anything The freezer sensor: It is used to control the freezer compressor, the code is SP3. the sensor can be adjusted by manual. The ambient temperature sensor: It can t show the temp, and can t control anything. 6.7 Lock and unlock the controller and temperature adjustment. a. control temperature settings Parameter Definition Min. Max. Unit Defaults SP1 Control temperature 1 r1 r0 0.2 SP2 Control temperature 2 r1 r0 4 SP3 Control temperature 3 r3 r

15 On standby: Nothing is showed on the screen. Press any button, the left window will show the temp of icebox, the right window will show the temp of freeze space. Press and over 5s at the same time, the controller will be unlocked (or locked), the buzzer will ring about 0.5s. After unlocking, Press show PS, then press for 5s, the right window will again, the window will show a number, then input -15 by pressing or,press to confirm it. After input the correct password, Press 5s, the left window will show SP1, the right window will show the temp of the icebox, the temperature can be checked only, can t be adjusted. After input the correct password, Press for 5s, the left window will show SP2, the right window will twinkle the setting temp of the heating module, the temperature can be adjusted by pressing or. If press over 5s, then the setting value will be saved. After input the correct password,press 5s, the left window will show SP3, the right window will twinkle the setting temp of the freezer space, the temperature can be adjusted by pressing or. If press over 5s, then the setting value will be saved. b. parameters of the regular menu 1. Press and hold for more than 5S till the screen displays the parameter code PS (password); 2. Adjust the parameters with and (PS, AH1, AL1, AH2, AL2, AH3, AL3) ; 3. Press to confirm one of the parameters, the value of the parameter is displayed; 4. Increase or decrease the value of the parameter by or ; 5. Press to temporarily store the modified parameter values and return to the parameter display; 14

16 6. Repeat steps 3 to 5 to modify other parameter values, if required; 7. Press and hold for more than 5 seconds to store the modified parameter values and return to normal. Controller parameters are divided into regular menu and management menu parameters. When you set the controller, If you do not touch any button after 3mintes, the controller will be locked,and the buzzer will ring about 0.5s. once the controller is locked, you will can t to adjust anything. The definition of the parameters: Parameters Definition Min. Max. Unit Defaults PS password AH1 high temp alarm for icebox AL o C 80 AL1 low temp alarm for icebox AH1-0.1 o C -45 AH2 high temp alarm for refrigerator AL o C 80 AL2 low temp alarm for refrigerator AH2-0.1 o C -45 AH3 high temp alarm for freezer AL o C 80 AL3 low temp alarm for freezer AH3-0.1 o C

17 c. Alarm code Alarm code Er1 Er2 Er3 Er4 6.8 wiring diagram Definition The icebox sensor error The refrigerator sensor error(chill space) The freeze sensor error The ambient temp sensor error Ice layer Refrigerator Freezer Heating wire Power Ice-layer Refrigerator Freezer Ambient temperature 1. Before switch on the power, please check and confirm the voltage of the power, otherwise the controller may be not working normally. Even burned out 2. HTCD-160 has 6 sensors, the color of the socket of the sensors: Ice layer sensor: blue Refrigerator sensor: red Freeze sensor: yellow Ambient sensor: white 6.9Temperature displayer introduction (HTCD-160) The temp display area solar receiving area REFRIGERATOR--the temp of vaccine storage area (upper area) FREEZER--the temp of icepack freezing area (lower area) The displayer is powered by solar, no need to connect other power. It can display the temp of cabinet only, can t control the cooling system. When the displayer is working, the solar receiving area can not to be sheltered, otherwise it can t work without solar. 16

18 7. Electrical principle diagram HTC-60H: 17

19 HTCD-160: 18

20 8. Maintenance 8.1 Replace compressor E-box Screw Suction pipe Exhaust pipe Recharge pipe If compressor needs to be replaced, follow the steps below a. Unplug the compressor attachment (E-box) ; b. Cut the recharge pipe to release the refrigerant(keep away from the fire); c. Remove the screws of the compressor; d. Use welding gun to disconnect the suction pipe & exhaust pipe; e. Replace the compressor; f. Use welding gun to connect the exhaust pipe and suction pipe of the compressor; g. Vacuum the cooling system from the recharge pipe of the compressor(ensure the pressure is lower than 3 Pa); h. Recharge R600a, 45g; i. Seal the recharge pipe. Note: 1. Because the oil of compressor is easy to absorb the moisture, which will Cause the cooling system failing. So it is necessary to weld the pipe in 10 minutes. 2. Before welding, you must release the refrigerant of the cooling system in case of fire and explosion. At the 8.2 Replace the fan same time, you should put the refrigerator in Ventilated place, because the gas R600a is flammable. 19

21 If the condenser fan was damaged, please follow the below steps: a. Unplug the power line of the fan b. Remove the two fixed bolts of the fan support c. Change a new one Note: Pay attention to the blade direction of the fan. Refer to the original one. 8.3 Replace the inner fan Follow the below steps to replace the inner fan: a. Remove the four bolts of the cover of the fan, and remove the cover. b. Remove the two fixing bolts of the fan, disconnect the line, and remove the fan. c. Replace a new fan. Note: Pay attention to the blade direction of the fan. 8.4Replace the battery(htc-60h) The right connection, the red line is connected the positive electrode, the black line is connected the negative electrode. 20

22 Note: Before change battery, you should switch off and take out the 3A fuse. Avoid the fuse is burned down. The battery should meet: 10Ah/12V, There are 2000 cycles at discharge 80%. Terminal Block Specifications is 6.3mm. The battery size: length* width* Height=151x99*94.5 mm a. Remove the battery holder screw first b. Take out the battery, and disconnect the line; c. Change the new battery, fix it,and connect the line.( the red line is connected the positive electrode, the black line is connected the negative electrode.) 8.5 Replace the 3A fuse(htc-60h) Fuse The fuse is in the electrical control box behind the refrigerator, changing step as follows: a. Open the cover of the electrical control box; b. Remove the silica gel cover of the fuse; c. Take out the broken fuse; d. Install a new fuse. 8.6 Replace the heater Heater Disconnect the heating wire Fig.1 Disconnect the heating wire Fig.2 Remove the fixing sensor probes 21

23 Fig.3 Take out the icepack and others. Fig.4 Unplug the fan Fig.5 Lift up and take out the middle Partitioned section Fig.6 remove the fixing bolts Fig.7 Change the heating wire on the back of the plate. Note: after finish the heating wire, please fill the hole well by putty, Prevent leakage of cold. 22

24 8.7 Replace the Mechanical thermostat(htc-60h). Fig.1 Unplug the wire, remove the bolts and the putty on the hole Fig.2 Remove the cover of the icepack area. Fig.3Take out the icepack Fig.4Take out the sensor,change a new thermostat Note: after finished, please fill the hole well by putty, Prevent leakage of cold. 8.8 Replace the condenser fan (HTCD-160) 23

25 Fig.1 Remove the front cabin cover Fig.2 remove the fixing fan bolts The connector of the fan (No.3 & No.4) Fig.3 Remove the back cabin cover Fig.4unplug the wire of the fan and change Note:Pay attention to the blade direction of the fan. 8.9HTCD-160 Change the thermostat a. Remove the front cover. b. Remove the thermostat support 24

26 c. Remove the thermostat and change it HTCD-160 Replace the monitor a. Pry out the monitor with a plat screwdriver. b. Pull out the quick plugs. 25

27 c. Change the monitor 8.11 HTCD-160 change the fuse a. Remove the back cover b. Remove the screw of the wire box c. Pull out the box d. Replace the fuse 8.12 HTCD-160Replace the compressor e-box. a. Remove the back cover 26

28 b. Remove the screw of the ebox. Screw c. Remove the EBOX,and pull out the plug. Plug Note: The plugs of the e-box need to be inserted tightly, otherwise the compressor can t work How to release the water from the tank? a. Remove the screw under the cover of the water tank, pull down the cover. 27

29 b. Remove the internal insulation material c. Take out the plug in the end of the hose, then bend down the hose, drain out the water. 28

30 9. Troubleshooting Problems Failed reason Trouble shooting Wait for the sunshine becoming strong Compressor work doesn t The sunshine is weak, Voltage is low Circuit fault Check the connection between solar panel and refrigerator. Check if the main switch is on Clean the dirty and others in grille or condenser. Ventilation grille is blocked Clean the blocked things or change the fan The fan don t work The ambient is too hot Ensure the air circulation, or lower the ambient temp The door isn t sealed tight Seal the door tightly Refrigerator or freezer temp is too high. Check the solar panel place,avoid the sunshine is blocked. The sunshine is not enough, the time for compressor is short a. The cooling system is blocked or leaked, resulting in bad cooling Cooling failure b. The mechanical thermostat is broken. The ambient temp is too low The thermostat was broken which caused the inner fan not to stop 29 R the ambient temp Check or change the electrical thermostat

31 The refrigerator temp is too low The cover of the icepack area is not sealed well. The middle Partitioned section is not sealed tight The wire failure Seal the cover Seal on both sides of the check the wire middle Partitioned Display nothing Electrical thermostat was failed Low battery Replace thermostat Charge the battery or change it 10. Explosive view &Spare part list HTC-60H explosive view 30

32 Spare part list No. Name Part code Remark 1 upper cold storage box Basket Lower cold storage box Inner fan Insulation board E thermostat Without sensor 7 Battery Condenser fan compressor Include EBOX 10 Filter drier Thermostat Main board A 13 Power switch condenser Ice pack Evaporator Hinging Knob Include lock 19 Sensor probe A 31

33 HTCD-160 explosive view: 32

34 Spare part list No. Name Part code Remark 1 Lock Handle Temperature displayer Without sensor 4 simulation hinge(cable cover) Hinge Heat pipe Evaporator Inner door handle Inner door upper hinge Inner door Inner door middle hinge Shelf support Shelf Icepack Heater Water collect box Switch Terminal Fuse seat Compressor Include EBOX 21 Filter drier Condenser A 23 Capacitor Electronic thermostat Include sensor 25 Condenser fan Foot Refrigerator sensor Red wire 28 Freezer sensor Yellow wire 29 Temperature displayer sensor A 33

35 Inspired living Haier Medical & Laboratory Products Co., Ltd. Room 403D, Brand Building, Haier Industrial Park, No.1 Haier Road Qingdao China Website: 34

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