Training Manual of ULT Freezer——Dual Cool ULT

freezer and Smart Frequency Conversion ULT freezer

DW-86L579BPT / 729BPT / 829BPT / 959BPT DW-86L578ST / 728ST / 578ST (120V60HZ)

Frequency Conversion Product model:

DW-86L579BPT / 729BPT / 829BPT / 959BPT

Dual Cool Product model:

DW-86L578ST (Europe Type) / 728ST(Europe Type) / 578ST(120V60HZ)

1
1. Model designation

Frequency Conversion ULT freezer

Dual Cool ULT freezer

2. Structure of Freezer

2
3
3. Electric control structure

后备系统板 开关电源
主控板
Backup system Switching power
Main control
board supply
panel
远程报警接线
Remote alarm wiring
冷凝器风机
Condenser fan

485 串口模块口
锂电池 485 communication
Lithium battery module port

电源开关
Power switch

热电偶板
电池开关
Thermocouple plate
Battery switch

电控箱 滤波器
接线排 Electric Filter
Line bank control box

4
4. System structure
4.1 System structure of Frequency Conversion ULT freezer

高温级变频器
High-temperatu
re inverter
变频器信号线长线接低温级变频器，短
线接高温级变频器
The long line of frequency converter
低温级变频器 signal line connects to low-temperature
Low-temperatu frequency converter, with the short-line
re inverter connected to high-temperature
frequency converter

5
4.2 System structure of Dual Cool ULT freezer

5. Principle of refrigeration
5.1 Frequency conversion ULT freezer
The low-temperature refrigerator adopts cascade refrigeration system which is usually
composed of two or more refrigeration systems, referred to as high-temperature level and
low-temperature level respectively. The high temperature level uses the medium-temperature
refrigerant and the low-temperature level uses the low-temperature refrigerant, each of them is
a complete refrigeration system; these two parts are contacted by a condensing evaporator, so
such evaporator is a high-temperature level evaporator and also a low-temperature level
condenser. The low temperature refrigerant absorbs heat of the cooled object in the
6
evaporator of the low-temperature level system and transfers such heat to the refrigerant of
the high temperature level system by means of a condensing evaporator, and then such heat
is transferred to the cooling medium in the high-temperature level condenser by the refrigerant
of the high-temperature level system.
Schematic diagram of frequency conversion ULT freezer:

5.2 Dual-cool ULT freezer:

Dual-system ultra-low temperature storage box is composed of two same independent

refrigerating systems. Each system can provide a cold storage environment for the cabinet

separately as a refrigeration unit. The refrigeration mode of each system is a single-machine

self-cascade refrigerating system, namely, a compressor is used for compressing the

refrigerant at different evaporation temperatures, and then the medium-temperature and the

low-temperature refrigerant are separated by a gas-liquid separator; the medium-temperature

refrigerant is allowed to cool and condense the low-temperature refrigerant in the intercooler,

so that the low-temperature refrigerant reaches the liquid state and achieve the refrigeration

effect after throttling.

Schematic diagram of Dual-cool ULT freezer

7
6. Working principle of pressure switch
6.1 Frequency conversion ULT freezer
A. Principle: When the pressure in middle of the pipeline at the pressure switch exceeds
2.1MPa, the contact is disconnected and the low temperature cabinet stops, the pressure
starts to drop; when the pressure drops to 1.35MPa, the contact is connected and the
low-temperature cabinet is started; and when the pressure exceeds 2.1MPa again, the contact
is disconnected again, repeating in such way in sequence.
B. Precautions: When the pressure switch is burnt, place the wet towel on it to keep the
temperature not higher than 100 degrees. This pressure switch parameter is not adjustable.
C. Parameter: Voltage 220V, 50Hz, Contact Capacity 6A
6.2 Dual-cool ULT freezer
The dual-system is not equipped with the pressure switch, and the pressure switch at the main
control board is short-circuited by connecting line. if the compressor does not start, it can see
whether the short-circuit connecting is reliable here.

7. Refrigerant
7.1 frequency conversion refrigeration
Refrigerant (type/ quantity)
Model High temperature level (g) Low temperature level(g)
R290 R170
DW-86L829BPT 148 110
DW-86L959BPT 148 110

8
 DW-86L729BPT 140 110

7.2 dual-system refrigeration

Refrigerant (type/ quantity)
Model
R600a R1150 R14
DW-86L578ST 100 40 5
DW-86L728ST 80 40 5
DW-86L578ST(120V60HZ) 70 35 5

8. Type failure and solutions

8.1 The display temperature is inconsistent with the actual test temperature of the
machine:
Because our display temperature is the temperature of a certain point inside the box, the
temperature detected by the user is the temperature of another point inside the box, and
the inconsistent position must cause different temperature, and meanwhile, there is certain
error between the test tools of the users and our temperature sensing probe;
8.2 The temperature difference between the upper and lower part of the machine box is
too large:
Since our machine starts to cool from top to bottom, the upper temperature is lower than
the temperature below, and the temperature difference between the upper and lower parts
is large; and the temperature difference of the similar products in the world is at 5-8
degrees, and ours is basically within 6 degrees; in addition, the frequent opening and
closing door by the user will also the big temperature difference between the upper and
lower parts;
8.3 User set -86 ℃, but the freezer displays -82℃?
In order to guarantee the service life of the machine, our products are designed so that
when the ambient temperature is higher than 35 ℃, and if the set temperature is lower
than -82 ℃, the product is adjusted to -82 ℃, and if the ambient temperature is lower
than 30 ℃ (inclusive), the product returns to the original set value;
8.4 What's the reason for the fast temperature rising at the time of opening the door?
Why the temperature rising of other brands is slow?
(1) The temperature of the ultra-low temperature cabinet is relatively low, which has a
big temperature difference with the ambient temperature, and our temperature sensor
probe is more sensitive, so the temperature rises rapidly when the door is opened;
The other brands add the function of slow temperature rising in the design of the computer
board and the temperature sensing probe, so the temperature rises slowly or the
temperature before opening door is displayed consistent for a long time when the user
opens the door (for example, the product of Meiling).
8.5 What's the matter that the low temperature cabinet door cannot be opened?
There are two cases:
The first reason is that the internal and external temperature difference is large, causing
the door body to be under negative pressure. The processing method is: the user inserts a
fine iron sheet between the door sealing strip and the door body, to make the air is fed into

9
 the line;
The other reason is that there is moisture inside when the user stores the items, causing

that the water flows to the sealing strip and freezes so that the door cannot be opened.

The processing method is: to open the door by means of a tool.

12.2 Troubleshooting common problems

Problems Cause analysis Maintenance measures

Use a multimeter to measure the resistance of
1. Power switch or fuse failure the switch or fuse; if the switch is confirmed
damaged, replace the fuse or power switch
Check whether the connecting plug of the
2. Connecting plug of the
connecting wire of engine room is damaged or
engine room connector is
the wire harness thereof falls, and replace the
damaged.
patch cord
Check that the patch cord is connected poorly
or not connected, and repair to normal
3. Poor contact of wires
connection
Use a multimeter to measure the resistance of
the connecting wire to determine that the
4. Display board and control
harness is short-circuited or open-circuited,
board connection failure
and then replace the wire harness that cannot
be repaired
Check whether the relay, capacitor or thermal
2.High-temperature 5.Relay, starting capacitor or
protector has signs of burnt and charred etc., if
compressor does not thermal protector fails.
yes, replace the electric device
start (frequency
In other normal power-on cases, check
conversion)
whether the connection plug of compressor is
normal, and observe the surface temperature,
2. The system
compressors A and B do abnormal noise etc. of compressor. if the
not start (dual system) 6. Compressor failure compressor does not heat or the noise is
abnormal, etc., the compressor is damaged
and needs to be replaced. When replacing the
compressor, the oil separator and the dry filter
shall be replaced at the same time

Check whether the product display panel

voltage is within the rated range (220 ± 10%),
and use a multimeter to measure whether the
7. The user voltage is too low voltage in the case of power-on operation is
over-voltage or not, and if the voltage is too low
or too high, the customer shall be required to
equip with a pressure-stabilizing booster or
pressure reducer
Check whether the pressure switch is
8. Dual system pressure
short-circuited or not, and the dual system
switch is not short-circuited
model is not provided with pressure switch.
In other normal power-on cases, check
whether the connection plug of compressor is
normal, and observe the surface temperature,
2. Low-temperature 1. The reason is the same as abnormal noise etc. of compressor. if the
compressor does not the high-temperature compressor does not heat or the noise is
start compressor abnormal, etc., the compressor is damaged
and needs to be replaced. When replacing the
compressor, the oil separator and the dry filter
shall be replaced at the same time
10
 Use a multimeter to measure whether the wire
harness of the pressure switch is
short-circuited or open-circuited, and also
2. Broken pressure switch
inspect whether the copper tube section of
pressure switch is damaged or not, if yes,
replace the pressure switch
If the high-temperature compressor does not
start after the low-temperature compressor has
been started for 10min, it indicates that the
3. High-temperature
high-temperature compressor has a poor
compressor has a poor
refrigerating effect; therefore, check whether
refrigerating effect
the system circuit and pipeline welding of the
high-temperature compressor are good
(leakage stopped) or not, and handle the fault
Check whether the patch cord of fan falls or is
1. Wiring of fan falls not plugged, and reprocess the thread ends
and realign for installation
Check whether the fan blade produces the
noise of touching wall during rotating or does
2. Fan blade is blocked by
not rotate, handle the foreign matters on and
foreign body
3. Fan does not turn around the blade, and keep the blade running
normally
Use a multimeter to measure whether the
resistance of the two ends of the fan wiring is
3. The fan fails short-circuited or open-circuited, and observe
whether the rotating shaft rotates, if yes, please
replace the fan.
Check whether the temperature set point of the
1.The temperature at the
product is set as required by customers, if not,
shutdown point set is high
re-set the temperature
Check all welding joints of the engine rooms,
2. Refrigerant leakage find leaked points and repair welding. Re-fill
refrigerant
If the display panel displays an abnormal code
alarm, e.g., E0/ E1/ E2E/ E3, it is indicated that
the product temperature sensing probe fails
3. The temperature sensing
4. The temperature inside while checking whether the patch cord is
probe fails
the cabinet is high normal, if yes, it indicates that the temperature
sensing line is bad, then replace the
corresponding temperature sensing line
4. Capillary or system is dirty, Open the system to clean capillary or replace
blocked and oil-blocked filter
If the ambient temperature is high, please add
5. High ambient temperature the air conditioners to reduce the room
temperature
In case of condenser dirty alarm, please clean
6. Condenser blockage
the filter screen in time.
When the input voltage of the 1. Check whether the terminal of the ambient
ambient temperature sensor temperature sensor is plugged poorly or
is more than and equal to dropped, and whether the sensor is damaged
5.Ambient temperature
4.9V, the sensor is
sensor failed (E11 Alarm) 2. Check whether the sensor plug-in terminal
open-circuited; if less than
on the display panel is loose or poor contact;
and equal to 0.1V,
and whether the display panel is damaged
short-circuited
When the input voltage of the 1. Check whether the terminal of the ambient
condenser sensor is more temperature sensor is plugged poorly or
6. Condenser sensor fault
than and equal to 4.9V, the dropped, and whether the sensor is damaged
alarm (E12 alarm)
sensor is open-circuited; if 2. Check whether the sensor plug-in terminal
less than and equal to 0.1V, on the display panel is loose or poor contact;

11
 short-circuited and whether the display panel is damaged

1. Check whether the terminal of the main

When the input voltage of the
sensor is plugged poorly or dropped, and
main sensor is more than and
whether the sensor is damaged
7. Main sensor fault alarm equal to 4.9V, the sensor is
(E10 alarm) open-circuited; if less than
2. Check whether the sensor plug-in terminal
and equal to 0.1V,
on the main control panel is loose or poor
short-circuited
contact; and whether the main control panel is
damaged
If the difference between the
temperature perceived by the 1. Open the front grille to clean the filter screen
condenser probe less the 2. Check if the condenser probe is too close to
8. Condenser dirty alarm ambient temperature is more the condenser outlet
than and equal to 13 ℃
3. Wrap the condenser probe with adhesive
(after lasting for 5 minutes),
tape.
the alarm is given
1. Check whether the battery has exceeded the
service life
2. Check whether the wiring terminal on the
battery switch is in good connection or whether
Low battery alarm goes off the switch is damaged.
9. Low battery alarm when the battery capacity ≤ 3. Check whether the charging circuit is
10.5V normal: after the refrigerator is powered
strongly for 5min, test whether the battery
terminal on the main control board outputs the
voltage, and the output voltage shall be less
than and equal to 5V
1. If the temperature of the top layer is too high,
handle the door seal and replace the inner door
10. The temperature to ensure the good sealing property;
Temperature difference inside
inside the box is 2. If the temperature of the bottom layer is too
the machine box is too big
non-uniform high, re-open the system to add the
low-temperature refrigerant R508B (or directly
use the needle valve to add the refrigerant)
When the switching power supply is damaged
due to short circuit of the isolation transformer
winding output of the switching power supply,
11. Control panel power
Control panel power and there is no + 12V output, the temperature
transformer fault alarm
transformer fails display area inside the box immediately flashes
(EEE displayed)
to display EEE, the alarm indicator lamp
flashes synchronously and gives the buzzing
alarm.

12