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Hi. I bought an ex display that was 3 years old in the store and when I brought it home the fridge part was just clicking on and off. just like that on and a second later off. I had called the service company they said it is a major repair and wrote it off. I had contacted Zanussi and they said they go by what the service company says. This unit is huge and I wasn’t gonna take it back to the store plus the price of it was really cheap as an ex 3 years old display. So I made a test cord and hooked it up to the compressor and it started right up with a little whyne first but after that it started right up on the flick of the switch. I had found the overload protector turning off the entire fridge part (as the freezer part has it’s separate compressor and control module). it seems that the start module or relay is not releasing and the overload protector heats up and turnes the power off to the compressor. I took the overload protector apart and it was all sootie inside I cleaned it up put put the whole assembly back onto the compressor and when I turned it on it did the same thing. On and off a second later. Back with the test cord and it worked fine. So I came to the conclusion that the start switch must be faulty but I can not find who made the switch or who would sell any of these kinds of parts. The overload protector is a Klixon 4TM which I also need because when I took it apart the second time and I had broke the contact somehow. It’s running now for almost 40 minutes continuously and the inside temperature is down to almost freezing on the bottom of the fridge and 9 celsius on the first shelf and 11 celsius on the top shelf.
So if anyone reading this and know where can I find these parts I would really appreciate it. I hope this experiment of mine will help someone else too with their problem. The test cord is easy to make and I got the info off of the net at http://www.davesrepair.com/drsn/Aug06bi.htm .
Just a piece of wire and a double switch. Thanx a lot for the help.Re: Zanussi ZI9454x Starter & overload problem
Hi Kimand,
I’d think that…
If it starts and runs with a test cord, it *usually* means the compressor’s OK. You’ll want to test the windings with an ohmmeter, though, to be certain there are no winding shorts causing it to ‘short-cycle’ and run hot.
…is your problem and the compressor is goosed, note the “usually” in the above. That’s because “usually” when the relay/klixon trips like that the compressor is either shorted or running too hot. The relay/klixons when they go usually blow or burn severely as all they are is a safety device for the compressor.
The reason it’s likely being written off is the compressor is probably expensive and/or you may have a system choke as the temperature hasn’t dropped enough. If you’ve got it on that lead I’d strongly advise you get it off before it goes up in flames!
Apart from which that’s a well dodgy way of checking a pot IMO.
HTH
K.
Re: Zanussi ZI9454x Starter & overload problem
Hi KWATT
Thanx for the quick reply. I am not running it on that test lead I am just testing it. I had it run for two one hour cycles and the compressor cooled the unit down to +1.6 celsius on the bottom of the fridge. I had the compressor warmed back up in between the cycles. there isn’t seems to be a blockage in the line as the whole line warms up althought the compressor is running on the hot side just like the car’s compressor would.
Yeah it would be a dodgy operation with the test cord.
What was unusual about the service guy coming out to look at it is that he didn’t do anything. He turned it on and off and he said it could be expensive to repair it although it is still under warranty.
So he puzzled me with his statement and I figured why not give it a try and see if I can fix it.
I was also wondering after all this if it would work with a room thermostat or some other just to click the power on and off, if I can’t find the part for it. A new compressor is around 250 pounds which is not much considering the price of the unit at 1500 pounds new. i would not be able to do a replacement tho and so I probably end up using it until it lasts and chuck it when it’s over. So it’s over priced but it’s an expensive junk if not fixed one way or another.
Would you know if the hard start pack is available here in the UK like in the US? 115 volts there versus 240 here. CheersRe: Zanussi ZI9454x Starter & overload problem
Hi Kimand,
Is this a US, EU or UK machine?
Fridge engineers have “knack”, we almost know by some sort of sixth sense what’s wrong and how much hassle it will be to effect a repair before we even start. It is an art in some ways.
It sounds as if the compressor is tripping under load which means that either the compressor is duff or that there’s a blockage which can cause an undue load on the compressor, overheat it and make it trip. Given the history either is possible.
I’d suspect that the engineer decided that it wasn’t worth trying to save given the time, money and hassle to do so. However, stranger things.
If it is a UK model then yes, spares will be available at that age, a mail to Dave on spares@ukwhitegoods.co.uk will get you info on the parts you need.
HTH
K.
Re: Zanussi ZI9454x Starter & overload problem
Thanx Kwatt
Yes it is a UK machine. Never been used because it was displayed at wickes for 3 years and when they decided to update their kitchen displays they put it up for sale at the reduced price. Thanx for the advice. I am a solver and hard to give something up as junk when it’s practically brand new. I am gonna give it a shot for the parts and if not working I am just putting it on a digital timer for a daily 20x 5 mins on and off click until dies. Cheers
Re: Zanussi ZI9454x Starter & overload problem
Hi
It may well be that either the start windings or run windings have failed as the compressor will switch over automaticly from start dependant on how the compressor is wired up.
You may have connected to either one which will work for a short period but it is NOT advisable as the klixon is a electrical safty device,bypassing this will invaledate your house insurance and will make you liable to manslaughter charges if it goes belly up and somebody dies.
Get a refrigeration company out to replace the compressor as you wont be able to do this yourself.
Bryan
Re: Zanussi ZI9454x Starter & overload problem
Hi Brian. thanx for the reply.
I’ve tried to read the ohms and the contacts but I could not get anything on either of the three. The top contact is the common and when I put the test cable on it I have the run on the left and start on the right. I switch on the run and when I just flip the start on for a second and I get an immediate start. The compressor doesn’ seems to be getting any hotter if I run it for 5 mins or 1 Hour. This unit does not have a fan on the outside or on the bottom of the unit. Just the two compressors underneat. No other visible parts. each compressor has it’s own Start and overload module attached to the sealed unit on the outside of it. Inside there is the small fan at the very top of the Fridge which has an on off switch on the control panel. The control panel seems to be alright as no visible damage or dry solder.
As I am not getting any reading on the run and start windings would this have a newer compressor that don’t have these? or is it controlled by something else? I am gonna go out now and get a digital timer and hook it up to the start side and we’ll see. The repair on this would be expensive and I rather buy another one if all fails. As the machanic said “it could be expensive to repair” and I guess that’s why Zanussi decided not to honor their warranty. Although WIckes would’ve gave me the money back if I take it back but I can’t fit it in my car and so it stayed and Now it’s my headache and to much time has passed since the purchase. (almost a year)
I knwo you guys are all advising me on abandonig this but I am just curious if it’ll work and if it does, how long. I mean people are using these compressor for all kinds of purposes when they take it out of the refrigerators. SOme ends up with plumbers or gas mechanics who use them to pressurize the lines for testing and I’ve heard of some other uses too. logically it could be alright for years. I thought if I put it on the timer for 5 mins on and 40 mins off it would keep the food cold and the motor has enough time to rest before the new five mins. Does that make sense? Would that be feasable? ThanxRe: Zanussi ZI9454x Starter & overload problem
kimand wrote:I knwo you guys are all advising me on abandonig this but I am just curious if it’ll work and if it does, how long. I mean people are using these compressor for all kinds of purposes when they take it out of the refrigerators. SOme ends up with plumbers or gas mechanics who use them to pressurize the lines for testing and I’ve heard of some other uses too.
New one on me, it’s a different kind of compressor for those uses, much more powerful and less fragile for a more rugged purpose.
kimand wrote:logically it could be alright for years.
If it isn’t goosed, which we’re pretty much telling you it is.
kimand wrote:I thought if I put it on the timer for 5 mins on and 40 mins off it would keep the food cold and the motor has enough time to rest before the new five mins. Does that make sense? Would that be feasable? Thanx
No as there’s no temperature regulation. I keep telling people, refrigeration is all about stable temperature control, not how long the things run for and it MUST be thermostatically regulated to ensure that the food in it is fit for human consumption. To think otherwise is utter madness and will almost inevitably lead to food being unfit to eat.
Keeping food cold and keeping food at a stable temperature are two entirely different premises.
K.
Re: Zanussi ZI9454x Starter & overload problem
Hi Brian
The compressor is an EMBRACO but I am not soure the model because I am not clear of the numbers. these are the numbers on it.
EECON
JLLE T80
513604500
213 615 020
100 921 8FLi was just wondering if the refrigerant could blow up in it or not. I have not heard of it yet and no one mentions in the forums that could happen but. If just the fire hazard of the start and overload relay burning up that would be bypassed with the timer. i had the overload relay bypassed by taking it out and leave the start module and connect the overloads wire directly to the common and the compressor got considerably hotter compare to when I had the whole thing connected directly to the test cord.
Logically the whole thing could work with just an on off switch unless the refrigerant would explode from the temperature although I can have my hand on the sealed unit for about 4-5 seconds before it gets to hot. But than it maintains that same temperature. I had not measured how hot it gets but I will and let you know as soon as I get under it again. the freezer’s compressor gets almost as hot but that of course is working fine.
i can keep my hand on that for about 2 seconds longer. Cheers.Re: Zanussi ZI9454x Starter & overload problem
Wouldn’t this indicate that the start switch not releasing? i mean why is the temperature difference whit the test cable versus when the start switch connected but the overload protector omitted?
Re: Zanussi ZI9454x Starter & overload problem
Hi R600a
Sorry I made amistake I gave the wrong compressor number. DUH!
It is an EMBRACO EMY 26 CLC
Sorry for that. read the star switch number.Re: Zanussi ZI9454x Starter & overload problem
kimand wrote:Logically the whole thing could work with just an on off switch
No, sorry that’s totally incorrect, it won’t. Please read back to my previous post, the temperature internally must regulate the compressor cut-in and cut-out times, the overload & klixon is overheat and short protection for the compressor itself.
You must not by-pass the internal thermostat from regulating the compressor cut-in/cut-out and internal temperature, to do so is dangerous, end of story.
K.
Re: Zanussi ZI9454x Starter & overload problem
Thanx Kwatt
You are very nice. Thanx for all your help.
So If I read your staement right than all I have to do is to get another start switch and hook it up to the internal thermostat and it should work fine.
There might be a blockage or might be a shorted winding but the compressor is working in the direct hook up and therefore it should work if the internal thermostat controlling a short direct buzz to the start switch and not a timer. Considering the temperature difference in the direct and indirect hookup (of the power test cord and start switch direct common) it seems that the start switch is the culprit. I mean it could happen. there are no moving parts on the little board thats inside of it but the one coil that touches the transistor. So the trouble could be with that. The coil and the little circuit board are two separate items inside the housing. I didn’t see any moving part and I think the power transistor is the one controlling the start function. I had the same thing with my plasma tv and those transistors fail quite often in Plasma tv-s. and that’s when you have sound but no picture in them. I am not giving it up that easy as you see adn I am gonna get to the end of it and let you know but for the most part the mechanic just pissed me off with his attitude of telling my wife the unit has a major problem. I was at work. I am a builder and not telling the client the roof has to be replaced if there is a leak somewhere. He didn’t even looked or mesured anything just turned it on and off she says. Now he might be right but everything is indicating a failed start switch. I am measuring the temperature right now of the sealed unit after 40 mins of continuous running, the outside temperature at the top is at 39 celsius and Ice formed on the back wall. am gonna let it go to an hour and check it again.
I don’t think at these temperatures the refrigerant will blow but I can’t measure the pressure of course. Now it’s one hour of continuous running and hte temp is almost steady at right around 48 celsius but he freezer’s compressor is at around 44 celsius for the same time of continuous running but that is connected normallybut with the doors open for the hour. Is that high or sort of normal? CheersRe: Zanussi ZI9454x Starter & overload problem
Nope Kimand.
The stats send a signal to the PCB then the PCB sends to the compressor to run or not. It is designed to and has to run that way. Deviation from the manufacturer’s design will lead to problems and the incorrect temperature range in which you can safely store food.
You are assuming it should work but you don’t know what winding in the compressor is working. You also don’t know if it is choked or not.
The risk of fire damage is from overheating components, not from the gas.
I’ve never measured the external temperature of a compressor, no need to do so, we know when they’re goosed. 😉
K.
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