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RS1500000 Amana Upright Freezers Service Manual

1. To 115 VAC plug A Black eS lia al 3 th amp al al Black Black White Light switch interior deca White ight piee 7 Black AKA Black Le Defrost Defrost 94 thermostat heater Blue Defrost timer Control Freezer fan d Red White e Overload Compressor protector 5 PTC SL relay 27 8 1 2 No interior light OPTIONAL ESUF15JW P1311105W P1179619W ESUF17JW ESUF20JW P1311107W P1179621W AUF150KW RS1500000 Rev 1 50 Ground schematic Fan NOoORWND Outer case Compressor Control Light plate motor Defrost timer Coil cover P1311106W P1179620W P1317705W Wiring Diagram and Schematic 44 WARNING To avoid risk of electrical shock personal injury or death disconnect power to freezer before servicing unless testing requires it Wires removed during disassembly must be replaced on proper terminals to insure correct grounding and polarization CAUTION High Voltage ix Green To 115 VAC plug Se i Light i i Black 2 Light J i k wi iH gt T sWitc Hg Black o e Black AD White Light G ntrol switch Interior light White Red Control Overload PTC protector Compressor relay 5 xo G ta 0 8 Ground schematic 1 Outer case 2 Compressor 3 Control 4 Light plate No interior li
2. 42 HFC134a Service Information 00cee 43 Health Safety and Handling c eee 44 Drier Replacement arene niie 44 Replacement HFC134a Service Compressot 45 Refrigerant Charge ccecseseeteeeeeeettteeeees 45 Leak Testing iit omn e att eases Bal RE EER 45 Evacuation and Charging s 45 Dehydrating Sealed Refrigeration System 47 BFAZING EEUE lke ahie sedis EEEE A ates hur 47 Refrigerant Precautions 0 ccceeceeeerteeeeeees 47 Open Lines 0 ce eeeccceeeeeceeeeeeeeeeeetecaeeetsneeeteaes 47 Line Piercing Valves enini iendea treenien 48 Altitude Adjustment ccceeceeeceeeeeeeteeeeeeennees 48 Cabinet Shells cgi 22 riea et Seances 49 Cabinet Liner Food 0c ccceeeeceeceeeeeeeeeeeeeeees 49 Drain System c cccececceeecceeeeeeeeeseneeeeteteeeeeneees 49 Wiring Diagram and Schematic 0 0 50 52 RS1500000 Rev 2 Model Identification Upright freezer models vary in trim and accessories but all models have the same basic construction Operating Instructions and Service Instructions apply to all cabinets unless stated otherwise 1997 Model Identification ESU F 15 J Ww Color W White Series H J Storage Capacity 12 Cubic Foot 15 Cubic Foot 17 Cubic Foot 20 Cubic Foot Defrost Type Blank Manual F Free O Frost Product ESU Energy Saving Upright Freezer RS
3. 3 Remove all unfrozen food from the freezer 4 Before taking final gauge readings allow freezer to run through several cycles with the door closed This will allow the temperature and pressures to stabilize 5 Compare the final gauge readings for the model being serviced see the category which applies to the readings indicated High Side near normal pressure Low Side lower pressure possible vacuum Wattage lower than normal Freezer shelf tubing or other low side tubing is probably restricted kinked or blocked with foreign particle This condition is usually accompanied with a frost build up on the low side of the restriction High side pressures will not unload and balance with the low side within the prescribed seven to ten minutes after the compressor is stopped High Side low pressure Low Side lower pressure possible vacuum Wattage lower than normal Indicates a leak in the high side of the system Both gauges will show progressively less pressure RS1500000 Rev 0 High Side much higher pressure Low Side slightly lower pressure Wattage higher than normal Indicates a leak in the low side of the system High side pressures will continually increase drawing through the leak becoming trapped in the high side tubing Low side gauge will show a slight pressure being drawn in through the leak High Side lower pressure Low Side lower pressure possible vacuum Wattage lower than normal Indica
4. IRN NOTE It may be necessary to turn control colder to maintain required operating time 7 Wattage reading must be recorded with temperature test to confirm proper operation 8 Suction and Head pressures are listed in the specification chart Condenser Condenser Evaporator Heat exchanger Heat exchanger line Compressor gt Discharge Evaporator Refrigerant Flow Diagram Manual Defrost Refrigerant Flow Diagram Automatic Defrost RS1500000 Rev 2 14 Component Testing To avoid risk electrical shock personal injury or death A WARNING always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Testing Main Condenser Before testing condenser verify no leaks exist elsewhere bottom Condenser loop must be disconnected from the system ttt ttt external and tested separately The following illustration shows the tubing as it is routed and fastened in the freezer cabinet flange NOTE Verify a leak is not present in any external tubing or joints before performing the following test Following equipment is required to test e An access fitting e A drum of oil pumped nitrogen e Pressure regulator To e Two gauges condensor evaporater
5. a b C Freezer has been filled with unfrozen or warm food Room temperature exceeds recommended maximum Cabinet is placed near radiator or other heat a Refrigerant charge is low Examine frost line at tail source such as strong sunlight Piore evaparaior d Temperature control is incorrectly adjusted or has b Compressor is inoperative see compressor f a y aoj sections e Refri erant charge is low c Control has been turned to OFF position f aed g d Freeze up p 2 Compressor will not start 5 Compressor runs too long This is usually a statement of opinion by a Pach or power Venly Powel evallabiliy et customer For a normal storage temperature at compressor terminals O F ted ing ti g h perg b Starting relay has failed Connecting starting relay Aa sci Ceo he co wean contacts L amp S for 1 second should result in a iter i p Narma SaN Sepigcr Saring TEB leat nee en bare dependin c Overload protector has failed in open position aA iea Sndicon ae y dep g Replace overload 6 pec d One of compressor windings is OpeneCnece Moisture freezing in the sealed system is extremely winding fesistaneo Resistance beeen CPs rare however it may be encountered when sealed and CDR should be less than 100 ohms s stem iso ened aa seice e Compressor is locked seized If voltage is y p normal there is no failure in the relay protector or any connections leading to the compressor terminals and the
6. tubing at the entrance hole to prevent a possible kink Pack entry hole with butyl sealer 23 If cut when removed swedge compressor suction tube to reconnect suction tubing 24 Clean all the tubes Install new drier and silver solder the joints with proper flux Excess flux must be wiped off tubing after soldering 25 Visually check the joints for leaks Evacuate and recharge the system 26 Lace white heater leads to both ends of the freezer coil Fasten wire leading to fan motor to the two clips on the mount panel 27 Join white defrost heater lead and white lead in wire with spade connector and attach spade terminal on fan motor 31 28 Connect defrost thermostat lead and fasten thermostat to freezer coil header 29 Connect green grounding wire to fan motor and to freezer coil cover 30 Test run the unit to verify proper operation 31 Pinch process tube and cut off the service valve Solder the joint and test for leaks Replacing Light Switch 1 Unplug line cord from electrical outlet and pry light switch from liner Pull lead wires out far enough to disconnect connectors Connect new switch plug in line cord and check the light Push new switch and wiring into position Replacing Control Unplug the power cord Pull control knob off remove control mounting screws and disconnect all wires On refrigerated shelf models remove feeler tube from underside of shelf front by loosening the clamp On no defr
7. used exclusively with HFC134a refrigerant Do not use filter must be replaced Cut drier out of system by this equipment to service devices using other types of Completing the following steps Do not unbraze drier refrigerant for example CFC12 or CFC22 filter Applying heat to remove drier will allow moisture refrigerants into system 1 Score capillary tube close to drier and break 2 Reform inlet tube to drier allowing enough space for large tube cutter 3 Cut circumference of drier 1 1 4 3 175 cm below Listed below are the tools and equipment needed for proper servicing of HFC134a systems NOTE Once equipment is designated for HFC134a condenser inlet tube joint to drier use it must be exclusively use for HFC134a 4 Remove drier only An will identify the following equipment 5 Unbraze remaining part of drier Remove drier from system e Evacuation pump Check with vacuum pump supplier to verify equipment is compatible for HFC134a Robinair Model 15600 2 stage 170 liters customer 6 cubic feet per minute pump is recommended Four way manifold gauge set with low loss quick couplers Leak detector Charging cylinder Line piercing saddle valve Seals must be HFC134a and ester oil compatible Line piercing valves may be used for diagnosis but are not suitable for evacuation or charging due to minute holes pierced in tubing Do not leave mechanical access valves on system Valves eventually will le
8. Detach heater leads and unlace from freezer coil 3 Remove clips at each end of heater Push downward on heater shield grasping radiant heater at both ends and lifting outward Retaining clip Defrost Heater and Retaining Clips 4 Replace heater in reverse of removal a CAUTION When installing radiant heater do not touch the heater glass Salt and oil on the hands may cause serious damage Thermostat may be loosened for replacement by merely spreading front tangs of retainer clips u l TTT TTT TT LN Defrost Thermostat and Mounting Clip RS1500000 Rev 0 Replacing Freezer Fan Motor Remove screws from coil cover and disconnect ground wire from cover Remove freezer coil cover Before checking fan circuit for failures spin the fan blade to verify nothing has lodged against it which could prevent normal fan operation If blade spins freely check fan motor as follows 1 Unplug line cord 2 Attach test cord leads to fan motor leads If motor runs check all cabinet wiring for an open circuit If motor fails to operate remove and replace it in the following manner 3 Disconnect lead and ground wire from fan motor 4 Remove complete fan motor assembly by removing screws securing fan motor bracket to mounting panel Remove motor from bracket Replace assembly in reverse order of removal 5 Attach ground wire to freezer coil cover and replace the cover No al
9. pressures are said to be unloaded Pressure unloading in the system will usually take from 3 to 6 minutes Pull Down Over Load If cabinet interior is warm when compressor starts pull down may overheat the compressor and cause cycling on the overload protector 37 RS1500000 Rev 0 Service Information 4 amp WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Checking Operating Pressures If refrigeration system is not operating properly check operating pressures Install a piercing valve on compressor process tube and on high side process tube NOTE Piercing valve should not be left on the tubing after tests are complete Remove the valve from discharge line and repair the opening Evacuate and recharge the system When using gauges to verify operating pressures observe the following precautions 1 Verify gauges are accurately calibrated When not connected into a system gauge pointers should indicate 0 pressure If necessary turn the recalibrating screw on the dial until the pointer indicates 0 2 Verify temperature control is set to normally maintain a O F 17 C temperature
10. 17 Connect wiring to freezer light if equipped and fasten top freezer plate verifying all spacers are in place 10 12 RS1500000 Rev 0 Disassembly Procedures To avoid risk of electrical shock personal injury or death disconnect power to unit before following any a WARNING 18 Secure control feeler tube to correct shelf with the clamp Verify feeler tube rests firmly against shelf surface to obtain thermal contact 19 Form heat exchanger tubing so it is similar in position to the original Be careful when bending tubing at the entry hole to prevent kinks 20 Pack tube entry hole with butyl sealer 21 If cut when remove swedge compressor suction tubing to fit replacement tubing 22 Install new drier and connect all tubing Silver solder the joints with proper flux Excess flux must be wiped off tubing after soldering 23 Visually check all joints for leaks Evacuate and recharge the system 24 Test run the unit to verify proper operation 25 Pinch process tube and cut off the service valve Solder the joint and test for leaks Replacing Freezer Coil No Defrosting Models Because of freezer coil location do not attempt replacement without first removing coil and heat exchanger from the cabinet Even though an experienced silver brazer can control a torch flame possibility of overheating and distorting plastic is high 1 Disconnect line cord from electrical outlet 2 Install service valve as close
11. 2 Model Identification 0ccceceeeceeeeeeeeeeteeeeeeneees 4 Installation Instructions WIA DACKING sea a an ioc peed nd 5 General 2 oF icee cs eh te test Moe Be PCa a a 5 POCAUOM 2 ietiie obec tucker as ten des insite Wha cane eit ee Late 5 Electrical Connection ccccceeeeteteeteetteeeees 5 DOOr Handle citer aa a sear EEN A 6 beven ni a tetera dd Mal al ue ok Ma 6 Test After Installation 00 ccccceeeesceeteeeeteeeeeeees 6 General Instructions Electrical Requirements 0 cccceeeseeeeeeeeeeeeeeee 7 Asure Extended Service Plan 0 eeees 7 Proper Disposal of your Freezer 0 eeee 7 Model Identification 0cecceeseeeeeeeeteeeeeeees 7 Operating Instructions Setting Controls 0 0 2 0 ieee eerren 8 Temperature Control ccccececeeseeeeeeeeteetsnees 8 Audible Alarm Some models ccereeee 8 Feat Ssi E a a EE 9 Reversible Rack some models ceeeees 9 Freezing Guide ccccecccccceeeeceeeeeeeteeeeetteeetens 9 Care and Cleaning GMC AD aeia hu na eee eae ede ae ed 10 Adhesives nia ei ae art natat iah ia 10 Door Gaskets era e E a td 10 Odor Removal esiseeeiseeieeeiisserisrerisreresrerrerernene 10 DE TOSUING a paran eta i a hel aa 11 Light Bulb some models ccceeeeceeerteeeeeees 11 General Tips Energy TIPS seices A A Ea i buaetncweaatvie 12 VacCation TIPS eiee deere dale Mave aide
12. CFC12 has much higher tolerance to system processing materials such as drawing compounds rust inhibitors and cleaning compounds than HFC134a Such materials are not soluble in HFC134a systems If materials were to be washed from system surfaces by ester oils they could accumulate and eventually plug capillary tube Care must be taken to minimize moisture from entering HFC134a system Do not leave compressor or system open to atmosphere for more than 10 minutes Excessive moisture in HFC134a system will react with compressor oil and generate acid Compressor must always be replaced when performing low side leak repair Drier filter must be replaced whenever seal system is opened Important Unbrazing drier filter from tubing will drive moisture from desiccant and into system causing acids to form Do not unbraze filter drier from tubing If CFC12 service drier was installed in HFC134a system drier could overload due to excessive moisture Clean dry HFC134a compatible copper tubing must be used when replacing tubing Avoid system contamination by using Towerdraw E610 evaporating oil part RO157532 when flaring swaging or cutting refrigeration tubing RS1500000 Rev 0 42 Service Information Q WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring f
13. RS1500000 Rev 0 24 Troubleshooting WARNING To avoid risk electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Problems Possible Causes Correction Compressor runs but short cycles Compressor runs but does not freeze Temperature control Improper setting of temperature control for prevailing environmental and usage conditions Failed Low Voltage Overload protector failed Excessive load of unfrozen food at one time Loose electrical connections Complete loss of sealed system charge Low Wattage Readings Restricted capillary or drier Low wattage readings while running Will cycle on overload when unit tries to come on after having been shut off and restriction still present Compressor defective Refer to CHECKING OPERATING TEMPERATURES and reset for proper setting Replace Check voltage must be at least 100 of moment of start time with all other loads on the line Replace Advise customer to freeze no more than 10 of freezer capacity at one time Locate and fix loose connections Locate and repair leaks before re charging with refrigerant Refer to operating pres
14. Remove charcoal briquettes and newspapers Wash all interior surfaces including door floor and walls according to General instructions Pay special attention to corners crevices and grooves Include all accessories shelves and gaskets 6 Wrap foods in tightly sealed wrap or containers to prevent further odor After 24 hours check if odor was eliminated If odor was still not eliminated contact Consumer Affairs Department at 1 800 843 0304 Care and Cleaning Defrosting Light Bulb some models 44 WARNING 44 WARNING To avoid electrical shock which can cause severe To avoid electrical shock which can cause severe personal injury or death disconnect power to freezer personal injury or death disconnect power to freezer before defrosting After defrosting restore power before replacing light bulb After replacing light bulb restore power 44 CAUTION Defrost freezer when frost has accumulated to 1 4 Upper section of freezer will normally have more frost than lower section 1 Transfer food to an alternate cooling source To avoid personal injury or property damage observe 2 Remove toe grille by pulling forward the following 3 Remove interior drain plug from freezer e Allow light bulb to cool 4 Verify drain pan is beneath drain opening to catch Wear gloves when replacing light bulb defrost water 5 Place pans of hot water in freezer Remove light bulb cover by pressing front and back of light bulb
15. a rubber band Attaching Thermocouple to Feeler Tube No Defrost Models On refrigerated shelf models use a few drops of water to freeze the bulb on thermocouple to the freezer shelf near control feeler tube thermal contact point 2 Set control halfway between Off and MAX Cool Close cabinet door and wait for compressor to run through 2 or 3 complete cycles 3 If cut in and cut out temperatures are not within 2 or 3 degrees of those specified below replace the control Temperature Control Auto Warm Calibration Pt Cold cut out Defrost 45 Cut in Cut out cut in 135 315 29 2 2 22 or below Yes 15 3 6 8 2 18 4 2 No 14 3 8 2 8 2 MID 180 19 Defrost Timer Freezer coil defrost system is actuated by an electric timer which is located on the rear leg of the cabinet Timer initiates defrost cycle every twelve hours of compressor running time regardless of control setting or of interior temperatures 1st Click Timer switches off compressor and freezer fan circuit At the same time it energizes the defrost circuit for approximately 30 minutes Once defrost heater warms coil header to approximately 52 degrees defrost thermostat contacts open to shut off the heater Defrost Timer Circuits To compressor Control 2nd Click Timer switches off defrost circuit and starts compressor and freezer fan to end the defrost cycle Compressor freezer fan and defrost time
16. amperage drawn is high Compressor has failed 3 Compressor overload thermostat is operating frequently but cabinet temperature has not risen noticeably a Voltage under 10 VAC a Moisture freeze up is indicated by continuous running and high cabinet temperatures Use a suction pressure gauge to diagnose problem As freezer pulls down back pressure drops to a vacuum By pulling freezer plug and warming cabinet until evaporate exceeds 0 C the ice will melt and cause a rapid rise in pressure This can be duplicated any number of times b Voltage over 127 VAC b Freeze up can only be corrected by evacuating c Lid is being opened frequently so compressor system with a vacuum pump and by installing a OFF time is too short for pressure equalization new oversized high side drier d Installation condition is causing compressor to run NOTE Effective July 1 1992 it is responsibility of hotter than usual for example lack of air service technician to capture refrigerant for safe circulation around freezer shell disposal e Overload thermostat has failed RS1500000 Rev 0 C 40 In case of freeze ups the unit s current draw amperage will usually be low about 70 percent of serial plate Service Information 44 WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power t
17. as possible to tip of process tube for easy pinch off after recharging the system 3 Connect a hose to service valve and capture the charge NOTE Effective July 1 1992 before opening any refrigeration system it is the responsibility of the service technician to capture the refrigerant for safe disposal 4 Remove butyl sealer from tube entry hole in the cabinet back 5 Clean approximately three inches 76 mm of the heat exchanger tubing at the compressor stub Unsolder at the joint or cut three inches 76 mm from the stub 6 Unsolder drier from condenser outlet tube and clean the outlet Remove drier from capillary tube so tubing assembly can be pulled through the tube entry opening 7 Remove screws securing freezer coil cover Lift cover out and detach green grounding wire 8 Remove styrofoam air block from each end of the coil 9 Disconnect defrost heater lead from spade terminal on fan motor RS1500000 Rev 0 disassembly procedures Red Orange oT Circulating Fan and Wiring With Coil Cover Removed 10 Spade connector is used to join the white defrost heater lead to the white lead in wire Separate these wires at the spade connector Release heater lead from the two clips on the coil mounting panel and unlace it from the coil Disconnect white defrost heater lead from defrost thermostat and unlace i
18. cover together Replace light bulb with 15 watt appliance bulb Amana part A3073101 6 Wash all interior surfaces including door floor and walls 7 Replace inside drain plug Drain plug must be properly installed for efficient operation 11 RS1500000 Rev 2 General Tips Energy Tips This freezer is designed to be one of the most energy efficient freezers available Reduce energy use by doing the following Operate in normal room temperatures away from heat sources and direct sunlight Set controls no colder than necessary Keep freezer full Keep door gaskets clean and pliable Replace gaskets if worn Vacation Tips For long vacations do the following 1 Empty freezer 2 Unplug freezer 3 Clean freezer including door gaskets 4 Prop doors open so air can circulate inside Normal Operating Sounds Today s freezers have new features and are more energy efficient As a result certain sounds may be unfamiliar These sounds are normal and will soon become familiar These sounds also indicate freezer is operating and performing as designed 1 Temperature Control Temperature control clicks when starting or stopping compressor 2 Evaporator Evaporator refrigerant flow gurgles pops or sounds like boiling water 3 Evaporator Fan Motor Makes a whirring noise or sounds like rushing air 4 Compressor Compressor has a high pitched hum or pulsating sound 5 Defrost Heater Sizzling hissing or p
19. cycle on the overload Moisture in the System Any moisture in the system will usually freeze at the outlet end of the capillary tube where it enters the evaporator coil Preventing refrigerant from entering the coil This results in loss of cooling with the compressor continuously operating When the evaporator temperature rises above freezing moisture restriction will melt and refrigerant will circulate through the system Freezer will operate normally until another freeze up occurs which depends upon the amount of moisture in the system If compressor is operating but evaporator coil or refrigerated shelves are not refrigerated stop the compressor and listen for refrigerant surging through tubing If a gurgling sound is heard capillary tube is not restricted Check for a leak or check operating pressures When first opening the door no refrigerant circulating sound is heard but after several minutes it is noticeable there is probably moisture in the system which is freezing at the capillary tube outlet Install a new drier evacuate and recharge If no moisture is in the system and no leaks check for kinked tubing Sometimes a kink in a large tube will not affect the system operation Kink in the capillary tube could cause erratic operation It cannot be straightened without cracking its walls Incorrect Refrigerant Charge An overcharged system may have a frost back condition appearing outside the insulation sleeve
20. e Line valve and tubing Access fitting should be prepared as follows Discharge condensor Pressure regulator Tube process Compressor Cutting or Unsoldering Points No Defrost Models Line n valve Prepare equipment as required and test condenser as follows 1 Cut tubing at arrow to condenser and from condenser as shown in the previous illustration Suction Crimp and solder the end to condenser that enters into the cabinet Silver solder access fitting of test equipment to the end from condenser tube that emerges from the cabinet Pressurize the system to 250 pounds with dry nitrogen Test all connections for leaks with a soap solution Check the pressure gauge If pressure drops there is a leak However it may be necessary to allow as much as 24 hours for test results to verify no leaks exist If there are no leaks reconnect the tubing Evacuate and recharge the system Nitrogen Tank and Fittings To Process __ condensor Discharge condensor x Tube process Compressor Cutting or Unsoldering Points Refrigerated Shelf Models RS1500000 Rev 2 Component Testing To avoid risk electrical shock personal injury or death A W ARNING always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they mus
21. in the pan Toe grille Toe grille at bottom front of freezer can be removed to locate drain tube and levelling gliders e Remove toe grille by grasping both ends and pulling straight outward Replace by pressing ends of toe grille into slots on cabinet and snapping into place ee General e Secure door before moving freezer Do not use door or handle to lift or push freezer If hinges must be removed check instruction label on rear of freezer cabinet Amana freezers are currently rated for domestic use not designed for commercial application Confirm the following items are installed Free O Frost Upright Freezer Models Defrost drain pan behind toe grille Standard Upright Freezer Models Drain plug in bottom front of freezer liner some models Location These recommendations and explanations may help customer receive maximum efficiency from freezer and avoid service calls 4 amp CAUTION To avoid personal injury wear gloves when installing freezer To avoid property damage protect soft vinyl or other flooring with cardboard rugs or other protective material during installation or servicing If freezer is to be placed in basement back porch etc place freezer on wooden slats up off floor Freezer is designed for installation as a freestanding not built in unit 2 Locate freezer with at least 3 inches of clearance on both ends and back to provide adequate air circu
22. inch 1 6 mm along the hinge side with door closed Handle side of door should be 1 16 inch 1 6 mm above the handle side of the cabinet viewed from the front Upper hinge side corner of door should be 1 16 inch 1 6 mm above the cabinet top In many cases levelling the freezer will eliminate needed for cabinet door adjustments Verify freezer is level by checking both front edges as well as both sides of the cabinet with a carpenter s level Adjust levellers until cabinet is in a true vertical position Checking Gasket Seal Door gasket seals effectively with its normal pull Visual inspection will usually reveal any point of poor seal Double check locations which are questionable by closing the door on a narrow strip of paper Any areas that will not support the weight of the paper are considered areas of poor gasket seal On areas which cannot be checked visually or with a paper rub blue carpenter s chalk on the gasket or dampen the gasket and close door several times Examine the cabinet flange for transfer of chalk or dampness Failure of the transfer indicates areas of poor seal 35 Improving Gasket Seal In order for gasket to compress evenly around the entire door it must make contact at the top and bottom at the same time For this reason the door should not toe in or toe out To correct a toe in or toe out condition verify hinge side of door is parallel to the cabinet 1 Check cabinet levellers Turni
23. product information Locate product information on the serial plate Chest freezer serial plate is located on upper right wall Record the following information Model Number Manufacturing Number S N or Serial Number Date of purchase Dealer s name and address Keep a copy of sales receipt for future reference Locate an authorized servicer by calling 1 800 NATLSVC 628 5782 inside U S A and 319 622 5511 outside U S A Warranty service must be performed by an authorized servicer Amana also recommends contacting an authorized servicer if service is required after warranty expires Amana offers a complete line of appliances refrigerators freezers ranges cooktops wall ovens microwave ovens dishwashers washers and dryers Amana also manufactures a complete selection of high efficiency gas furnaces plus both central and room air conditioners Enjoy this new Amana freezer 7 RS1500000 Rev 2 Operating Instructions Setting Controls This freezer operates most efficiently in normal household temperatures of 65 to 90 F Temperature Control Locate temperature control on right side of interior freezer cabinet wall When control is set to OFF freezer will not cool Initially set control to 4 Wait 3 hours after connecting power for freezer to reach desired temperatures then add food After 24 hours adjust control as desired 1 is warmest setting and 7 is coldest Set temperatures p
24. responsibility of the service technician to capture the refrigerant for safe disposal Remove butyl sealer from around the tube entry hole Unsolder suction tubing at compressor stub or cut tubing three inches 76 mm from compressor stub 6 Cut drier from condenser tubing Then cut drier from capillary tube 7 Straighten heat exchanger tubing to slide tube through entry hole from inside the cabinet 8 Remove clamp retaining the control feeler tube to underside of second shelf counting downward 9 Carefully bend feeler tube down against liner side to be out of the way 10 Remove screws securing top freezer plate to liner top As front edge of plate drops clearing the liner 11 Carefully remove each shelf from food liner support rails Push outward on liner side just above front retainer embossment Lift shelf front free of retainer If necessary repeat this operation on opposite side ak 12 Pull entire shelving assembly out of cabinet and position to allow detachment of heat exchanger Freezer Shelf Assembly Joints Refrigerated Shelf Model 13 Unsolder capillary tube and suction line cut suction line away from original joint and swage the end of it for new tubing if desired 14 Clean joints and solder new heat exchanger to shelving assembly Clean amp paint soldered joints before reinstalling evapora
25. the lock is in Unlocked Lock design is simple and no major operating difficulties should be encountered If the lock is not locking in a positive enough manner position the door to verify it is high enough for the bolt to catch firmly Side way movement to the door may also improve lock operation Sometimes levelling the freezer will eliminate need for cabinet door adjustments Verify freezer is level from side to side and from front to back with a carpenters level Adjust levelling glide until freezer is in a true vertical position 34 Disassembly Procedures 44 WARNING To avoid risk of electrical shock personal injury or death disconnect power to unit before following any disassembly procedures Removing Door Lock Assembly 1 Remove all inner door liner mounting screws on door lock side and four from the top and bottom working in from the lock side 2 Pull inner door liner out far enough to reach the lock bolt 3 Using a screw driver pushed through foam block Remove screw securing lock cam Lock cam then can be removed 4 Remove clip holding lock to outer door panel Push lock out of door panel 5 Reassemble in reverse order Cabinet Door Alignment Cabinet door on each model is in correct alignment when e Hinge side of door is equidistant from cabinet flange at the top and bottom Gasket seals smoothly and is compressed no more than 1 16
26. variance in altitude Screw turns are very critical use circular scale as a guide Cut out screw Cut in screw Temperature Control Alititude in feet 2 000 3 000 4 000 5 000 6 000 7 000 8 000 9 000 10 000 Counter Clockwise turns 7 60 13 60 19 60 25 60 31 60 37 60 43 60 49 60 55 60 Altitude Correction Both Cut In and Cut Out Screws Must Be Adjusted This scale may be used as a guide for measuring degrees of rotation required for altitude correction The arrows indicate direction of screw rotation 1 60 of a turn equals 6 of rotation Turn cut in or cut out screws clockwise to obtain colder operating temperatures 48 Service Information 44 WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Cabinet Shell Cabinet shell is made of steel with all seams welded and all points of stress adequately braced Refrigeration system condenser tubes are attached to the inner surfaces of the cabinet shell by means of spot welded clamps Forming a shell type condenser which
27. 1500000 Rev 2 For positive identifications of individual units state complete serial number model and type This information is found on the serial plate located on front upper right hand corner of foodliner or on some models exterior back of the outer casing An explanation of coding contained in Type position is shown below 1998 and 1999 Model Identification gt gt gt gt gt gt Color W White Series K Feature Level 0 Good Storage Capacity 7 Cubic Foot 10 Cubic Foot 15 Cubic Foot 22 Cubic Foot Defrost Type Blank Manual F Free O Frost Product U Upright Freezer Amana Installation Instructions Unpacking Remove all protective packaging Cardboard shipping braces and or protective tape used to prevent damage to baskets shelves speciality racks and compartment dividers during shipment Use soapy water to remove any adhesive residue Do not use alcohol or nail polish remover Door Lid handles and hinges e Support and secure door lid before transporting or moving the freezer e Install freezer handle if applicable Do not use door or handle for leverage to lift or push unit Defrost drain plug and drain pan e Verify drain plug is installed on non frost free freezers e Before operating frost free freezer verify frost drain pan is installed behind toe grille located at bottom front of freezer with drain hose placed
28. G always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Performance Data at Control Setting 4 Manual Defrost l l l Capacity Insulation Amb Wattage High Low Amps Running Cu Ft Type Running Side Side Capacitor 11 7 Foam 70 90 110 35 45 95 115 5 3 0 7 1 0 12 uF 90 95 115 50 60 125 145 4 2 0 8 1 1 210 V 110 100 120 80 90 170 190 2 0 0 8 1 1 15 2 Foam 70 95 115 35 45 95 115 4 2 0 9 1 2 12 uF 90 100 120 55 65 125 145 3 1 0 9 1 2 210 V 110 105 125 90 100 165 185 3 1 1 0 1 3 16 9 Foam 70 105 125 40 50 95 115 4 2 0 9 1 2 12 uF 90 110 130 55 65 130 150 3 1 0 9 1 2 210 V 110 115 135 90 100 165 185 2 1 1 0 1 3 19 7 Foam 70 120 140 40 50 100 120 4 2 1 0 1 3 12 uF 90 125 145 55 65 135 155 3 1 1 0 1 3 210 V 110 130 150 90 100 175 195 1 1 1 2 1 5 Performance Data at Control Setting 4 Auto Defrost l l l 15 0 Foam 70 125 145 45 55 105 125 3 1 1 0 1 3 12 uF 90 130 150 60 70 140 160 3 1 1 1 1 4 210 V 110 135 155 90 100 185 205 1 1 1 2 1 5 16 7 Foam 70 135 155 35 45 100 120 3 1 1 2 1 5 12 uF 90 140 160 45 55 135 155 2 0 1 2 1 5 210
29. Service Upright Freezers This manual is to be used by qualified appliance technicians only Amana does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person Amone Models and manufacturing numbers in this manual ESU12JW ESU15JW ESU17JW ESU20JW ESUF15JW ESUF17JW ESUF20JW ESU12JW ESU15JW ESU17JW ESU20JW ESUF15JW ESUF17JW ESUF20JW AU120KW AU120KW AU150KW AU150KW AU170KW AU170KW AU200KW AU200KW AUF150KW AUF150KW AUF170KW AUF170KW AUF200KW AUF200KW P1311101W P1311102W P1311103W P1311104W P1311105W P1311106W P1311107W P1179615W P1179616W P1179617W P1179618W P1179619W P1179620W P1179621W P1317701WW P1317714WW P1317702WW P1317715WW P1317703WW P1317716WW P1317704WW P1317717WW P1317705WW P1317718WW P1317706WW P1317719WW P1317707WW P1317720WW RS1500000 Revision 2 November 1999 Important Information Pride and workmanship go into every product to provide our customers with quality products It is possible however that during its lifetime a product may require service Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools parts testing instruments and the appropriate service manual REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS Impor
30. To reduce risk of fire sealed refrigeration system must be air free To reduce risk of air contamination follow evacuation procedures exactly 45 RS1500000 Rev 0 Service Information 4 amp WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Thermistor Low Side Gauge ign Side Gauge Vacuum Gauge x Vacuum Pump Charging Cylinder Evacuation and Charging Typical Setup Before opening system evaporator coil must be at ambient temperature to minimize moisture infiltration into system NOTE Itis the responsibility of the service technician to capture refrigerant in system for safe disposal before opening any refrigeration system 1 After capturing refrigerant replacing drier and making any repairs evacuate system from high side through drier process tube and low side through compressor process tube simultaneously Evacuation should not be done through line piercing valve but through I D opening of tubes 2 With valves C and F closed to thermistor vacuum gauge and charging cylinder open all other valves and start vacuum pump 3 At approximately 77 66 cm 29 of vacuum open val
31. V 110 145 165 90 100 175 195 2 0 1 2 1 6 19 6 Foam 70 135 155 40 50 95 115 4 2 1 2 1 5 12 uF 90 140 160 60 70 130 150 4 2 1 2 1 5 210 V 110 145 165 90 100 175 195 2 0 1 3 1 6 RS1500000 Rev 2 22 Troubleshooting To avoid risk electrical shock personal injury or death A WARNING always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Problems Possible Causes Correction Frost build up on freezer coil Timer no frost models only Stuck in freeze cycle Replace Motor not running Replace Defrost heater no frost models only AC circuit to heater open See wiring diagram and check circuit Failed Replace Bi metal AC circuit to bi metal open See wiring diagram and check circuit Failed Replace Door Seal Poor door seal Adjust door Failed Replace AC circuit to control open See wiring diagram and check circuit Failed Replace Starting relay AC circuit to relay open See wiring diagram and check circuit Failed Replace Overload protector AC circuit to overload open See wiring diagram and check circuit Failed Replace Low voltage Check voltage must be at least 110 volts at moment of Start Time with all loads on the line Tim
32. ak Molecules of HFC134a are smaller than other refrigerants and will leak where other refrigerants would not Swaging tools Flaring tools Tubing cutter e Flux Sil Fos Silver solder Oil for swaging and flaring Copper tubing Dry nitrogen 99 5 minimum purity with 40 C 40 F or lower dew point Crimp tool Tube bender Micron vacuum gauge Process tube adaptor kit Heat trap paste Appliance grade HFC134a 6 Discard drier in safe place Do not leave drier with RS1500000 Rev 0 44 Service Information 44 WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational 44 WARNING To avoid death or severe personal injury cut drier at correct location Cutting drier at incorrect location will allow desiccant beads to scatter Completely clean area of beads if spilled Replacement HFC134a Service Compressor HFC134a service compressors are charged with ester oil and pressurized with dry nitrogen Before replacement compressor is installed pull out one rubber plug A pop from pressure release should be heard If a pop sound is not heard do not use compressor Positive pressure i
33. al e Confirm freezer has proper clearance on each side Water droplets form on outside of freezer Check door gaskets for proper seal Water is on floor beneath freezer e Confirm drain plugs are properly positioned e Empty drain pan Freezer has an odor See Odor Removal instructions in Care and Cleaning section Freezer makes unfamiliar sounds or seems too loud It may be normal See Normal Operating Sounds section this page General Tips Operating Sounds Today s freezers are designed for economical operation and energy efficiency New features and designs may create sounds which are different Following is normal operating sounds which may be encountered no service call is required Defrost heater Sizzling hissing or popping sounds are caused by water dropping on the defrost heater during the defrost cycle rm FSU Temperature control Clicks when the compressor starts or stops Evaporator Gurgling sound like boiling water when refrigerent flows through the freezer cooling coil Defrost timer Automatic timer sounds like an electric clock that snaps in and out of the defrost cycle Freezer fan Makes a whirring noise or sounds like rushing air as cold air ciculates in the freezer compartment Insulation High efficiency foam is used for its excellent energy insulation capacity even though it does not offer the same level of sound insulation as less energy efficient
34. ally accepted brazing materials are Copper to copper joints SIL FOS alloy of 15 silver 80 copper and 5 phosphorous Use without flux Recommended brazing temperature is approximately 1400 F DO NOT USE FOR COPPER TO STEEL CONNECTION Copper to steel joints SILVER SOLDER alloy of 30 silver 38 copper 32 zinc Use with fluoride based flux Recommended brazing temperature is approximately 1200 F Steel to steel joints SILVER SOLDER see above Brass to copper joints SILVER SOLDER see copper to steel connections Brass to steel joints SILVER SOLDER see copper to steel connections Refrigerant Precautions 44 WARNING To avoid personal injury do not allow refrigerant to contact eyes or skin Do not burn refrigerant a CAUTION Do not use refrigerant other than that shown on unit serial number identification plate NOTE All precautionary measures recommended by refrigerant manufacturers and suppliers apply and should be observed Open Lines During any processing of refrigeration system never leave lines open to the atmosphere Open lines allow water vapor to enter system making proper evacuation more difficult 47 RS1500000 Rev 0 Service Information 44 WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wir
35. alve Low side gauge pressure should rise shortly after opening charging cylinder valve as system pressure equalizes through capillary tube If pressure does not equalize a restriction typically exists at capillary drier braze joint 9 If no restriction exists open valve E low side manifold gauge and pinch off high side drier process tube 10 Start compressor and draw remaining refrigerant in charging hoses and manifold into compressor through compressor process tube To check high side pinch off drier process tube close valve D high side gauge If pinch off is not leaking high side pressure will not rise If high side pressure gauge shows an increase repeat high side pinch off and open valve D Repeat until high side pinch off no longer leaks 11 Pinch off compressor process tube and remove charging hose Braze stub closed while compressor is operating 12 Unplug dehumidifier from electrical outlet Remove charging hose and braze high side drier process tube closed 46 Service Information 44 WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Dehydrating Sealed Refrigeration Sy
36. an to capture the refrigerant for safe disposal 5 Remove all paint and scale from the capillary tube for a distance of approximately three inches from the original joint use steel wool or emery cloth 6 Cut the capillary tube approximately one inch from the old joint Verify the cut is uniform around the tubing then break it with the fingers we Score here then snap tube Cutting Capillary Tube 7 Cut the drier from condenser outlet and thoroughly clean the end of the tube 8 Make an offset 1 2 inch 13 mm from the end of the capillary tube to prevent its penetrating too far into drier tubing When forming the offset use a radius large enough so the inside diameter of the tubing is not reduced RS1500000 Rev 0 26 Condenser end inlet end Capillary end outlet end Flow direction Form offset Capillary Tube Insertion 9 Cut the inlet tube on the new drier 10 Snap off the scored end of replacement drier with your fingers 11 Install new drier and solder all joints Use silfos on all copper to copper joints On copper to steel joints silver solder with proper flux must be used Excess flux must be wiped off after soldering 12 Visually check all soldered joints evacuate and recharge the system 13 Test run the unit to verify proper operation 14 Pinch process tube and cut off the service valve Solder the joint and test for leaks Replacing Compressor Replacement compresso
37. attempting to service unless test procedures require power to be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Operational Testing Thorough operational checking of freezer will minimize future service calls 1 Set control to No 4 position 2 Place thermometer in the center of the freezer Operating temperatures should cycle between 3 F cut in to 2 F cut out in an empty cabinet 3 Check thoroughly with reliable leak detector for leaks 4 Attach a cycle recorder and plug into outlet Verify power source is not overloaded with other appliances Compare test results with Performance Data table see Component Testing section page 12 Running time will vary according to design characteristics of the system and will be influenced by conditions listed below e Temperature control setting e Room temperature e Length of time and number of lid openings Quantity and temperature of food placed in freezer Service Hints Owner s Manual If you find customer is not familiar with Owner s Manual acquaint customer with manual Usage Common types of abnormal usage that may lead to service calls include the following 1 Excessive unfrozen food load e Amount of unfrozen food to be placed in freezer should not exceed approximately 3 pounds per cubic foot in 24 hours unless otherwise no
38. charging the system 3 Connect a hose to the service valve and capture the charge NOTE Effective July 1 1992 before opening any refrigeration system it is the responsibility of the service technician to capture the refrigerant for safe disposal To avoid risk of electrical shock personal injury or 4 Remove butyl sealer from around tube entry hole 5 Unsolder suction tubing at compressor stub or cut tubing three inches 76 mm from compressor stub 6 Cut drier from condenser tubing Then cut drier from capillary tube 7 Remove screws securing freezer coil cover and detach green grounding wire Removing Defrost Thermostat No Defrost Models 13 Detach green grounding wire from freezer coil header 14 Remove screws securing freezer coil to coil mounting panel Coil is now free to be removed 15 Straighten heat exchanger tubing to pass through the Red opening in the cabinet back Orange 16 Pull entire assembly out of the cabinet 17 Unsolder cap tube and suction line from freezer coil careful not to overheat the epoxy joints A a Unsolder these joints Tom Circulating Fan and Wiring With Coil Cover Removed 8 Remove styrofoam air block from each end of the coil 9 Disconnect defrost heater lead from spade terminal on fan motor 10 Spade con
39. d Attach a service valve to it and leave the valve open 6 Cut drier from condenser tubing Cut drier from capillary tube To cut capillary tube score the walls with a knife or file Cut around entire tube uniformly then break it with your fingers A Score here then snap tube Cutting Capillary Tube 7 Straighten heat exchanger tubing to slide tube through entry hole from inside the cabinet 8 Remove clamp securing control feeler tube to underside of second shelf counting downward 9 Carefully bend feeler tube down against liner side to be out of the way Remove screws securing top freezer plate to liner top Front edge of the plate drops clear of the liner disconnect lead wires from interior light if equipped 11 Carefully remove each shelf from the food liner support rails Push out on liner side just above front retainer embossment Lift the shelf front free of the retainer If necessary repeat this operation on the opposite side Carefully pull entire shelving assembly out of cabinet and position to allow detachment of failed shelf 13 Cut or unsolder failed shelf and remove 14 Clean joints and solder new shelf to assembly and paint new joints 15 Carefully position assembly back in the cabinet verifying heat exchanger tubing passes through rear opening without damaging the rubber sleeve 16 Carefully work each shelf into its proper support rails Replace non refrigerant shelf in the same manner
40. death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Evacuation and Charging Procedures 44 WARNING Sealed system on these freezer models use R134a refrigerant If sealed system work on these models is required used approved equipment and follow service procedures See HFC134a Service Information section of this manual or Service Letter F842 for service procedures 4 amp CAUTION To minimize contamination exercise extreme care when servicing HFC134a sealed systems No trace of other refrigerants is allowed in HFC134a systems Chlorinated molecules in other refrigerants such as CFC12 etc lead to capillary tube plugging Ester oil is used in HFC134a systems Do not use mineral oil HFC134a and mineral oils cannot be mixed If mineral oils are used in HFC134a systems lubricant would not return to compressor and would cause early compressor failure If significant amount of oil has been lost from compressor replace oil rather than adding oil Low side leak repairs of HFC134a systems are different from those of CFC 12 systems Ester oils used in HFC134a systems are so hydroscopic that by the time an inadequate system performance is detected oil will be saturated with moisture
41. ds of handle until end caps snap in place End cap marked L goes on top end of handle End cap marked R goes on bottom end of handle Trim retainer RS1500000 Rev 2 Leveling 1 2 3 Install leveling legs under front corners behind toe grille Level freezer side to side and tilt freezer 1 4 from front to back Turn legs clockwise to raise freezer and counterclockwise to lower freezer If freezer cannot be level due to flooring use shims under rear of freezer cabinet to level freezer Leveling foot Check freezer 2 or 3 weeks after loading with food and confirm freezer is level Test After Installation 1 AnhWN For proper compressor operation voltage must be measured at the compressor terminals at the moment of starting Voltage must be in the range shown on Freezer Wiring Diagram Check freezer is reasonably level Check lid gasket seal Be sure light s work Check lock Wipe off any dirt and smudges RS1500000 Rev 0 General Instructions Electrical Requirements 4 amp WARNING Electrical Grounding Instructions This freezer is equipped with a three prong grounding plug for protection against possible shock hazards If a two prong wall receptacle is encountered contact a qualified electrician and have the two prong wall receptacle replaced with a properly grounded three prong wall receptacle in accordance with the National Electrical Code Freezers are designed to ope
42. er no frost models only AC circuit to timer open See wiring diagram and check circuit Failed Replace Compressor AC circuit to compressor open See wiring diagram and check circuit _ Failed Replace Excessively noisy but works Freezer not level or firmly setting on Level unit by lowering the levelling all four corners legs to make sure unit is firmly on the floor Structural weakness in floor Advise customer Compressor mounts fail Replace Defrost water pan rattles no frost Adjust defrost pan or install foam pad models only if necessary Freezer fan motor noisy rattles no Replace Compressor does not run Temperature control frost models only 23 RS1500000 Rev 0 Troubleshooting 44 WARNING To avoid risk electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Problems Possible Causes Correction Compressor runs but freezer temperature is higher than necessary Temperature control Misadjusted or out of calibration Failed Freezer fan motor no frost only AC circuit to fan motor open Failed Excessive load of unfrozen food Door Seal Poor seal Failed Loss of sealed system c
43. er or butcher paper does not provide proper protection for frozen food Materials not WARNING designed for freezer use may give off odors To help prevent child entrapment keep key out of reach of children and away from cabinet Freezing Guidelines Item Recommended storage times at 0 F Months Reversible Rack Some models Meat Racks separates food for more storage space 9 12 Remove rack by releasing rack from shelf wires Pull down if located under shelf or lift up if located above 3 6 shelf ee Hamburger 3 4 Replace rack by positioning on top or underneath shelf Pork cured 1 3 wires Slide rack until rack locks in place 4 8 Roast fresh 4 8 Sausage 1 3 Veal 8 9 Lamb 9 12 Poultry Chicken fresh 9 12 Chicken cooked 1 3 Duck 6 Goose 6 Turkey fresh 6 12 Turkey cooked 1 3 Fish 3 6 Vegetables 8 Fruits 12 Bread and Pastries Bread 1 3 Yeast Rolls 1 3 Layer Cake 2 4 Fruit Pie unbaked 8 Ice Cream Sherbert 1 2 9 RS1500000 Rev 2 Care and Cleaning 44 WARNING To avoid electrical shock which can cause severe personal injury or death disconnect power to freezer before cleaning After cleaning restore power 44 CAUTION To avoid personal injury or property damage read and follow all cleaning product manufacturer s directions General 1 Wash surfaces with four tablespoons baking soda dissolved in one quart warm water and a soft clean clot
44. es a leak Always use a leak detector to determine if the joint is leaking Pressurise the system to a minimum of 75 PSIG by running the compressor for high side testing To pressurise the low side allow entire system to warm up to room temperature If pressure is low enough a leak test will be impossible to perform Install a service valve to compressor process tube and check pressure Recover remaining refrigerant Separate and pressurise high amp low side independently allowing unit to settle Check gauges for pressure drop Leak detector can insolate larger leaks and generally locate small ones but to actually pinpoint extremely small leaks in the high side soap bubble solution will need to be performed RS1500000 Rev 0 NOTE Use soap bubble solution only when the system has a positive pressure Using it where a vacuum is present could pull moisture or soap bubbles into the system Brush liquid detergent over testing area and watch for bubbles This may take a few minutes for a bubble to appear if leaks are extermely small After replacing a component always evacuate add refrigerant and test for leaks on all joints before recharging Clean excess soldering flux from new joints before testing to prevent pinhole leaks at a later time Altitude Adjustment All models covered in this manual are equipped with a Cutler Hammer temperature control It has two adjustment screws both of which must be turned to compensate for
45. ezer and wait 10 minutes This will allow condenser and skin of outer casing to cool down to room temperature c Move your palm around skin of outer casing searching for cold spots e If avoid exists area will feel colder than neighboring area To access that cold spot is a void try to flex sheet metal with your thumb Metal over a void will be more flexible than metal backed with foam e If no void is found observed condensation or dripping which is caused by insulation void on the food liner side of the foam insulation 2 Action to be taken e If void is in an area which can be repaired in the field bottom or back using the foam kit proceed with the repair If void is found in an area which is exposed to view then freezer should be returned to source 39 RS1500000 Rev 0 Service Information 44 WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Refrigeration System Complaints Common occasions for customer requesting service are listed below with possible reasons and tests to diagnose problem before replacements are made 1 Cabinet temperature does not come down 4 Continuous running
46. fiberglass insulation once found in freezers Frost free models only Defrost drain pan Dripping sound is defrost Compressor Runs faster for higher efficiency and has a higher pitched hum or pulsating sound water falling onto drain pan RS1500000 Rev 2 Component Testing To avoid risk electrical shock personal injury or death A W ARNING always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Refrigeration System Test Procedures Careful testing of the refrigeration system is essential in determining if a malfunction is present Temperature testing is accomplished by using a three lead thermocouple temperature tester in specific locations Test point 1 is attached to inlet on the evaporator coil Test point 2 is attached to outlet on the evaporator coil Test point 3 is approximately 6 8 inches from suction port of compressor on the suction line Thermocouple tips should be attached securely to the locations specified Do not test during initial pull down Allow one complete OFF cycle or a balanced temperature condition to occur before proceeding 6 Unit must operate a minimum of 20 minutes after thermocouples are installed
47. gerated shelf models defrost water is carried through the front face plate of the cabinet where it can be collected into a container for disposal G a 2 CON L O gt ye SE i he SS Drain System Refrigerated Shelf Models On no defrost models drain grommet and sleeve are located in the center of drain trough which has been formed in the cabinet liner During defrost cycle water is carried through the drain hose and tube into the moisture pan which is located under the cabinet Heat from the precooler condenser hastens the evaporation process Drain System No Defrost Models Drain tube grommets should never need replacing unless it has deteriorated If drain system becomes clogged push a length of plastic cloths line completely through and flush with warm water 49 RS1500000 Rev 0 Wiring Diagram and Schematic grounding and polarization 44 WARNING To avoid risk of electrical shock personal injury or death disconnect power to freezer before servicing unless testing requires it Wires removed during disassembly must be replaced on proper terminals to insure correct CAUTION High Voltage Light plate switch White Fan Defrost thermostat Defrost timer ue 4 Heater White T3 Yellow T2 Black T1 Plug Ground Capacitor
48. ght OPTIONAL ESU12JW P1311101W P1179615W ESU15JW P1311102W P1179616W ESU17JW P1311103W P1179617W ESU20JW P1311104W P1179618W AU120KW P1317701WW AU150KW P1317702WW AU170KW P1317703WW AU200KW P1317704WW 51 RS1500000 Rev 1 Wiring Diagram and Schematic 44 WARNING To avoid risk of electrical shock personal injury or death disconnect power to freezer before servicing unless testing requires it Wires removed during disassembly must be replaced on proper terminals to insure correct grounding and polarization CAUTION High Voltage Black so Black Y White Door Switch Lamp Black Tan Defrost tks Green Timer 7 Blue 4 2 Yellow White onpi e White Defrost Heat Light Al wlat 3 Defrost 348 37 5 ohms Light Thermostat switch 4000 d ohms o Red Red White 1124 h Red 4 ohms Overload Compressor Protector c R Relay Run le i Start or Sr 4 White S Thermostat Capacitor Black Brown Pane cs SN Red White Defrost switch Black Swich 7 MBuzzer thermostat LH LV iN Black Identified Conductor Black e o Power Green Heater Supply ae Thermostat Plug Defrost timer 3 4 5 6 Buzzer i i Capacitor 1 Outer case 2 Compressor 3 Coil Cover 4 Control 5 Light Plate 6 Fan Motor AUF170KW P1317706WW AUF200KW P1317707WW RS1500000 Rev 1 52 1998 Ama
49. h 2 Rinse surfaces with warm water Dry surfaces with a soft clean cloth NOTE e Do not use the following items abrasive or harsh cleaners ammonia chlorine bleach etc concentrated detergents or solvents metal scouring pads These items can scratch crack and discolor surfaces e Do not place shelves or accessories in dish washer Adhesives Remove glue residue by dabbing toothpaste over adhesive Rub toothpaste into adhesive with fingers until adhesive loosens Rinse surface with warm water Dry surface with a soft clean cloth Door Gaskets 1 Clean door gaskets every three months or more frequently if necessary 2 Rinse and dry gaskets thoroughly 3 Apply a light film of petroleum jelly on cabinet hinge side to keep gaskets pliable RS1500000 Rev 2 Odor Removal 1 Remove all food 2 Wash all interior surfaces including door floor and walls according to General instructions Pay special attention to corners crevices and grooves Include all accessories shelves and gaskets 3 Rinse and dry thoroughly 4 Wrap foods in tightly sealed wrap or containers to prevent further odor After 24 hours check if odor was eliminated If odor was not eliminated do the following 1 Complete procedures in steps 1 3 above 2 Pack freezer with crumpled sheets of black and white newspaper 3 Place charcoal briquettes randomly throughout newspaper 4 Close door and let stand 24 48 hours 5
50. harge Timer stuck in defrost Partial restriction Frost build up on freezer coil over 1 2 inch thick 12 7 mm Separation of heat exchanger Adjust control Replace See wiring diagram and check circuit Replace Advise customer to freeze no more than 10 of freezer capacity at one time Adjust door amp gasket as instructed under improving gasket seal Replace Locate and repair leak Evacuate undercharge system proper amount of refrigerant Replace Locate and repair restriction Evacuate and recharge system with proper amount of refrigerant Check door seal If not Frost Free model advise customer to defrost every time frost builds up to almost 1 thick 25 mm Install heat exchanger repair kit Compressor does not run and no light No power at AC outlet Failed fuse Failed outlet Line cord Disconnect Failed Open machine compartment wiring harness Two simultaneous problems light bulb out and open AC circuit to compressor Replace Advise customer to replace Plug in line cord to AC outlet Replace See wiring diagram and check circuit Replace light bulb See wiring diagram and check circuit Sweating but freezer is working normally otherwise Exterior sweating Void in insulation Overcharged Defective door seal Add insulation inside the affected area if possible Evacuate and recharge system with right amount of refrigerant See specification chart Replace
51. ignment is necessary when replacing fan blade Fit blade on the shaft and push Blade is equipped with a built in stop Disassembly Procedures VN WARNING death disconnect power to unit before following any disassembly procedures Cabinet Door Assembly Cabinet door assembly consists of outer door panel bezel and nameplate insert door handle and insert door lock assembly if equipped hinge bushings fiberglass insulation inner door liner door shelf trim and door seal gasket To avoid risk of electrical shock personal injury or Top door hinge Tapping plate aca Outer door panel lt Washer 5 Serial plate Bezel coe Door handle Lock assembly 3 a p A lt i Bushing all A Kickplate lt Washer p Inner door liner Spacer om eC y eee Lower door hinge 33 RS1500000 Rev 0 Disassembly Procedures 44 WARNING To avoid risk of electrical shock personal injury or death disconnect power to unit before following any disassembly procedures Removing Cabinet Door Assembly 1 Remove screws securing upper hinge to cabinet top 2 Open door assembly and lift door off lower hinge pin Install Cabinet Door Assembly 1 Hold door assembly in open position and place on lower hinge with hinge pin entering the hinge bushing at the door bottom 2 Close door and install upper hinge mounting screws Check gasket seal Install Door L
52. iner And Gasket The DURA LAST inner door liner and gasket are mounted to outer door panel by screws place every 4 inches 102 mm around the door flange perimeter Removing Inner Liner and Gasket 1 Remove cabinet door assembly as previously described 2 Lay door assembly on a flat padded surface 3 Remove all mounting screws and lift off inner liner and gasket Installing Inner Liner and Gasket 1 Position gasket around inner panel so gasket lip will be sandwiched between inner liner and outer door panel flange 2 Replace and tighten all inner liner mounting screws until snug NOTE Do not over tighten screws this could crack liner or cause screw head to pull through the hole 3 Always align door Door Handle Door handle and insert are attached to outer door panel by mounting screws which are located under the insert Removing the Door Handle 1 Bow insert slightly and unhook top and bottom from door handle 2 Remove mounting screws which secure the handle NOTE Longer mounting screw must be used to attach the bottom of door handle RS1500000 Rev 0 Door Lock Assembly Door lock assembly if equipped is attached to outer door panel and consists of the cam and bolt lock bolt Illustration below indicates movement of the lock bolt as the key is turned clockwise to locked position An ejector spring in the lock forces the key out Key will not remain in the lock once it is released regardless of position
53. ing from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Line Piercing Valves Line piercing valves may be used for diagnosis but are not suitable for evacuating or charging due to the minute holes pierced in the tubing a WARNING Line piercing valve should not be left on the system connection to tubing is not hermetically sealed and eventually a leak will occur Upright freezers which are insulated with foamed in polyurethane foam have their condenser tubing embedded in this foamed insulation within the cabinet wall Liner cannot be removed and there is no access to the tubing to removed repaired or replaced NOTE Polyurethane insulation contains refrigerant R 11 R141B R22 Care must be taken when testing Isolate the area as much as possible so that the leak detector will not falsely indicate a leak of R 11 R141B R22 vapor If there is an undercharge of refrigerant and the system has not been recently opened there is probably a leak in the system First locate and repair the leak evacuated and recharged with the proper amount of refrigerant Replaced the dryer whenever a new charge of refrigerant is added NOTE Effective July 1 1992 before opening any refrigeration system it is the responsibility of the service technician to capture the refrigerant for safe disposal Presence of oil around a tubing joint usually indicat
54. is a magnetic switch with starting contacts Its magnetic coil is in series with the run winding of the compressor When current is applied to the compressor the magnetic coil raises the relay plunger and closes the starting contacts connecting the start winding in parallel with the run winding As the compressor motor approaches running speed current in the run winding and in the relay coil decreases and plunger drops out opening the start winding circuit Compressor motor continues to operate on the run winding Testing PTC Relay Disconnect relay from compressor terminals Place meter leads on relay terminals 2 and 3 or 5 and 6 a reading of approximately 4 7 ohms should be indicated 4 1 Back Front Testing PTC Relay With An Ohmmeter Connect one meter lead to terminal 8 and the other meter lead to terminal 2 on the relay There should be no continuity open circuit Connect one meter lead to terminal 8 and the other meter lead to terminal 3 on the relay There should be no continuity open circuit If not PTC relay has failed and must be replaced RS1500000 Rev 2 18 Interior Light and Switch If the light does not operate and bulb is good place the blade of a putty knife or similar object under the flange of the switch and carefully remove Short across the light switch terminals If light operates switch has failed If light fails to operate either the la
55. ith Coil Cover Removed Testing Freezer Fan Motor Remove screws from coil cover and disconnect ground wire from cover Remove freezer coil cover Before checking fan circuit for failures spin the fan blade to verify nothing has lodged against it which could prevent normal fan operation If blade spins freely check fan motor as follows 1 Unplug line cord 2 Attach test cord leads to fan motor leads If motor runs check all cabinet wiring for an open circuit If motor fails to operate remove and replace Audible Warning System some models This system is also know as line voltage operated LVO system or temperature monitor system Alarm sounds if temperature in freezer is 10 F higher than normal for selected temperature control setting The alarm is located in the unit compartment which is controlled by a 3 position switch 0 Prevents alarm from sounding when freezer is warm V Sounds alarm regardless of temperature Test alarm system regularly at least once a month 1 Sets alarm for normal freezer use Be sure to return the switch to ON when the freezer has cooled down after defrosting Alarm may sound if temperature control dial is turned to a much colder setting for example from 2 to 5 Alarm may also sound if a large amount of unfrozen food is added at one time causing the freezer temperature to rise RS1500000 Rev 2 Component Testing To avoid risk electrical shock personal injury or death A W ARNIN
56. jury or Run A Q Common 5 S _p Start death disconnect power before servicing Follow specific steps listed in this manual for testing or replacement of a suspected failed component All electrical components are grounded to the cabinet The green center conductor of three wire lead cord is also attached to the cabinet to provide a grounding circuit Power D when the lead cord is plugged into a properly grounded cord y electrical outlet After replacing an electrical component always verify the ground wire is reconnected ti The electrical outlet from which the appliance is to L sea sala receive its power should always be checked to verify it is properly wired Compressor Tester RS1500000 Rev 2 16 Component Testing WARNING To avoid risk electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Tester leads are marked RUN START and COMMON Connect common lead to common terminal start lead to start terminal and run lead to run terminal of the compressor Compressor Terminals The other two leads are for the start capacitor When not in use connect the two leads together i
57. lacing Heat Exchanger Refrigerated Shelf Model eeseeeeeteeee 27 Replacing Heat Exchanger No Defrosting Models cceseseeteeeeeeeeees 28 Replacing Freezer Shelving Refrigerated Shelf Models eeseeeereees 29 Replacing Freezer Coil No Defrosting Models 30 Replacing Light Switch 0 c cee 31 Replacing Control ccccceceecceeeeeeeeeeeeeeeeeees 31 Replacing Heater ee a aa ea a aat 32 Replacing Freezer Fan Motor o e 32 Cabinet Door Assembly 0 ceeceeeeteeeeeteees 33 Door Handle a arere at a enek ia ha enia 34 Door Lock ASSEMDIy suessrerranniariecia 34 Removing Door Lock Assembly a 35 Cabinet Door Alignment 0 ceeeeeeetteeeees 35 Checking Gasket Seal 0 ccseeceesseeeeeeeeeees 35 Improving Gasket Seal 0 ccceeceeeetteeeeeeees 35 Hinge Adjustment cccceceeceeeeeeeteeeeeeenneees 35 Cabinet Assembly cceceeeeceeeeeeeeeeetteeeeeeees 36 Service Information System Operation 0 cccccceeeeeeeeeteeesteeeeeees 37 Checking Operational Pressures 0 008 38 Operational Testing ccccscceseeeeeseeeeeteeeeees 39 Service Hints cccecceeceeeeeeeeeeeeeseneeeeeeteeeetees 39 Refrigeration System Complaints 04 40 Refrigerant Leaks cccceceeeeeeeeceeeeeeeteeeeeteeees 41 Evacuation and Charging Procedures
58. lation to dissipate condenser heat 3 Avoid locations near stoves radiators hot air ducts or where sun may cause excessive heat 4 Do not locate where surrounding temperature could drop below 32 F 0 C Temperatures below 32 F 0 C cause compressor oil to thicken delaying lubrication of sensitive components at compressor start up 5 Avoid placing freezer on plush carpet which may retard air flow over bottom causing bottom sweating Electrical Connection 1 Electrical supply should be checked for proper voltage and ground 44 WARNING Do not under any circumstances cut or remove the round grounding prong from the plug Freezer must be grounded at all times Do not remove warning tag from power cord 2 Avoid extension cords If absolutely necessary use an Appliance Extension cord at least 16 AWG of less than 10 feet If possible have freezer on separate circuit RS1500000 Rev 2 Installation Instructions Door Handle 1 If handle trim has not been factory installed slide right edge of handle trim under right edge of trim retainer Verify rib on right inside edge of handle trim fits into trim retainer notch Snap outside edge of handle trim over outside edge of trim retainer Install handle on freezer door as shown Verify freezer handle is angled inward towards opposite side of freezer Secure handle to freezer door with screws provided Verify screws are secure Slide end caps over en
59. led out refer to the electrical system and perform the necessary electrical tests before making any test which requires opening the system If there is no electrical failure and system does not operate properly such as long run periods or warmer than normal compartment temperatures the cause may be one of the following Failed Compressor A compressor which is not pumping adequately will produce very little cooling effect The shelf tubing may be covered with a thin film of frost but the temperature will not reach control cut off level even with continuous running Because these conditions are similar to those for a refrigerant leak perform leak test If no leak is found install gauges and check the operating pressures If high side pressures are lower than those in the table in the Specification section and low side pressures are higher than specified the compressor must be replaced Restricted Capillary Tube The inner diameter of a capillary tube is about the same size as the period at the end of this sentence It doesn t take much to restrict this area Use care when moving or touching the capillary tube slight kink can cause a restriction Restrictions of capillary tube may be caused by moisture freeze up foreign particles lodged in the tube or a kink If capillary tube is restricted there will be noticeable lack of frost on the refrigerated shelves or evaporator The compressor will operate for a short time then
60. m beneath it Lower hinge can be moved out by adding a 1 32 inch 0 8 mm shim between it and the cabinet RS1500000 Rev 0 Disassembly Procedures G WARNING death disconnect power to unit before following any disassembly procedures Cabinet Assembly To avoid risk of electrical shock personal injury or Temperature control knob Cabinet shell Lah tah re Temperature control plate Cabinet shell control knob ere Temperature V Light switch J control piate Temperature Temperature EN T control Light nae o A contro w i ea assembly g ANV Light AL Y J 3 RSA assembly ER AS S Light switch Ss Cabinet _ 7 inner J N y A liner S Dy Cabinet A inner liner lt Evaportator Drain tube cap A cover Drain N AN S a Drain tube eee Me i 7 Gate brackets and VW Gate brackets grommet ll oe Wire gate lt Cabinet leveller Wire gate L lt Cabinet leveller RS1500000 Rev 0 36 Service Information 44 WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational System Operation If freezer is not operating properly and electrical failure is not ru
61. mp socket or wiring has failed The lamp socket in the cabinet can be removed in the following manner 1 Disconnect power cord from electrical outlet 2 On refrigerated shelf models remove screws securing top freezer plate and pull the plate down slightly On no defrosting models remove the light housing from food liner top 3 Unplug light leads and disconnect grounding wire Check the socket with an ohmmeter or test cord to verify it has failed 4 Place new light socket into opening of the housing If necessary wet for lubricating purposes 5 Replace light housing in reverse order of removal verify green grounding wire is securely attached Checking Control Operation A failed control contact points stuck open or closed a leak in the bellows may cause compressor to run continuously or not at all Should one of these conditions exist check the control as follows 1 Remove control knob and control mounting screws 2 Work control out of opening far enough to reach the terminals on no defrosting models it may be necessary to remove feeler tube cover and straighten feeler tube enough to allow control to be pulled out far enough 3 Look for faulty wiring connections 4 Check for control points stuck or closed as follows If compressor will not run short across the control terminals If compressor starts control has failed and must be replaced If compressor does not start check cabinet wiring and compress
62. n compressor is vital to keep moisture out of ester oil Do not leave compressor open to atmosphere for more than 10 minutes The holding charge assures the compressor is dry A compressor it is recommended that the tubes be cut close to the soldered joints where they are connected to the compressor tube If the tubes are not long enough it may be necessary to unsolder the joints to allow connections to the replacement compressor When replacing compressor proceed as follows Disconnect power cord from electrical outlet Install a service valve on process tube Connect a hose to service valve and capture charge Clean the tubing for about 3 inches 76 mm at the points to be cut Before cutting tube be sure it will be long enough to reconnect to replacement compressor If not unbraze joints Disconnect wires from compressor terminals Remove retaining clips from compressor mounts Lift compressor from mounting rails and transfer rubber grommets to replacement compressor 7 Set replacement compressor into position and install retaining clips 8 Remove all rubber plugs Clean stubs of compressor and compare the size of tubing to stubs of replacement compressor It may be necessary to swag copper tubing to make the joints 9 Install a 6 inch 152 mm copper tube to low side process tube on compressor Add a service valve to end of this tube 10 Connect all tubing Apply flux to compressor stubs and braze all the joints Fl
63. n 12 Normal Operating Sounds cceeeeeeeereees 12 Before Calling For Service ccececeeeeee 12 Operating SOUNS 0 eect teeteeeeeeeeeeeteeees 13 Component Testing Refrigeration System Test Procedures 14 Testing Main Condenser 15 Testing for Leaks 2 0 0 2 cece ereere erener 16 Electrical System cccceececceeeeeeceeeeeeeeteeeeneeees 16 Compressor Electrical Tests 0 c eeeeeee 16 Testing Compressor Direct 0 cece 16 CapacitOr be seis eek aah eg ice T 17 Overload Protector 0 cccceceeeeeeeeeeeeteeeeeeteeees 17 Testing Overload Protector 0 cceseeeeeeeeeees 17 PT Ci Relayer ien e a e a hy inte 18 Testing PTC Relay erreser 18 Interior Light and Switch 00 ccc 18 Checking Control Operation 0 c eee 18 Temperature Control 0 cccccceeteeeeeteeeeeeeeeees 19 Defrost Timer 0cceccceceeceeeeeeeeeeeeeeeeeeeeeetneeeeees 19 Checking Timer 0 ccceeeceeeceeeeeeeeeeeeeeeeeeees 20 Defrost Heater and Thermostat No Defrosting Models ceeeeseetseeeteeeees 20 Freezer Fan No Defrosting Models 0 5 21 Testing Freezer Fan Motor o e 21 Troubleshooting 2 0 2 cee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeteeeees 23 25 Disassembly Procedures Replacing Dryer iurien anaana i iah 26 Replacing Compressot c cceeeseeeeeteeeeeeees 26 Rep
64. n the OFF position Verify there are no bare leads touching the cabinet Plug in the tester cord and flip the switch to START position As soon as the compressor starts release the switch to RUN position If compressor starts trouble is in another electrical component overload protector starting relay temperature control or wiring harness If compressor fails to start or run compressor has failed and must be replaced Perform continuity check on compressor 1 Check resistance of compressor windings a Attach ohmmeter between winding C and S Ohmmeter indicates lt 10 Q but gt 0 Q b Attach ohmmeter between winding C and M Ohmmeter indicates lt 10 Q but gt 0 Q 2 Check compressor for grounds e Attach one ohmmeter lead to compressor case Attach second ohmmeter lead to C then S then M terminals on compressor Ohmmeter indicates open on each terminal Capacitor Capacitor can be tested by an analog meter Attach one meter lead to one terminal and once the other meter lead touches the second terminal meter will indicate a reading but will discharge through the meter and indicate no reading Reverse the meter leads and indication will be the same If testing with a digital meter the only indication will be capacitor has a direct short 17 Overload Protector Overload protector is located under the terminal cover on the compressor If compressor becomes overheated and or draws too much curren
65. na Appliances Amana lowa 52204
66. nector is used to join the defrost heater lead to the lead in wire Separate these two wires at the spade connector Release lead from the two clips on coil mounting panel 11 Disconnect heater lead from defrost thermostat 12 Remove defrost thermostat from coil header to release the front tang See following illustration Protect these joints Heat Exchanger To Freezer Coil Joints No Defrost Models RS1500000 Rev 0 28 Disassembly Procedures a WARNING To avoid risk of electrical shock personal injury or death disconnect power to unit before following any disassembly procedures 18 Transfer rubber insulating sleeve to replacement heat exchanger assembly and tape the same points 19 Clean tubing and silver solder new heat exchanger to coil with proper flux Excess flux must be wiped off after soldering 20 Clean tubing and silver solder new heat exchanger to the coil 21 Work new tubing through rear opening careful not to tear rubber sleeve 22 Position freezer coil and install mounting screws Replace styrofoam air blocks at the upper ends of the coil This is necessary to channel the air flow properly through the coil 23 Carefully form tubing and route it in the same manner as the original Use extreme care when bending the tubing at entrance hole to prevent kinking Pack entry with butyl sealer 24 Clean the suction line and silver solder the joint with proper flux Excess flux mus
67. ng leveller in or out may correct a toe in or toe out condition 2 Loosen all inner door panel mounting screws along the top bottom and latch side of the door NOTE Do not loosen screws along hinge side 3 Hold the corner that toes in stationary push in on the toe out corner until door is lined up parallel with the cabinet Tighten a few screws on latch side to hold door in position 4 Open and close door several times to insure proper fit If necessary repeat steps 2 and 3 5 Tighten all loosened screws until they are snug Do not tighten screws too much heads may pull through screw hole Hinge Adjustments Hinge adjustments are necessary when e Gasket is not sealing sufficiently along hinge side of door e Gasket is compressed more than 1 16 inch 1 6 mm on hinge side causing a poor seal elsewhere around the door e Distance between the door and cabinet is greater at the top than it is at the bottom or vice versa e Handle side of the door does not line up with cabinet side when viewed from the front or upper latch side corner is higher or lower than the cabinet top If one or more of these conditions exist verify cabinet is level and make necessary hinge adjustments as instructed below Turning out the hinge side front leveller may correct a door sag Oversized holes in the cabinet top permit some sideways or in and out adjustments of the top hinge Raise top hinge by placing a 1 32 inch 0 8 mm shi
68. o be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Refrigerant Leaks 44 DANGER Free oxygen will explode on contact with oil Acetylene will explode spontaneously when put under pressure To prevent violent explosions that may result in serious injury or death to persons in or near the immediate vicinity NEVER use oxygen or acetylene for pressure testing or cleanout of refrigeration systems Before attempting to locate a leak study the diagrams showing the route of refrigeration tubing and serviceable joints NOTE Urethane foam cells are filled with trapped gas and if cells are broken by removing a piece of foam etc a leak detector will indicate a strong leak When foam cells are broken liberated gas should be blown off surface or allow unit to stand for at least 5 minutes before testing Symptoms of refrigerant leaks 1 Frost line visible inside food liner does not extend to tail end of evaporator In properly refrigerated system frost line on the food liner back wall of the chest freezer will extend down to 5 6 inches from the food liner bottom In slow leaks this frost line gradually recedes upward When an internal refrigerant leak is suspected recharge freezer with proper amount of refrigerant and mark end of the frost line nearest spot to the bottom with a c
69. o skin No effect Same Liquid exposure to skin Can cause frostbite Same Vapor exposure to eye Very slight irritant Same Liquid exposure to eye Can cause frostbite Same Above minimum exposure limit Can cause Asphyxiation Same Tachycardis and Cardia Arrhythmias Safety and handling Wear appropriate skin Same and eye protection Use with adequate ventilation Spill management Remove or extinguish Same ignition or combustion sources Evacuate or ventilate area Fire and explosion hazards May decompose if contact with flames and heating elements Container may explode if heated due to resulting pressure rise Combustion products are toxic Storage conditions Procedures rules for Same CFC12 also apply for HFC134a Disposal procedures Recycle or reclaim Same 43 RS1500000 Rev 0 Service Information Q WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Service Equipment Drier Replacement Before opening sealed system recover HFC134a 7 iN CAUTION refrigerant for safe disposal Service equipment for HFC134a systems must be Every time sealed HFC134a system is repaired drier
70. on is 430 watts timer has not advancing to defrost failed and must be replaced 4 Disconnect freezer line cord plug from wattmeter 5 Remove freezer coil cover and check defrost heater for continuity If heater shows continuity defrost thermostat has failed and must be replaced NOTE Set meter to X1 scale If reading is approximately 35 ohms defrost thermostat and defrost heater are operative Component Testing To avoid risk electrical shock personal injury or death A WARNING always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Freezer Fan No Defrosting Models Freezer fan is designed and located in the cabinet to create movement of uniform low temperature air throughout freezer interior It is wired to run simultaneously with the compressor If fan fails to operate or runs erratically reduced air circulation will cause unsatisfactory temperatures throughout the freezer Freezer fan is located above freezer coil and is mounted inside an opening in the freezer liner back Tom Circulating Fan and Wiring W
71. on the suction line at the rear of the cabinet When the compressor stops frost melts and drips on the floor System must be purged evacuated and recharged with the correct amount of refrigerant An undercharged system will operate with temperatures above normal and compressor operating time will be increased The greater the undercharge higher the temperatures and longer the operating time The system must be purged evacuated and recharged with the correct amount of refrigerant Before recharging test for refrigerant leaks Partial Restriction in Low Side Tubing Bent tubing foreign matter or moisture in the system may cause a partial restriction in the low side tubing This usually results in frost free tubing between the restriction and capillary tube and frost covered tubing between the restriction and suction line This restrictions acts like a second capillary tube increasing pressure behind it warming and decreasing pressure beyond it cooling Replace component if there is a partial restriction in the refrigerant tubing Pressure Unloading in System Compressor may stall and cycle on overload if an attempt is made to restart unit immediately after it has stopped Compressor is trying to start while refrigerant pressure is high on condenser side and low on evaporator side When the compressor stops operating pressure in both sides equalizes as the liquid slowly passes through the capillary tube When this occurs the
72. opping sounds are caused by water dropping on the defrost heater during the defrost cycle 6 Defrost Drain Pan Dripping sounds is defrost water falling onto drain pan 7 Defrost Timer Automatic timer sounds like an electronic clock that snaps in and out of the defrost cycle 8 Insulation Foam insulation is very energy efficient and has excellent insulating capabilities However foam insulation is not as sound absorbent as previously used fiberglass insulation RS1500000 Rev 2 Before Calling For Service Freezer does not operate e Confirm temperature control is on Confirm freezer is plugged in e Check fuse or circuit breaker Plug in another item at that wall outlet Wait 20 minutes to see if freezer restarts If freezer control is on freezer may be in defrost cycle Freezer still won t operate e Unplug freezer Transfer food to another unit or place dry ice in freezer to preserve food e Call 1 800 NATLSVC 628 5782 inside U S A and 319 622 5511 outside U S A to locate an authorized servicer Food temperature appears too warm e See above sections e Allow time for recently added food to reach freezer temperature e Check gasket for proper seal e Adjust temperature control Freezer runs too frequently e It may be normal to maintain an even temperature e Doors may have been opened frequently or for an extended period of time e Adjust temperature control e Check gaskets for proper se
73. or components for failures On no defrosting models verify timer is not in the defrost cycle If compressor runs all the time even though freezer temperature is below the control cut out point make the following applicable check On refrigerated shelf models check control feeler tube attachment to underside of shelf front for a positive thermal contact Component Testing To avoid risk electrical shock personal injury or death A W ARNING always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational On no defrosting models check control feeler tube cover to verify air is allowed to pass freely under it and circulate around the feeler tube If compressor continues to run disconnect wire from one control terminal If compressor stops control has failed and must be replace If compressor still runs check cabinet wiring for a short circuit Temperature Control Freezer temperature should vary considerably by changing control knob setting If not check control cut in and cut out temperatures as follows 1 On no defrost models disconnect control feeler tube cover from food liner side by pulling straight out at its center Fasten a thermocouple to feeler tube with
74. osting models disconnect control feeler tube cover from the liner side by pulling straight out at its center On refrigerated shelf models securely tape a piece of heavy string to the end of the feeler tube On no defrosting models observe feeler tube is coiled behind the cover then straighten it Pull complete assembly out of cabinet on refrigerated shelf models string end should follow through the hole in the liner side so it can be used to pull replacement back through Transfer plastic sleeve to new feeler tube On refrigerated shelf models tape string to new feeler tube Pull tube through the hole in the liner side On no defrosting models work feeler tube through the opening and reshape it so it will not contact the inner side or cover Connect all wires including grounding wire and push control into position Reinstall mounting screws On refrigerated shelf models secure feeler tube to underside of shelf front On no defrosting models attach feeler tube cover by bowing it out at the center until tabs on the cover can be fitted into slots in the liner Reinstall control knob Plug in power cord and check freezer operation 1 RS1500000 Rev 0 Disassembly Procedures a WARNING To avoid risk of electrical shock personal injury or death disconnect power to unit before following any disassembly procedures Replacing Heater Remove defrost heater as follows 1 Remove freezer coil cover 2
75. provides quiet operation and efficient heat dissipation This method of dissipating the condenser heat eliminates the formation of condensation on exterior surfaces of the cabinet Steel base rails provide a platform on which the cabinet shell is mounted Two adjustable levelling glides are inserted into the base rails one at each front corner Door lock retainer and strike are also attached to the cabinet shell if equipped Cabinet Liner Food Cabinet liner is made of a tough flexible plastic or high impact polystyrene material and is secured to the cabinet shell with retaining clips Following components are attached to the cabinet liner by utilising special snap nuts clips and other fasteners interior light and switch cold control assembly and cover evaporator coil and cover no frost models shelves and gate mounting hardware and drain tube and grommet Once system components and cabinet liner have been assembled to the cabinet shell polyurethane insulation is foamed in to fill the void between the shell and liner NOTE Cabinet food liner cannot be removed on the current models with foam insulation Drain System Freezer drain system consists of a drain grommet and sleeve at the liner and cabinet bottom and a drain hose and tube that carries the defrost water NOTE Refrigerated shelf models are equipped with a drain cap that must be removed before defrosting and replaced securely afterwards On refri
76. r are now controlled by the temperature control for a period of approximately 12 hours after which a new defrost cycle begins Line white To compressor 3 i Timer te Control RS1500000 Rev 2 Component Testing To avoid risk electrical shock personal injury or death A W ARNING always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Checking Timer Unplug line cord from electrical outlet Remove 1 4 Spin Tight screws and remove the timer Disconnect all wires from timer and attach ohmmeter leads to terminals specified in the accompanying chart If no continuity is indicated timer has failed and must be replaced When replacing timer connect wire leads to timer terminals Verify grounding wire is connected Timer mounting screws Ground _ wire Defrost Timer Mounting To test Turn timer knob to ee motor ee as is Check between terminals 1and3 ee Defrost circuit Compressor 2 click 1 and 4 circuit Turn defrost timer one full turn clockwise to locate start defrost cycle 1st click and end defrost cycle 2nd click positions The 1st and 2nd clicks are only a few degrees of shaft rotation apart Turn the
77. rate on a separate 103 to 126 VAC 15A with a 60 Hz cycle Do not under any circumstances cut or remove the round grounding prong from the plug Freezers must be grounded at all times Do not remove warning tag from power cord Do not use a two prong adapter Do not use an extension cord Asure Extended Service Plan Amana offers long term service protection for this new freezer Asure Extended Service Plan is specially designed to supplement Amana s strong warranty This plan covers parts labor and travel charges Call 1 800 528 2682 for information Proper Disposal of your Freezer NOTE Child entrapment and suffocation are not problems of the past Junked or abandoned freezers are still dangerous even if they sit for just a few days When you get rid of your old freezer please follow the instructions below to help prevent accidents Before Throwing Away Old Freezers e Take off the doors e Leave the shelves in place to prevent children from easily climbing inside unit Model Identification Read the Owner s Manual thoroughly This manual provides proper maintenance information for consumers Any questions call the Consumer Affairs Department at 1 800 843 0304 inside U S A and 1 319 622 5511 outside U S A Complete enclosed registration card provided in owners manual and promptly return If registration card is missing call the Consumer Affairs Department When contacting Amana provide
78. rayon Leave freezer running sometimes for months and observe mark periodically If frost line moves away from mark a leak external or internal is certain 2 Feeler bulb of thermostat is located toward tail end of evaporator In case of shortage in refrigerant tail end of evaporator will not be refrigerated and thermostat will not cut out causing freezer to run continuously This can be confused with a faulty thermostat 3 Although compressor is running continuously food liner temperature will rise 4 Low suction pressures External Or Internal Leak e Internal leaks are refrigerant leaks inside foam insulation All other leaks are considered external e Once presence of a leak has been determined from symptoms described above locate leak e First test all joints in compressor compartment Hold nozzle of detector on every joint for at least 1 minute If no leak can be found at these joints check for internal leak Finding Internal Leak Confirm existence of an internal leak by pressure testing NOTE For this test evaporator and condenser must be disconnected and individually pressure tested with dry air or dry nitrogen at pressures between 200 300 psi Leave the components under pressure for a minimum of 3 days If after 3 days pressure drop is more than 10 psig at approximately same room temperature presence of an internal leak can be assumed e Be sure there are no leaks in connections between pressu
79. recisely using a household thermometer that includes temperatures between 5 to 50 F Put thermometer snugly between frozen packages in freezer Wait 5 8 hours If freezer temperature is not 0 to 2 F adjust control one number at a time Check again after 5 8 hours RS1500000 Rev 2 Audible Alarm Some models Locate audible alarm on right side of freezer cabinet near bottom right corner Alarm sounds if temperature in freezer rises 10 F or more above normal for selected setting Alarm may sound if temperature control dial is turned to a much lower colder setting or if a large amount of unfrozen food is added at one time Alarm is controlled by a three position switch e 0 prevents alarm from sounding when freezer is warm such as during initial start up or defrosting e V sounds alarm regardless of temperature Alarm system should be tested at least once a month e 7 is proper setting for normal freezer use Return switch to 7 after defrosting OV 1 iD Operating Instructions Features Freezing Guide Door Lock Wrapping Lock freezer door by completing the following e Use moisture vapor proof materials and seal tightly 1 Insert key into lock approximately 1 4 When lids are furnished follow manufacturer s f directions for best results 2 Turn key clockwise to lock door and counterclockwise to unlock door e Choose materials which are labeled for freezer use Ordinary waxed pap
80. rizing device and gauge or between gauge and cabinet A leak at these joints could be misinterpreted as an internal leak e Apply soap solution to all joints and connections to check for leaks bubbles e If pressure drop after 3 days is not more than 10 psig there is no internal leak Pressure test described above will indicate e leaking condenser or e leaking evaporator or e no leak Condenser Leak Internal If indications are that internal leak is in condenser leak is considered to be nonrepairable If unit is under warranty contact factory for permission to replace unit Evaporator Leak Internal If pressure test indicates leak in the evaporator the leak could be e at the evaporator suction line or e at the evaporator inlet joints or e at an unknown location Joint is located approximately 2 4 inches below breaker strip at back left corner After breaker strip has been removed carefully search for capillary by gradually removing foam insulation Evaporator inlet can be lifted above cabinet flange for examination and repair After leak has been repaired repack void with fiberglass insulation NOTE Removal of breaker strip will destroy it Replace breaker strip with new one If evaporator leak is at unknown location contact factory for permission to replace unit if product is under warranty 41 RS1500000 Rev 0 Service Information Q WARNING To avoid risk of electrical shock personal injury or
81. rom terminals replace on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational HFC134a Service Information Comparison of CFC12 and HFC134a HFC134a Refrigerant HFC134a is alternative refrigerant for CFC12 HFC134a has an ozone depletion potential ODP factor of 0 0 and a global warming potential GWP factor of 0 27 HFC134a is not flammable and has acceptable toxicity levels HFC134a is not interchangeable with CFC12 There are significant differences between HFC134a and CFC12 which must be considered when handling and processing refrigeration system Properties Characteristics HFC134a Ozone Depletion Potential ODP 0 0 Global Warming Potential GPW 3 2 0 27 Molecular weight 121 102 Boiling point at 1 atmosphere 22 F 30 C 15 F 26 C Vapor pressure at 77 F 25 C 80 psig 82 psig Liquid density at 77 F 25 C 82 Ib ft3 75 Ib ft3 Flammability High side system operating Pressure at 65 F 18 C ambient Health Safety and Handling Lowside system operating Health safety and handling considerations for HFC134a messire a 65 ieee are virtually no different than those for CFC12 nina HFC134a approximately 3 psig higher than CFC12 HFC134a approximately 2 psig lower than CFC12 Health Safety and Handling CFC12 HFC134a Allowable overall exposure limit 1 000 ppm Same Vapor exposure t
82. rs are charged with the correct amount of oil and contain a holding charge of either dry nitrogen or a refrigerant The replacement compressor will be similar to the type of compressor originally used and may or may not have an oil cooler If the sealed system does not use the oil cooler do not disturb the oil cooler plugs Simply disregard the oil cooler The holding charge assures compressor is dry A compressor which shows no evidence of internal pressure when cutting the line or pulling the plugs should be returned for replacement When replacing a compressor cut as close to the soldered joints as possible If tubes are not long enough it may be necessary to unsolder the joints to allow connections to the replacement compressor When replacing compressor proceed as follows 1 Disconnect line cord from electrical outlet 2 Install a service valve on the process tube 3 Connect a hose to the service valve and capture the charge NOTE Effective July 1 1992 before opening any refrigeration system it is the responsibility of the service technician to capture the refrigerant for safe disposal 4 Clean the tubing approximately three inches 76 mm at the point of intended cut Before cutting the tube verify it will be long enough to reconnect to the replacement compressor If not unsolder the joints Disassembly Procedures a WARNING To avoid risk of electrical shock personal injury or death disconnec
83. shaft slowly and stop immediately when the 1st click is heard RS1500000 Rev 2 Defrost Heater and Thermostat No Defrosting Models Defrost heater is a radiant heater and will melt all frost that collected during the proceeding 12 hour period when operating properly Failure to perform this function will eventually cause an ice build up between the coil fins blockage in air flow and unsatisfactory refrigeration Defrost heater extends across the bottom of freezer coil above the built in drain trough Heater is clamped at both ends to a shield Shield is attached to coil mounting panel and is slotted to permit free drainage into the drain trough Defrost thermostat is located on upper header of freezer coil Thermostat senses temperature of the header and automatically shuts off the defrost heater when temperature reaches 51 F 11 C To test defrost thermostat and defrost heater when the freezer coil temperature is 15 F 9 C or below use a wattmeter or an ohmmeter and proceed as follows 1 Disconnect freezer line cord plug from electrical outlet and plug it into wattmeter 2 Plug in wattmeter line cord into electrical outlet and manually advance timer to defrost cycle 3 Wattmeter should indicate approximately 430 watts total wattage of timer motor and defrost heater If indication is 3 watts defrost heater or defrost thermostat has failed To isolate failed component proceed to step 4 However if indicati
84. stem It is a misconception that moisture in a sealed refrigerant system is harmless Moisture in a sealed refrigerant system when exposed to heat generated by the compressor and motor reacts chemically with refrigerant and oil in the system and forms corrosive hydrochloric and hydrofluoric acids These acids contribute to the breakdown of motor winding insulation and corrosion of compressor working parts causing compressor failure In addition sludge a residue of the chemical reaction coats all surfaces in the sealed system and will eventually restrict refrigerant flow through the capillary tube To dehydrate the sealed system 1 Perform the leak test 2 Capture refrigerant in system NOTE It is the responsibility of the service technician to capture refrigerant in system for safe disposal before opening any refrigeration system 3 Repair any leaks in system 4 Evacuate system 5 Recharge to specification with new refrigerant NOTE Do not use captured or recycled refrigerant in Amana units Captured or recycled refrigerant voids any Amana and or compressor manufacturers warranty Brazing 44 CAUTION Brazing requires high temperatures Take all necessary precautions to protect against personal injury and property damage Satisfactory results require cleanliness experience and use of proper materials and equipment Connections to be brazed must be properly sized free of rough edges and clean Gener
85. sure and wattage s replace failed parts Replace Compressor runs excessively Freezer too cold Defrost water disposal problem Temperature control Misadjusted Feeler tube not touching freezer shelf Failed Water frozen in drain trough Failed defrost timer radiant heater or thermostat on No Frost Models Only Restriction in drain system 25 Adjust control for normal operation Install control feeler tube to sense proper temperature Replace Check and replace defective part or parts Clean drain system RS1500000 Rev 0 Disassembly Procedures 44 WARNING To avoid risk of electrical shock personal injury or death disconnect power to unit before following any disassembly procedures Replacing Dryer NOTE A new drier must be installed whenever any system component is replaced or whenever the system is opened The replacement drier is sealed at both ends to prevent entrance of moisture Do not break these seals until all preparations for the installation have been completed 1 Disconnect line cord from electrical outlet 2 Clean the process tube using steel wool or fine emery cloth 3 Install service valve as close as possible to the tip of the process tube for easy pinch off after recharging the system 4 Connect a hose to the service valve and capture the charge NOTE Effective July 1 1992 before opening any refrigeration system it is the responsibility of the service technici
86. t overload trips open and shuts compressor off If overload does this repeatedly the compressor is cycling on the overload Cycling on the overload may be caused by Insufficient air circulation around the compressor and condenser Pull down overload caused by a large quantity of warm food placed in the freezer Compressor stalling due to lack of pressure unloading Low line voltage Failed starting relay Testing Overload Protector To test the overload protector remove compressor terminal cover Examine bottom of the overload for possible signs of arcing If there are no signs of arcing check for continuity across the terminals there should be a reading of approximately 0 7 ohms If continuity is not indicated replace overload protector Overload protector Overload Protector Terminals When examining the overload protector evidence of arcing is present replace overload protector RS1500000 Rev 2 Component Testing To avoid risk electrical shock personal injury or death A W ARNING always disconnect electrical power source to the freezer before attempting to service unless test procedures require power to be connected When removing any wiring from terminals they must be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational PTC Relay PTC relay is a push on type that mounts to the start and run terminals of the compressor It
87. t be replaced on the same terminals Ensure all ground wires are connected before certifying unit as repaired and or operational Testing for Leaks Compressor Electrical Tests Compressor terminals on all models can be reached only 7 IN DANGER from the rear of the cabinet If freezer does not operate do not assum mpressor Free oxygen will explode on contact with oil P i ae ee Acetylene will explode spontaneously when put under has failed until all other possibilities are eliminated pressure Is current entering the compressor through the power cord To prevent violent explosions that may result in Check for low voltage at the compressor terminals a serious injury or death to persons in or near the minimum of 100 volts is required for compressor to immediate vicinity NEVER use oxygen or acetylene start for pressure testing or cleanout of refrigeration If the necessary voltage is available check for failures systems in Over load protector 4 amp WARNING Starting relay Temperature control Cabinet wiring harness To avoid severe personal injury or death from fire keep system free from contamination due to presence of air Follow instructions exactly Testing Compressor Direct To test compressor with no other wiring in the circuit is called DIRECT TEST Safest way to check the compressor is by using a compressor tester Electrical System 44 WARNING To avoid possible electric shock personal in
88. t be wiped off after soldering 25 Install new drier 26 Visually check all joints for leaks Evacuate and recharge the system 27 Lace the defrost heater leads to both ends of the freezer coil Fasten wire leading to fan motor to the two clips on the mounting panel 28 Connect white defrost heater lead to white lead in wire with spade connector attach other wire to spade terminal on fan motor 29 Secure defrost thermostat to coil and connect lead wire 30 Connect green grounding wire to fan motor and to freezer coil cover 31 Reinstall coil cover and secure with screws 32 Test run the unit to verify proper operation 33 Pinch process tube and cut off the service valve Solder the joint and test for leaks Replacing Freezer Shelving Refrigerated Shelf Models Current freezer models are equipped with steel shelves and can be individually repaired or replaced as follows 1 Disconnect line cord from electrical outlet 2 Install service valve as close as possible to the tip of process tube for easy pinch off after recharging the system 3 Connect a hose to service valve and capture the charge NOTE Effective July 1 1992 before opening any refrigeration system it is the responsibility of the service technician to capture the refrigerant for safe disposal 29 4 Remove butyl sealer from tube entry hole in the cabinet back 5 Cut the end off of compressor process tube after the refrigerant has been capture
89. t from freezer coil 12 Remove defrost thermostat from coil header to release the front tang 1 NA a Removing Defrost Thermostat No Defrost Models 13 Detach green grounding wire from freezer coil header 14 Remove screws securing freezer coil to coil mounting panel The coil is now free to be removed Disassembly Procedures a WARNING To avoid risk of electrical shock personal injury or death disconnect power to unit before following any disassembly procedures 15 Straighten heat exchanger tubing to pass through the opening in the cabinet back 16 Pull entire assembly out through the front Position to allow detachment of heat exchanger 17 Unsolder suction and capillary tube from the coil Unsolder these joints Protect these joints Heat Exchanger To Freezer Coil Joints No Defrost Models 18 Remove freezer coil and replace with new coil 19 Clean and connect tubes and silver solder the joints with proper flux Excess flux must be wiped off tubing after soldering 20 Work heat exchanger tubing through rear opening careful not to tear rubber sleeve 21 Position freezer coil and install mounting screws Replace styrofoam air blocks at the upper ends of freezer coil This is necessary in order to channel air flow through the coil 22 Carefully form tubing and route in the same manner as the original Use extreme caution when bending
90. t power to unit before following any disassembly procedures 5 Disconnect wire from compressor terminals 6 Remove retaining clips from compressor mounts Lift compressor from mounting rails and transfer the rubber grommets to replacement compressor 7 Set replacement compressor into position and install retaining clips 8 Remove all rubber plugs clean the stubs of the compressor and compare the size of tubing to stubs of replacement compressor It may be necessary to swage the copper tubing in order to make the joints 9 Install a six inch 152 mm long copper tube to low side process tube on the compressor Add service valve to end of this tube 10 Connect all tubing apply flux to compressor stubs and solder all the joints Excess flux must be wiped off after soldering 11 Install a new drier 12 Visually check all joints for leaks Evacuate and recharge the system 13 Reconnect wire leads to compressor terminals and test run the unit to verify proper operation 14 Pinch process tube and cut off the service valve Solder the joint and test for leaks Replacing Heat Exchanger Refrigerated Shelf Models 1 Disconnect line cord from electrical outlet 2 Install a service valve as close as possible to the tip of process tube for easy pinch off after recharging the system 3 Connect a hose to the service valve and capture the charge NOTE Effective July 1 1992 before opening any refrigeration system it is the
91. tant Notices for Consumers and Servicers 4 amp WARNING To avoid risk of serious injury or death repairs should not be attempted by an unauthorized personal dangerous conditions such as exposure to electrical shock may result 4 amp 4 CAUTION Amana will not be responsible for any injury or property damage from improper service procedures If performing service on your own product assume responsibility for any personal injury or property damage which may result To locate an authorized servicer consult your telephone book or the dealer from whom you purchased this product For further assistance contact 1 800 628 5782 first if no answer call number listed below CONSUMER AFFAIRS DEPT OR 1 800 843 0304 AMANA APPLIANCES CALL AMANA IOWA 52204 If outside the United States contact AMANA ATTN CONSUMER AFFAIRS DEPT AMANA IOWA 52204 USA Telephone 319 622 5511 Facsimile 319 622 2180 TELEX 4330076 AMANA CABLE AMANA AMANA IOWA USA Recognize Safety Symbols Words and Labels 44 DANGER DANGER Immediate hazards which WILL result in severe personal injury or death 44 WARNING WARNING Hazards or unsafe practices which COULD result in severe personal injury or death 4 amp CAUTION CAUTION Hazards or unsafe practices which COULD result in minor personal injury or product or property damage RS1500000 Rev 2 2 Table of Contents Important Information 0 ccceeeeeeeeeeeeeeteeeeeeeeees
92. ted e Recommend to customer that larger quantities of food be frozen commercially before placing in freezer e Larger unfrozen food loads may cause customer complaints of continuous running or may raise temperature of frozen food Larger unfrozen food loads may also result in longer freezing times 2 Excessive Lid Opening e Freezer is not designed to be operated as a refrigerator Length of time and number of lid openings should be kept to minimum Compressor On And Off Periods Variations in compressor cycles per hour are affected by factors such as usage ambient conditions electric power supply and others Compressor off period is at least 8 minutes Tripping on overload may occur Noise Some noise especially during starting and stopping of compressor is normal In some cases noise described by customer as gurgling is experienced This gurgling noise is caused by liquid entering evaporator Voids In Urethane Foam Insulation e Some condensation occurs on outer casing of freezer when humidity is 85 or higher which is considered normal If condensation occurs at lower humidity level or persistently causes dripping water there may be a void in the foam insulation where condensation occurs Theoretically voids can occur in any part of the freezer insulation 1 Diagnosing presence of a void a Freezer should be operating and food liner temperature should be close to 0 F b Disconnect power supply to fre
93. tes restriction at the entrance of the capillary tube High side pressures will take much longer than the prescribed seven to ten minutes to unload and balance with the low side after compressor has stopped High Side higher pressure Low Side higher pressure Wattage higher than normal Indicates an overcharge of refrigerant Pressure increasing depends on the amount of overcharge and room temperature A slight overcharge may not cause trouble in 70 F 21 C temperatures where as in 90 F 32 C temperatures a considerable rise in pressure will result An overcharge may also cause the suction line under the cabinet to be frosted during the run cycle This condition will confirm the existence of an overcharge High Side higher pressure Low Side near normal pressure Wattage higher than normal Indicates air in the system Resulting from a low side leak being repaired without the system being thoroughly evacuated and purged before recharging In most cases you will find that the freezer is not as cold as it should be because the efficiency of the system is greatly reduced by the presence of air Simply purging air from the system is not practical The system being undercharged due to the loss of refrigerant Evacuate purge and recharge the system 38 Service Information 44 WARNING To avoid risk of electrical shock personal injury or death always disconnect electrical power source to the freezer before
94. tor 15 Transfer vinyl insulating sleeve to new heat exchanger Tape the same points 16 Carefully position assembly back in the cabinet verify heat exchanger tubing passes through the opening without damaging the vinyl sleeve 17 Carefully work each shelf into its proper support rails Replace non refrigerated shelf in the same manner 18 Secure control feeler tube to correct shelf with the clamp Verify feeler tube rests firmly against shelf surface to obtain thermal contact 19 Fasten top freezer plate verifying all spacers are in place 20 Form heat exchange so it is similar in position to the original Be careful when bending the tubing at the entry hole to prevent kinks 21 Pack entry hole with butyl sealer 22 If suction tubing was cut from compressor when removed swage compressor suction tube to fit replacement suction tubing 23 Solder the suction lines 24 Install new drier 25 Visually check all joints for leaks Evacuate and recharge the system 26 Test run the unit to verify proper operation 27 Pinch process tube and cut off the service valve Solder the joint and test for leaks RS1500000 Rev 0 Disassembly Procedures VIN WARNING death disconnect power to unit before following any disassembly procedures Replacing Heat Exchanger No Defrosting Models 1 Disconnect line cord from electrical outlet 2 Install service valve as close as possible to the tip of process tube for easy pinch off after re
95. ux must be wiped off after brazing 11 Install a new drier ONS Qn 12 Visually check all joints for leaks Evacuate and recharge the system 13 Reconnect wire leads to compressor terminals and test unit to make sure it is operating properly 14 Pinch the process tube and cut off service valve Braze joint and test for leaks Refrigerant Charge Refrigerant charge in all capillary tube systems is critical and exact amount is required for proper performance Factory charges are shown on serial plate Do not use refrigerant other than shown on serial plate Leak Testing Undetected leaks lead to repeated service calls and eventually result in system contaminations restrictions and burned out compressors After recharging sealed system must be thoroughly tested for leaks If a very small leak is difficult to isolate coat area with soap suds and observe Bubbles will form in location of leak Evacuation and Charging 44 DANGER Free oxygen will explode on contact with oil Acetylene will explode spontaneously when put under pressure To prevent violent explosions that may result in serious injury or death to persons in or near the immediate vicinity NEVER use oxygen or acetylene for pressure testing or cleanout of refrigeration systems a WARNING To avoid severe personal injury or death from fire keep system free from contamination due to presence of air Follow instructions exactly a WARNING
96. ve C to thermistor vacuum gauge and take micron reading 4 Continue evacuating system until thermistor vacuum gauge registers 600 microns 5 At 600 microns close valve A to vacuum pump to allow micron reading in system to balance Micron level will rise If in 2 minutes micron level stabilizes at 1000 microns or below system is ready for charging e If micron rises above 1000 micron level and stabilizes open valve A to vacuum pump and continue evacuating RS1500000 Rev 0 e If micron reading rises rapidly and does not stabilize a leak still exists in system Close valve A to vacuum pump and C to thermistor vacuum gauge Invert charging cylinder and open charging cylinder valve F to add partial charge for leak checking With leak detector check manifold connections and system for leaks After locating leak capture refrigerant charge repair leak and begin at step 1 6 Once system is ready to charge close valve A vacuum pump C thermistor vacuum gauge and E low side manifold gauge 7 Check serial plate for correct charge and set scale on dial a charge cylinder for corresponding HFC134a pressure reading NOTE Do not use captured or recycled refrigerant in Amana units Captured or recycled refrigerant voids any Amana and or compressor manufacture s warranty 8 Open valve F to charging cylinder and let exact amount of refrigerant out of cylinder Close v

RS1500000 Amana Upright Freezers Service Manual

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