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Ice Maker - Appliance Outlet Service

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3. 64 To Replace Ice Maker Thermostat ccspcscsenajecsciemesnaceushateCotanensbioctvndcauseancebasdacsheecdaad esguascdenaces a 64 To Replace Thermal RC ic sda 64 Replace Mold Heater m m 65 miaBItescIct 65 Complaint Ice Maker Fails ES 65 Complaint Ice Maker Fails To Complete 65 Complaint Ice Maker Fails To Stop At End 65 Complaint Ice Maker Continues To Eject When Container Is 65 Complaint Ice Maker Produces Undersized lce 65 Maker MOSHING OS us EU 66 66 Operating Cycle Illustrations Manual 66 Operating Cycle Illustrations Electrical uos osten iD RF EHE UROU Drs UR US Fees ve 66 Operating Cycle Illustrations 73 Maker Exploded VIEW EUN 76 Ice Maker Wiring Diagrams Enlarged View 77 Rear Mount Ice Maker Rear Mounted Ice Maker for Counter Depth Model Refrigerators
4. Motor Housing Molex Connector Lamp Socket amp Bulb Assembly Figure G1 Auger Motor Motor Cover Figure G2 To Remove Solenoid Assembly 1 Disconnectrefrigerator from electrical supply 2 Slide Container forward and off Rail Assembly 3 Remove bottom screws and Lift up on Rail Assembly and pull forward freeing itfrom mount ing brackets 4 DisconnectMolex connector located at back of Rail Assembly and pull Rail Assembly free 5 Remove rear cover orice maker support 6 Remove screw securing green ground wire to Solenoid Assembly on the back of Motor Cover See Figure G1 7 Disconnect two 2 leads hooked to solenoid coil Leads are blue with a white stripe and white See Figure G1 8 Remove four 4 mounting screws on front of Motor Cover and pull Solenoid Assembly free See Figure G3 9 Replace assembly in reverse order 96 To Test Solenoid Assembly oleno ssem 1 Read ohms value of solenoid coil using Multi Solenoid meter on resistance scale Put test leads on terminals where blue with white stripe and light blue wires were disconnected from Step 6 of procedure To Remove Solenoid Assembly 2 Ifresistance reading should be 34 ohms or 20 if reading is extremely high or low replace solenoid coil Actuator To Remove Lamp Socket and Light Bulb Soleno
5. TO Remove Reingerator DOOF m T TOoRemove Freezer DOO EN CQ NE sa D TO E SECTION B REFRIGERATOR CABINET Basie CONS EC NO ERE Compressor NA OUNCE TODO Om Ins lation amp We Cabinet Doors amp Gaskets EE EDO DRE Adjustable Door BINS Frontand Rear Rollers qE To Remove Front Roller Assembly Remove Rear Rolo DOT Do D DEDERE Lacguer mic INSEL m SECTION C ELECTRICAL COMPONENTS Compressor Electrical Components and Sold State Relay NR To Check Replace Relay MI TT TET TET LITT ProleCtO MN TRE EN Um Check Replace Overload Check Replace Run Compressor Start CCN RN T UU Uc Sene SS Or PR UN TN Compressor Operating Characteristics usocernonicito tos ain Me T Penmeter and Mullon Hot TUDE REN Evaporator Felice Motor
6. eese 78 FONTO ONG m C 78 Maker compone RE TTE 78 rn hojom 78 Musei cs 78 CI T UU Ts 78 M 78 vater T 78 RR 79 Sensing Amm amp Linkage Sender ster gp eee 79 Bn gehe icy mT P 79 CUO Pc 79 COUPIO umm 79 TAMING OU E 79 rr 79 GEBEN ERR 79 PK 79 Installing Water Supply Line to Ice 80 Test Cycling Maker MEET UU T c UU uu 80 Water Valve Switch Water Fill 9 80 Parts Replacemeni rc 80 To Replace Fron GOVT 80 To Replace Fill Trough 4 Bearings cccccceececsecceeeeseecceseeseeeeeseeseuseeseeseueesseeseasensesse
7. WATER FILL SWITCH THERMOSTAT BLU SECTION F REAR MOUNT ICE MAKER REAR MOUNTED ICE MAKER FOR COUNTER DEPTH MODEL REFRIGERATORS The automatic Ice Maker is mounted in the freezer compartment It is attached to a bracket extending up from the back of the Auger motor cover The Ice Maker is designed to produce ice automatically The length of time between Harvest Cycles will vary depending on load conditions door openings ambient temperature and freezer temperature These factors must be taken into consideration when checking the ice production rate With a temperature of 2 F to 5 F in the freezer the rate of harvest will be 8 12 cycles per 24 hour period The Ice Maker is wired across the line and will harvest ice in the refrigeration or defrost cycles The Water Valve and Solenoid Assembly are both mounted in the compressor compartment A tube extends from the water valve up the rear wall of the refrigerator to a water inlet spout that directs the water into the fill trough The water fill spout will twist lock into a housing in the back of the refrigerator and direct water flow into the ice maker from the side of the mold Front Cover A decorative front cover made of molded plastic encloses the operating mechanism of the Ice Maker protecting it from moisture It is essential that the cover be in place on an operating Ice Maker to protect against possible contact with
8. Straight Connector Adhesive Clip attaches to the bottom of unit YELLOW SOLENOID TO DOOR CONNECTOR Figure H7 109 TO TEST THE WATER FILL SYSTEM The wiring harness has two diodes in the line between the fill switch on the ice maker and the green coil of the secondary water valve as well as the water switch or relay on the freezer door and the secondary valve The diodes are part of the wiring harness See wiring diagram Figure G10 If the diodes fail open the primary valve will not open for ice and or water depending on what diode is open The open diode will not effectthe coil on the secondary valve the secondary valve will open butif the primary valve does not open you will not supply water to the secondary valve Resistance Check Voltage Check Digital Meter Voltage Drop From Heater Valve Coil Voltage Readings Are Different Between Primary And Secondary Valve Coils No Water at Door NOTE Diode Kit Checking Water Valves Ice Maker Valve Green Coil Chilled Water Valve Yellow Coil To test the diodes you can use a ohm meter with at least a 10K ohm or higher scale Take a reading across the diode reverse your leads and take another reading the diode should check 10 times higher in one direction than the other You can also use a volt meter to check the circuit Connect a volt meter to the valve coil of the primary valve and connect a second volt meter to the g
9. 9 9 J LT BLUE Hold 3 Ham Switch Shut Off AAAA HCT VWV WV WV Waler Valve MOLD HEATER 85 Walls Water Fill Swilch Ice Maker Electric 7 8 Section F Ice Maker NEUTRAL Ice Maker connected to electricity Mold temperature below 15 F Power on heater Thermostat closed Control Arm is swinging up ON OFF switch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill Switch open Off On On Thermal Cut Out acy ile T 9 9 9 e 3 LT BLUE eat Shut Off V VN V Waler Valve _ _ JL jt dt MOLD HEATER 85 Walls Water Fill Ice Maker Electric 8 NEUTRAL Ice Maker connected to electricity Mold temperature below 15 F Motor is rotating Power on heater Thermostat closed Control Arm is swinging up ON OFF switch in the ON position Shut Off Switch closed C to NC Hold Switch closed C to NO Water Fill Switch open Off On 0n Thermal Cut Out wd Q gt BLACK Q l Q C J LT BLUE Shut Off NO Thermostat Rd 9 L2 J A5 AN AN IL IL IE V V V V Waler Valve MOLD HEATER 85 Walis Water Fill Switch Ice Maker Electric 9 88 Section F Ice Maker NEUTRAL Ice Maker connected to electricity Mold temperature above15 Motor is rotating Mold heater is off Thermostat opens Control Arm is swinging up ON OFF switch in the ON posit
10. SEE cau 84 Operating Cycle Illustrations Electrical suus aga muc 84 Operating Cycle Illustrations 2 91 Ice Maker Wiring Diagrams Enlarged 94 lce 95 SECTION G ICE amp WATER DISPENSER Ice Dispenser Container amp Rail Assembly wessisinivsiencvwenvavangedievnbawnduns vee 96 Dispenser Auger Motor amp Solenoid 96 To dsemove MODE RUM NU tad x Ur PU Und EP Oed 96 TOTES AUGO o gr 96 To Remove Solenoid missae bna per idu FOI ROTE ee Du 96 Test Solenoid FS Sy 97 To Remove Lamp Socket 97 Ice Auger amp Crusher C EN DP QUUD 97 To Remove Ice Auger amp Crusher Assembly ccccceccecssseeceseeceeeeceesecsuececsusecssueeseaeeeseeesaueesseeeessaeeens 97 NEN t DET 97 loce amp Water Dispenser AssembDiy DNI ICH eU Rd C LM NL NN Tap
11. 56 ODE 56 HFC 134a CFC 12 Pressure Temperature 57 R 134a Health amp Safety Information e 58 AON Fe roo e E MU 58 cardiac oeni ZAM o aT TITO 58 2212 een e m 58 SKM and Eye COMAC ETE TETTE 58 bea e 59 LOIK 59 amp Stora RT T 59 Filing amp Charging 59 Refrigerant Recovery Systems arcta adiac oma anti ones ate Hand d v ot 59 thermal ES COMO cio e sesser E n 59 SECTION F ICE MAKER Left Side Mount Ice Maker Maker for Side DY Side Models soda ean uncut 60 FOM GT Tr 60 Ilce Maker EE 60 CEMO 60 Mie NG NOM m 60 1 uu Tut 60 ICO EJ CIOT 60 Water Valve Assembly 60 eiae T t 61 Sensing Arm amp Linkage aecessses ie
12. 0 ru c J gt 2224 5 2 LI C3 gt TS C3 Lu x O Or DEFR EY LO u NJ 24 ELECTRONIG DISPENSER _ _ DSP EMBER BLL PHT i LEBHT REL FAC BAC WATER MD e IE AT cia eum za ea WHT aia Lt Tk nog HE JATE OM A ba X la PET FAEEZE RE FLECTRO MECHANICAL DISPENSER RED HLE 4129 VEI MATER DIFP TEH ICE M Hos is Mm M PURPLE LALEA TAH TALE S3TSHTEH WETH CAPAC XHP FTE HOTU 5 GALT LEO WITH JIPE P T C 25 SYSTEM EXPLODED VIEW DIAGRAM Evaporator Defrost Heater Mounting Bracket 5 6 2 E gt AQ O e he S od m O Q Compressor Shoulder Screws a S x E m a 5 tc x S ee 59 X de NW S Y NZD SS dv Na N N 9 SS SS SW AP CRINE GNIS SIS SNORE 418 S Por 5 e o ED S JON 5 Fan Shroud
13. 1 Disconnect refrigerator from electrical supply 2 Slide Ice Container forward and off of Rail Assembly Remove 2 screws holding Rail Assembly to the two channels fastened to the liner 3 Liftup on Rail Assembly and pull forward freeing it from mounting brackets 4 DisconnectMolex connector located at back of Rail Assembly and pull Rail Assembly free 5 Removetherear cover on products with left mount ice maker or the ice maker support on models with the rear mounted ice maker 6 Remove screw securing green ground wire to motor housing on back of Motor Cover See Figure G1 7 Disconnect two 2 leads hooked to Auger Motor windings See Figure G1 8 Rotate Drive Bar and Nut located on front of Motor Cover in counterclockwise position until it comes free of Auger Motor shaft See Figure G2 9 Remove the motor mounting screws 3 or 4 depending on motortype and pull Auger Motor free from Motor Cover 10 Replace assembly in reverse order To Test Auger Motor 1 Readohmic value of motor windings using Multimeter on resistance scale Put test leads on terminals where purple and light blue wires were disconnected from Step 6 of procedure To Remove Auger Motor 2 Resistances reading should be 4 ohms or 20 If you get anything else replace motor E Windings
14. PERIMETER AND MULLION HOT TUBE reduce the possibility of condensation forming on the exterior of the cabinet in high humidity areas units are equipped with a one piece perimeter and mullion hottube which is part of the refrigeration system No electric heaters are used Referto the Refrigeration Section for more information EVAPORATOR FAN amp MOTOR ASSEMBLY The fan and motor assembly are located behind the freezer compartmentair ductdirectly abovethe evapo rator in the freezer compartment The fan is a suction type pulling air up through the evaporator and blowing itthrough the refrigerator com partmentfan grille On current production models the fan blade is not adjustable and is designed to be pressed onto the motor shaft until it bottoms out against the stop at the front of the fan blade 13 To Remove Evaporator Fan Motor 1 Disconnectrefrigerator from electrical supply 2 Remove freezer section bottom shelves and baskets Remove ice container and railassembly The multiconnector at the back of the railassembly must be disconnected before rail assembly will come free Loosen the 2 screws holding ice maker to right side of compartment just enough to maker free The multiconnector must be disconnected before ice maker will come free from compartment Remove two rail assembly supports two screws on each one Remove four screws from evaporator cover Remove five screws on evaporator air
15. Control Board Push Tabs Switches When you install control board in cover make sure you position Push Tabs over switches on board Figure 39 SECTION WATER SYSTEM Water Systems Water for the ice maker and water dispenser is controlled by a dual coil valve and a single coil valve joined together as one It s mounted just to the right of the condenser on the cabinet Plastic tubing connects the water valve valves to the ice maker fill tube the water dispenser and water filter on models so equipped Water Valve Next Generation models have 1 dual coil valve and 1 single Coil valve see figure H1 The green coil on dual coil valve is for the ice maker and the yellow coil is for the water dispenser The beige coil on the single coil valve is energized for both water for the ice maker and water for the dispenser Plastic tubing connects the primary water valve to the filter water tank and to the secondary valve On models with a single coil valve for a primary you have 2 diodes in the wiring harness connecting the coil of the single coil valve to the 2 coils of the dual coil valve The diodes are used to prevent current leakage from opening both coils on the dual coil valve every time the single coil valve is energized If a diode is shorted when the single coil valve opens current leakage through the shorted diode will cause both coils on the secondary valve to open and you ll have water going i
16. Filter Release amp Y Button Front Filter r n Filter Cup Cover i lt 107 Water Tanks Figure H4 Side by Sides will have a Water Tube Assembly as shown in Figure H4 To Filter The water line from the primary water valve single coil valve goes behind the trim located on the right side of the Water Tube inside food compartment liner to the water filter From the Assembly water filter the line goes to the water tank then to the secondary water valve two coil valve The two coil valve dispenses water to the ice maker and to the dispenser in the door By filling the ice maker for the water tank you will get chilled water to the ice maker helping to increase ice production See Figures H5 H6 and H7 for water system flow diagrams To Valve Front Filter System HB Water Filter Base Icemaker MC p GREEN COIL ELLOW COIL Ice Dispenser 2 z HOME OWNER S SUPPLY 5 E 4 Water Tank Water Filter Cassette 2 Lu lt front 5 jurc gt E attached to liner E SOLENOID VALVE M E 2 gt YELLOW SOLENOID TO DOOR CONNECTOR f Adhesive Clip
17. Ice Maker Mold With Heater Bracket Ice Maker Control Arm gt Screw To Replace Motor and Switch Mounting Plate 1 Removefront Cover 2 Remove three screws that attach Mounting Plate to Support Housing 3 Carefully remove Mounting Plate disengaging end of Sweep Arm and noting relative position of oweep Arm Spring 4 Transfer Motor Switches Cam Gear and WaterFill Adjusting Spring and Arm to replacement Mounting Plate 5 Attach new Mounting Plate to Support Housing with three screws NOTE Ensure that the wiring harness is properly positioned and the Sweep Arm is in place 6 Check Water Fill Cycle and adjust as required 7 Replace front Cover To Replace Ejector Blades 1 2 COND OF Leveling E Remove front Cover Remove three screws holding Mounting Plate in place Carefully remove Mounting Plate disengaging end of Ice Maker Control Arm and Ejector Blades from Motor coupling noting relative position of Ice Maker Control Arm Spring Remove Fill Trough and bearing Turn blades to 12 O clock position Slide Ejector Blades back and up to remove Replace in reverse order Lubricate bearing ends of Ejector with Silicone grease Ice Stripper Figure F5 To Replace Motor Removefront Cover Remove three screws that attach Mounting Plate to Support Housing Disconnect two Motor leads Remove two Motor mounting screws Replace
18. 11 Close both of the manifold gauge valves If the high side gauge reading rises the pinch off must be corrected before proceeding 12 Remove the high side process tube adaptor and solder the process tube closed 13 Clamp the low side process tube with the pinch off tool while the unit is running Remove the low side process tube adaptor and solder the process tube closed 14 Check the process tubes for refrigerant leaks FINALLEAK TEST 1 With the refrigerator turned OFF leak test all low side system components 2 Turn the unit ON and run until the condenser is warm Leak test the high side system components COMPOUND GAUGE PRESSURE gt GAUGE GAGE MANIFOLD HAND SHUTOFF VALVE zzi HEATED 4 CHARGING t CYLINDER ay EN 2 STAGE VACUUM PUMP R 134a SERVICE INFORMATION NOTICE Instructions given here are furnished as a guide Persons attempting to use these instructions to make repairs to the sealed refrigeration system should have a working knowledge of refrigeration and previous training on sealed system repair VERIFY REFRIGERANT TYPE IN THE SYSTEM CAUTION R 134a and R 12 are completely incompatible Before starting any sealed system repair it is extremely important to check serial plate of product to verify the type of refrigerant in the system Dedicated Equipment R 134a must not be mixed with other types of refrigerants R 134a must be recovered i
19. Water Fill Hasrefrigerator been properly installed and Adjustment connected to sources of electrical power and water e Has Freezer compartment Evaporator pulled down to temperature e Have several ice making cycles been completed and is the Ice Maker in the Freeze Cycle sthe Ice Maker Thermostat single throw switch in 4 Mounting series with the Mold Heater Screws Do Ejector Blades make two revolutions per cycle Is ice stored on blades after harvest sthe Water Solenoid wired in series with the Mold D Mounting Heater Plate Screw Operating Cycle Illustrations Electrical The following wiring diagrams illustrate the electrical operation of an Ice Maker This procedure is on the Internet at http www frigidaire com tip Ice Maker connected to electricity Mold temperature above 15 F Thermostat open Motor not rotating Mold Heater off Control Arm in the down position Neutral Shut Off Switch closed C to NO Hold Switch closed C to NC Water Fill Switch open Thermal Cut out Mold Heater Shut Off Switch 1000001 Hold Switch WVDYWYW I Ice Maker Electric 1 Water Fill Water Valve Switch 66 Ice Maker connected to electricity Mold temperature below 15 F Thermostat closes Motor starting Heater starting to heat Control Arm in the down position Shut Off Switch closed C to NO Hold Switch closed C to NC Water Fill Switch o
20. Adjustable Door Bins Some models have adjustable door bins that can be moved to suit individual needs To move door bins 1 Lift bin straight up 2 Remove bin 3 Place bin in desired position 4 Lower bin onto supports until locked in place CL 1 2 Gallon Adjustable 1 Gallon Not Adjustable Figure B3 FRONT ANDREAR ROLLERS Thefrontrolleris mounted with two screwsto the cabinet base and one screw to the front of the cabinet See Figure B4 The adjustment screw atthe top of the roller is turned clockwise to raise the cabinet and counter clockwise to lower the cabinet See Figure B5 While making adjustments slightly raise the cabinetto reduce the strain on the roller assembly Roller Assembly Roller Mounting Screw Roller Roller lj Adjusting Mounting Bolt Bolts Figure B4 Figure B5 To Remove Front Roller Assembly 1 Disconnect refrigerator from electrical power 2 Raise and support cabinet 3 Remove two bolts securing roller to bottom of refrigerator 4 Remove one screw securing roller to front of cabinet Roller should fall free 5 Reassemble in reverse order To Remove Rear Roller See Figure B6 NOTE The rear roller assembly is mounted to the bottom of the compressor base Raise and support cabinet before removing rear roller 1 Disconnect refrigerator from electrical power 2 Raise and support cabinet NO
21. Electric 9 Water Fill Water Valve Switch 70 Ice Maker connected to electricity Mold temperature above 15 F Motor is rotating Mold Heater off Thermostat opens Shut Off Switch closed C to NC Neutral Hold Switch closed C to NO Water Fill Switch is open Control Arm is swinging up Thermal Cut out Mold Heater Thermostat O Q Shut Off O Switch Switch I Ice Maker Electric 10 Water Fill Water Valve Switch Ice Maker connected to electricity Mold temperature above 15 F Motor is rotating Mold Heater off Thermostat open Shut Off Switch closed C to NO Neutral Hold Switch closed C to NO Water Fill Switch is open Control Arm is swinging down Thermal Cut out Mold Heater Hold Switch KG an Ka WYYYF I Ice Maker Electric 11 Water Fill Water Valve Switch 71 Ice Maker connected to electricity Mold temperature above 15 F Motor is rotating Mold Heater in series with Water Valve Thermostat open Shut Off Switch closed C to NO Neutral Hold Switch closed C to NO Water Fill Switch is closed Control Arm is swinging down Thermal Cut out Mold Heater Thermostat JUUUL b Hold Switch Ice Maker Electric 12 Water Fill Water Valve Switch Ice Maker connected to electricity Mold temperature above 15 F Motor is rotating Mold Heater off Thermostat open Shut Off Switch closed C to NO Neutral
22. Hold Switch closed C to NO Water Fill Switch is open Control Arm is swinging down Thermal Cut out Mold Heater VW WW Water Fill Water Valve Switch 12 Ice Maker connected to electricity Mold temperature above 15 F Motor not rotating Mold Heater off Control Arm in the down position Shut Off Switch closed C to NO Neutral Hold Switch closed C to NC Water Fill Switch is open Thermal Cut out Mold Heater Shut off Switch CODOQU Y Hold Switch I Ice Maker Electric 14 Water Fill Water Valve Switch Operating Cycle Illustrations Mechanical The following Figures illustrate the mechanical operation of an Ice Maker Step 1 Step 2 Ejector Ejector Q P Q Water Y Water X Mater A Mater A Ice Storage Bin Ice Storage Bin Freezer Cycle Start of Harvest Cycle 1 Mold is filled with water 1 Thermostat closes 2 Thermostat is open 2 Mold heater amp Motor is energized 3 All components are de energized 3 Ejector begins to turn T3 Ejector 2 X gt Mater Ejector Q 9 X 2 2 Ice Storage Bin Ice Storage Bin Harvest Cycle y Harvest Cycle Holding Switch in normally open position Heater remains energized
23. P T C Relay With Run Capacitor O O 5 ad P T C Relay Overload Comp Motor Capacitor Is Only Used With Some P T C Models Figure C3 Compressor Circuit When the self heating solid state relay has reached sufficient temperature it will abruptly change from low resistance 3 12 ohms to very high resistance 10 20K ohms and in effect switches off the start windings The relay no longer shunts the run capacitor The run capacitor is now in series with the start windings The only purpose of the run capacitor is to improve compressor operating efficiency which it does by cor recting the power factor of the compressor motor See Figure C4 P T C Relay With Run Capacitor O O X P T C Relay Overload Comp Motor Capacitor Is Only Used With Some P T C Models Figure C4 COMPRESSOR OPERATING CHARACTERISTICS When the compressor electrical circuit is energized the start winding current causes the relay to heat and switch off the start winding circuit NOTE The relay will switch off the start winding circuit even though the compressor has not started as when attempting to restart after momentary power interrup tion The overload protector is designed and calibrated to open the compressor electrical circuit with locked rotor run winding current only With an open relay the compressor will not start since
24. Use protective gloves when handling Crusher Blades Spacer Ss 2 1 Remove Auger Nut to gain access to Crusher Fixed Blade 4 Blades Each blade is separated by Spacer ewe SQL fe See Figure G6 S UP 2 Remove Crusher Blades and Spacers until you get to one that needs replacement 3 Replace assembly in reverse order Figure G6 97 ICE AND WATER DISPENSER ASSEMBLY FEATURE LEVELS The ice and water dispenser will have two actuators One for Fiye Selection Dispenser See Figure 3 water and a second for ice See Figure 1 1 Extralce Press to increase ice production 2 Cube Press to get cubed ice 3 Crush Press to get crushed ice 4 Light Press to turn on light in dispenser 5 Filter Status Press and Hold five seconds to reset light This light will tell you when to replace the water filter Figure 1 There will be different feature lay outs used on the ice and water side by sides 2 3 4 5 Figure 3 Seven Selection Dispenser See Figure 2 l ACCELERFREEZE Press to drop freezer temp to 6 F for a period of 16 hours Four Selection Dispenser See Figure 4 2 ACCELERICE Press to increase ice l Cube Press to get cubed ice production for a period of 12 hours 2 Crush Press to get crushed ice 3 CUBE Press to get cubed ice 3 Light Press to turn on light in dispenser 4 CRUSH Press to get crushed ice 4 FilterStatus Press and Hold five seconds to reset 5 LIGHT Press to turn on light in dispens
25. all components except the Ice Maker Thermostat should perform normally Once the Ice Maker completes its cycle remove the front Cover see instructions for replacing the front Cover in To Replace Front Cover on this page If further test cycling is necessary place screwdriver blade in slot located in the Motor Drive Gear and turn counterclockwise until the Hold Switch circuit to the Motor is completed WATER VALVE SWITCH WATER FILL VOLUME The amount of water fill is directly proportional to the length of time terminals C NC of the Water Fill Switch are closed Closing occurs when the switch plunger drops into a cavity formed in the Cam Different water valves have different flow rates For this reason anytime a Water Valve is replaced the Water Fill Switch must be adjusted The correct water fill volume is 95 105 cc To measure the fill volume test cycle the Ice Maker and collect the water Measure in a container calibrated in cubic centimeters cc or ounces The fill volume is adjusted by increasing or decreasing the length of time the Water Fill Switch remains closed To adjust the Water Fill Switch first determine how much water is needed The adjusting screw is calibrated so that one complete revolution changes the water fill about 18 cubic centimeters Turning the screw clockwise decreases the fill while turning counter clockwise increases the fill EXAMPLE An Ice Makeristest cycled and the water fill s
26. and Fast Ice Acceler Ice Feature are accomplished by the use of a 2 watt electric heater on the freezer control thermostat cap tube on mechanical control models See Figure 28 On electronic control models the freezer cycling temperature is lowered in the control when fast ice or fast freeze are selected When you select the Fast Freeze Acceler Freeze the control board will turn the heater on 100 of the time for a period of 16 hours to pull the freezer temperature down to 6 F for faster freezing of food When you select Fast Ice Acceler Ice the control board will cycle the heater so that it is on 50 2 Watt Heater Plastic sleeve for control cap tube Figure 28 of the time over a 12 hour period to maintain a colder freezer temperature to increase ice production To test the heater unplug the connector and take a ohm reading across the terminals You should read 6 6 K Ohms 10 On electronic control models the 12 hour for fast ice and 16 hour for fast freeze still apply The electronic control will lower the freezer cycling temperature The connector on the left side of the board is for the door wiring harness to plug into See Figure 29 This wiring harness connects with the Main Harness through the top freezer door hinge See Figure 30 The main harness will connect to the machine compartment harness and to the service cord The board will then send power to other parts that operate through the board Wires con
27. holding the cover over the board See Figure 34 Figure 34 Current will be carried between the power board and the con trol board by a ribbon connector See Figure 35 You can check the wires with a ohm meter if you suspect a broken wire Ribbon Connector The top of the ribbor is marked with the word UP to aid in proper connection Figure 35 104 The test points to check for voltage are located on the face of the power board See Figure 36 To do your voltage test it will be necessary to remove the front cover but do not disconnect the ribbon connector Using a paper clip bend a loop around the end hook on the front face and a hook in the other end of the wire Place the second hook in the center slot used for holding the front face See Figure 37 Use electrical tape around the wire to prevent it from touching any of the connection points on the power board Voltage Test Points For Relay Operation gt Voltage Test Points For Power To Control Board Figure 36 To test voltage set your volt meter on DC 25 volts or higher scale With the front removed and hanging on the wire you can check for 8 to 12 VDC to supply voltage to the control board between the points called out in Figure 38 You will be able to make water and ice selections on the control board Press in the actuator arm and look for your voltage drop to close the relay on the board that operates the Auger Water Valve Soleno
28. 2 Startvacuum pump 9 Open hand shut off valve and slowly open both manifold valves turning counterclockwise for two full rotations CAUTION If high vacuum equipment is used just crack both manifold valves for a few minutes and then open slowly for the two full turns counterclockwise This will prevent the compressor oil from foaming and being drawn into the vacuum pump Operate the vacuum pump for a minimum of 30 minutes to a minimum of 29 9 500 micron vacuum Closehand shut off valve to vacuum pump Watch compound gauge for several minutes If reading rises there is a leak in the system go to step 6 If no leak is indicated stop vacuum pump System is now ready for charging If aleakis indicated stop vacuum pump and introduce a small charge of refrigerant into system by cracking valve on bottom of charging cylinder until system is pressurized to 40 or 50 Ibs psig Leak test low side Close compound gauge compressor for a few minutes and leak test high side When leak is found recapture refrigerant using EPA approved recovery system Repair and go back to step 1 Charging The System CAUTION Check the serial plate forthe correct refrigerant type It is extremely important to verify the type of refrigerant in the system before starting any sealed system repairs CAUTION After charging the system with liquid be certain to wait at least 5 minutes before starting the compresso
29. 4 O O YELLOW RED PLATE 321 94 YELLOW A z t l l lt 7 2 95 SECTION G ICE amp WATER DISPENSER ICE DISPENSER CONTAINER amp RAIL ASSEMBLY The Ice Dispenser Container slides into the Rail Assembly mounted directly below the Ice Maker Ice is ejected from the container by an Ice Auger connected to the Solenoid Assembly and dispensed at the bottom front of the container where it enters through a Gate on the Crusher Housing The Gate is opened and closed by a Control Rod that fits in the Actuator of the Solenoid Assembly The ice is then directed into an ice chute mounted on the interior of the freezer door The Ice Container must be properly placed on the rail assembly to assure proper dispensing The container should be slid on top of the rails on the Rail Assembly up against the Motor Cover with the Rotation Stop and Ice Auger protruding through the holes in the back of the Ice Container Dispenser Auger Motor amp Solenoid Assembly Solenoid Assembly not on all models The dispenser Auger Motor Solenoid Assembly Light Socket and Bulb 40 Watt appliance bulb and wiring disconnects are mounted on the back on the Rail Assembly Motor Cover The motor and solenoid mounting screws are located on the front of the Motor Cover To Remove Auger Motor
30. 5 Straight Connector attaches to the bottom of unit F 0 u re H 5 108 Rear Filter System Ice Dispenser Elbow Connectors Y Icemaker LS a Housing Water Filter 5 ilter rear ue GREEN COIL O ring cup T YELLOW COIL 2 2 2 2 BROWN COIL M B z HOME OWNER S SUPPLY 5 E 6 Water Tank P 5 l lt gt Z 7 Ili b 5 j Cover TO SOLENOID VALVE attached to liner YELLOW SOLENOID TO DOOR CONNECTOR Adhesive Clip Straight Connector attaches to the bottom of unit Figure H6 No Filter System I Ice Dispenser Cover attached to liner Water Tank L LI 2 PS daa Icemaker GREEN COIL YELLOW COIL a HOME OWNER S SUPPLY GREEN SOLENOID TO ICE MAKER Ne 2
31. Alignment Side by Side cabinets due to their large size may flex wheninstalled on an unevenfloor To correct alignment proceed as follows 1 Level refrigerator front to back and side to side Open doors and rock refrigerator after each adjustment to relieve cabinet strains 2 After refrigerator is level close doors and check for proper alignment 3 Ifrefrigerator dooris higherthan freezer door raise left corner of cabinet by adjusting roller Refrigerator Door Is Higher Than Freezer Door Raise Left Front Corner 4 Ifrefrigerator door is lower than freezer door raise right corner of cabinet by adjusting roller Refrigerator Door Is Lower Than Freezer Door Raise Right Front Corner 5 After cabinet is leveled and doors are properly aligned ensure refrigerator sets solidly on all four corners When both doors have been reinstalled and are correctly aligned replace toe grille and plug in electrical power cord Turn both temperature controls to center position Adjust settings as necessary SECTION B REFRIGERATOR CABINET BASIC CONSTRUCTION Counter Depth models have clean back cabinets and or forced air condensers The condenser is located under the cabinet bottom The cabinet wrapper consists of a one piece top and sides formed of prepainted steel with aninterlocking snap in galvanized steel back panel A separate steel frame is attached to the cabinet bottom The compressor com
32. Control Arm is rising 1 Ejector reaches ice 2 Motor stalls until ice loosens 3 Heater remains energized Step 3 Step 4 Ejector Ejector Ice e 2 AO NS EO PA A X 2 2 2 Ice Storage Bin Ice Storage Bin Harvest Cycle Harvest Cycle End of 1st revolution 1 Completing 1st revolution of Hold Switch opens Ejector Since Thermostat is still closed 2 Water Fill Switch closes but 2nd revolution of Ejector begins heater remains on preventing water fill Step 5 Step 6 74 Ice Storage Bin Harvest Cycle Hold Switch closes Motor energizes Mold Heater remains energized Shut Off Arm raises and lowers Ice dumps into bin Step 9 Ejector 4 2 Water x 2 Ice Ice Storage Bin Fill Cycle 1 Near completion of 2nd revolution of Ejector Water Fill Switch closes and water fills mold 79 Ejector IN Ice Ice Storage Bin End of Harvest Cycle During end of 2nd revolution Mold Heater resets Thermostat Mold Heater de energized If container is full Control Arm opens Shut Off Switch Ejector x Ice Ice Storage Bin End of Fill Cycle Hold Switch goes to normally closed position Water Fill Switch opens Freez
33. Dt 41 SECTION E REFRIGERATION SYSTEM PED TA Ne EE 42 ais me T 42 anie ge sami 42 TM 42 M TT m T 42 Compressor Testing ERREUR 42 Charging Sealed Systems cocos nace mti Sit toti naeh rne demens 42 OIG CHING NER RE 43 Basic GOMPONENIS sce ase gcse ge gee etnies 43 m n assed bo qe M 43 m 43 Low or High Side Leak Or 43 Testingfor RefrigerantLeaks a aan aaa uk a xa FE Rad ruta AR Ga E Cu RA 44 Checking for Internal Hot Tube 44 Compressor Replacement 44 Horario ME E m 44 To Use Dry Nitrogen To Flush The System 45 To Use Refrigerant To Flush The System eese eene enne nnne nnne nnne nnns 45 Installing a New COM Iles SOM 45 Evaporator Repla
34. F Control System One position read out for freezer and food Compartment Freezer Temperature Colder key increments setting one number each key press Setting Upper Limit 9 Temperature Warmer key decrements setting one num ber each key press Setting Lower Limit 0 Off Number Setting to Temperature Conversion 0 Off All Loads Damper Closed Displays 0 1 6 F 14 C 2 4 15 5 C 3 3 16 C 4 2 17 C 5 0 F 18 C 6 2 F 19 C 7 3 F 19 5 C 8 4 F 20 C 9 6 F 21 C Displays are off when Fresh Food Door is closed Communications remain active Default 5 Fresh Food Temperature Colder key increments setting one number each key press Upper Limit 9 Temperature Warmer key decrements setting one num ber each key press Lower Limit 1 Number Setting to Temperature Conversion 1 47 F 8 C 2 44 F 6 5 3 42 F 5 5 4 40 F 4 C 5 38 F 3 5 C 37 F 3 Fe C 2 C F 1 C Default 5 33 Freezer Fresh Food GENESIS WIRING DIAGRAM LINE NEUTRAL J 3 J COIL H C MOTOR EVAP FAN DEFROST THERM EATER Air Filter _ Fan E FF Thermistor FRZ Thermistor C 11 P2 lt 1 AL 7 27 GE
35. Maker connected to electricity Mold temperature below 15 F Motor stalls as finger hits ice cubes Power on heater Thermostat closed Control Arm swinging down ON OFF switch in the ON position Shut Off Switch closed C to NC Hold Switch closed C to NO Water Fill Switch open LT BLUE Hold Suilch Shut Off MOLD HEATER 85 Walls Water Fill Switch 86 NEUTRAL AAJNIS Dimmi V NV V V Waler Valve NEUTRAL Waler Volve CUL PS a VV WV WV Section F Ice Maker NEUTRAL Ice Maker connected to electricity Mold temperature below 15 F Ice breaks loose and motor starts to rotate again Power on heater Thermostat closed Control Arm is down ON OFF switch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill Switch closed but shorted out by thermostat 0f 0n On Thermal Cul Qul Switch BLACK C J BLACK LT BLUE LT BLUE Shai Off V MV V V Waler Valve MOLD HEATER 85 Walls Woler Fill Switch Ice Maker Electric 6 NEUTRAL Ice Maker connected to electricity Mold temperature below 15 F Motor is rotating Power on heater Thermostat closed Control Arm is down ON OFF switch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NC Water Fill Switch open Off On 0 Thermal Cul Qul BLACK Sui Ich T
36. Mold groove to mold 11 Clean remaining thermal mastic sealer from 6 Replace thermostatin reverse order Mold groove Apply layer of thermal mastic sealer to Mold groove Install replacement Mold Heater 12 To Replace Thermal Cut Out i 1 Remove Ice Maker from Freezer 14 Replace parts in reverse order Ensure that Thermo 2 Removefront Cover stat gasket is in place Bond the Thermostat to Mold 3 Remove three screws that attach Mounting Plate with thermal mastic sealer to Support Housing 4 Pull cable assembly free from support housing It will should be between 2 F to 4 F slide out easily Loosen screw securing clamp to TCO TCO should come free after tension from clamp is released Disconnect TCO from two wire nuts One end is connect to the cable assembly and the other end is connected to the motor and mold heater 82 FAULT DIAGNOSIS Complaint Ice Maker Fails to Start 1 Check to see if Ice Maker Control Arm is locked in raised position 2 Check terminals from Cabinet wiring to Ice Maker for open circuit in wiring or components 3 Check operation of the Maker with test service cord 4 Check Mold temperature at a mounting screw If temperature is above 15 F freezer air temperature is not cold enough to switch Ice Maker Thermostat to closed position If Mold is below 9 F manually start Ice Maker by rotating Timer gear If motor fails to start check Motor for continuity If Motor
37. The refrigerator power cord is equipped with a three prong grounding plug It must be plugged directly into a properly grounded three prong receptacle The recep tacle must be installed in accordance with local codes and ordinances Do not use an extension cord or an adapter plug NOTE If voltage varies by 10 of 115 volts performance of the refrigerator may be affected Operating the refrigerator with insufficient power can damage the compressor Figure A1 Serial Plate LEVELING Therefrigerator must be leveled with all bottom corners resting firmly on a solid floor Adjust the front rollers to levelthe cabinet from side to side and front to rear Keep the cabinet as low as possible for stability Never adjust the cabinet rollers so the front is lower than the rear To adjust the front rollers 1 Openrefrigerator and freezer doors 2 Remove toe grill by pulling it straight out See Figure A2 3 Adjust rollers by turning each roller adjusting bolt with flat blade screwdriver adjustable wrench 3 8 socket wrench or 3 8 nutdriver until refrigerator is level and stable See Figure A3 D N NOTE Rear rollers are not adjustable lt Figure Figure 2 t DOOR REMOVAL NOTE If installation requires the removal of the doors trace around all hinges with a soft lead pencil for easy relocation 1 Disconnect electrical supply 2 Op
38. a blockage In addition sealed system components that have been used with CFC systems must not be used with R 134a systems These components may contain residual amounts of refrigerant and oil which could damage an R 134a system At the earliest stage of development work on R 134a tests were carried out on a different type of synthetic oil known as Poly Alkaline Glycol PAG This oil is also used in certain air conditioning systems for cars PAG and Ester oil DO NOT mix with one another Service equipment used for R 134a Ester oil must not come into contact with PAG 54 WATER IN THE REFRIGERATION SYSTEM Even in very small quantities water in any refrigeration system can cause the following problems e Ice plugs in capillary tubes Copper plating in compressor Reactions with organic materials in systems Corrosion of metals R 134a and Ester oil will aggravate the problem of water in the refrigeration system Ester oil may react with water vapor and is hydroscopic it will absorb water if it comes in contact with humid air Water is also more soluble in R 134a than R 12 minimize the water content whenever service work is performed the refrigeration system should always be thoroughly evacuated through process tube adaptors on both the high and low sides of the system Evacuation must be for a minimum of 30 minutes to at least a 29 9 inch 500 micron vacuum VACUUM CHART Vacuum Boiling Point Inches Hg o
39. a triac located on the control board Fresh Food Temp 30 Condenser Fan Motorized Fan 115VAC that circulates air through the condenser coils The relay controlling compressor is used to control the condenser fan motor Fresh Food Door Switch Single poll single through mechanical switch Air Filter Motorized Fan 12VDC that circulates air through a filter in the Fresh Food Section Sensors Negative Temperature Coefficient Thermistor Alarm Audible Transducer Piezo Control Main Board Power Supply AC Input Voltage 115 V AC 60 Hz Numeric Display Version A 2 digit 7 segment numeric with degrees symbol minus sign segment and a 4 segment character to represent F and C Version B 1 digit segment numeric Fresh Food Door Sensor Magnetically activated reed switch Switch will detect Fresh Food Door state Show Room Setting Active Function Displays Freezer Fresh Food Temperature Keys Fresh Food Lights Air Filter Key Key Tone and green LED toggles on amp off All other functions are disabled including alarm s en abling Alarms and Signals Door Ajar LED flashing green Either door open for 5 minutes this light blinks and control beeps Condition is reset if the opened door is closed Disabling Door Ajar Alarm Audio Press and hold Freezer UP Key while pressing the Fresh Food DOWN Key 3 Times Only the audio transducer is disabled Door Ajar monitor ingand LEDremain ena
40. check its operation This can be done on the repair bench or while mounted in the Refrigerator If the Ice Maker is in an operating refrigerator take precautions against the formation of condensate by allowing the cold metal components to warm up before removing the front cover This can be expedited by cycling the assembly with the cover in place and the water supply valve closed Tomanually cycle the Ice Maker slowly turn the Ejector blades clockwise until the Hold Switch circuit to the Motor is completed When the Motor starts all components except the Ice Maker Thermostat should perform normally Once the Ice Maker completes its cycle if additional testing is necessary you can turn the Ejector blades again to start the icemaker into another cycle WATER VALVE SWITCH WATER FILL VOLUME The amount of water fill is directly proportional to the length of time terminals C NC of the Water Fill Switch are closed Closing occurs when the switch plunger drops into a cavity formed in the Cam Different water valves have different flow rates For this reason anytime a Water Valve is replaced the Water Fill Switch must be adjusted Thecorrect waterfill volume is 78 83 cc To measure the fill volume test cycle the Ice Maker and collect the water Measure in a container calibrated in cubic centimeters cc the fill time is 5 4 seconds The fill volume is adjusted by increasing or decreasing the length of time the Water Fill Switch
41. during either revolution the switch will remain open and stop the Ice Maker at the end of that revolution When sufficient ice is removed from the Storage Container the Sensing Arm lowers and ice production resumes To manually stop the Ice Maker raise the Sensing Arm until it locks in the upper position Operation is resumed when the Sensing Arm is manually lowered Timing Switches See Figure F2 Thethree Timing Switches used are single pole double throw SPDT Theyare identical exceptforfunction and can be used interchangeably 1 Hold Switch Assures completion of a revolution once the Ice Maker operation has started Water Fill Switch Opens the Water Valve during the Fill Cycle It is the only adjustable component in the Ice Maker Shut Off Switch Stops Ice Maker operation when the Storage Container is full of Ice The switch is opened after the Sensing Arm is raised to its most upright position The switch is mounted to the top right wall of the Ice Maker Support Not shown in Figure F2 2 Mounting Plate Back View O Water Fill Switch Figure F2 61 Thermal Cut Out TCO The Thermal Cut Out is a one time limit fuse used as a safety device It is located under the mounting plate in the head of the Ice Maker between the Thermostat and wire connector Ifthe Thermal Cut Out opens the cause of failure must be determined and corrected priorto replacing the TCO Normal causes of the TCO failing ar
42. efficiency of an electromagnetic coil Figure H10 112
43. freezer compartment For example a small amount of water spilled in the freezer compartment will freeze immediately However this intime willevaporate and transferto the colder surfaces ofthe freezer evaporator coil Air Circulation Patterns Automatic defrost models have a single evaporator in the freezer compartment and have forced air cooling in the freezer andrefrigerator compartments The fin and tube aluminum type evaporator is located on the lower back wall of the freezer compartment A circulating fan suction type pulls air from the freezer compartmentthrough the grill in the bottom ofthe freezer and from the refrigerator compartment through a duct located in the separating wall in the bottom rearleft hand corner of the cabinet interior The air is than drawn up through the fin and tubes ofthe evaporator surface The cold air is forced into afan cover and discharged intothe top ofthe freezer and outthe air discharge underthe ice maker Figure D1 If the food compartment control is calling for cooling the automatic damper control in the top ofthe food compartment will open and allow cold air to enterthe food compartment Ifthe food compartment calls for cooling but the fan is not running the fan will start is soon as the damper is open and will continue to run as long as the food compartment control or the freezer control call for cooling The air circulating fan operates any time the food compartment control orthe fre
44. is 22 000 defrost cycles over a 15 year period Defrost Heater Compressor Running Initial Start amp Power Interruptions When power is applied to the power cord If the defrost termination thermostat is closed the compressor will start and the ADC will start a defrost cycle after 1 hour If the defrost termination thermostat is open a compressor cycle starts immediately The ADC will start the first defrost cycle in 6 hours of compressor run time ADC Characteristics The ADC has a base defrost interval of 6 hours of run time All defrost interval timing starts with the compres sor pull down after a defrost or initial cabinet power When time for defrost Ifthe compressor has been running equal to or more than one hour defrost immediately If the compressor continues to run less than one hour initiate the defrost at beginning of next NO cycle If compressor continues to run for one hour after time for defrost initiate the defrost immediately after that one hour The maximum defrost cycle is 30 minutes Ifthe Defrost thermostat does notopen shutting off the defrost heater the ADC will shut off the heater and start the compressor after 30 minutes After each defrost termination there must be a 6 minute delay before compressor start and one additional minute before evaporator fan start The exception is if the heater is on the full 30 minutes the compressor will start as soon as the heater shuts off and the fan wi
45. itin a roll at the open end of the Hot Tube It will make heater installation go faster Using of a good two stage 5 CFM Vacuum Pump will also make heater installa tion go faster 5 Disconnect Plastic Sleeve 6 Pull braid out while pushing equal amount of braided heater into tube at other end until heater wire inside braid appears Connect to Condenser Outlet 221 Adapter and plastic sleeve Vacuum Pump INSTALLING THE HEATER WIRE STEP 3 1 Remove wires with terminals from compressor starter overload On some models you will need to depress locking tabs located in relay housing See Drawing below 2 Install harness adapter into refrigerator circuit as shown below Wire splice connector to heater Wire splice connector to heater Refrigerator Harness 3 Cutoff braid at start of heater Strip insulation back about 5 16 inch Be careful notto damage heater resistance wire Splice heater wire ends to loose leads of adapter harness with furnished wire connectors 4 Dress wires away from Condenser Fan Blade and any sharp edges 5 Secure wires with electrical tape as necessary 6 Reinstall Back Panelfor proper air flow over condenser and compressor 50 CONDENSER REPLACEMENT 19 14 15 Disconnect electrical supply to refrigerator Remove compressor access panel Recoverrefrigerant by using EPA approved recovery system Remove condenser fan mounting screws Unplug fan moto
46. left wall with two screws and can be removed for servicing Thelce Makeris designed to produce ice automatically The length of time between Harvest Cycles will vary depending on load conditions door openings ambient temperature and freezer temperature These factors must be taken into consideration when checking the ice production rate With a temperature of 2 F to 5 F in the freezer the rate of harvest will be 8 12 cycles per 24 hour period The Ice Maker is wired across the line and will harvest ice in the refrigeration or defrost cycles The Water Valve and Solenoid Assembly are both mounted in the compressor compartment A 3 16 polyethylene tube extends from the water valve up the rear wall of the refrigerator to a water inlet spout that directs the water into the fill trough A bead of sealer around the inlet water tube prevents the migration of air and moisture into the freezer compartment Front Cover A decorative front cover made of molded plastic encloses the operating mechanism of the Ice Maker protecting it from moisture It is essential that the cover be in place on an operating Ice Makerto protect against possible contact with the mechanism by the user See Figure F1 Water Fill Adjustment Mounting Plate Screws Mounting Plate Screw Figure F1 ICE MAKER COMPONENTS Ice Mold The Ice Mold is die cast aluminum with the Ice Maker Thermostat bonded to its front surfa
47. located in the rear control box See Figure 2 Side Screws Front Screws Figure 2 16 The 2 housings will separate at the left back of the front housing by sliding the rear housing to the right until the buttons line up with the larger hole in the slots See Figure 3 Figure 3 FREEZERCOMPARTMENT CONTROL The Freezer Control is mounted on the left as shown in Figure 4 and it controls the cycling of the compressor and fan motors The cap tube for the control runs along the right side ofthe rear housing and has a plastic sleeve installed on the last eight inches Toreplace the Freezer Control remove screws and drop housing Pull the cap tube for the control from the guide tube under the air inlet at the back of the rear housing See figure 4 Cap Tube Freezer Control with Plastic Tube Runs along rear housing and out under Damper Control Food Compartment Control Freezer Control Figure 4 When you install the new Freezer Control connect wires as shown in Figure 5 The ground wire green must be attached as well GE Control White Invensys Green Figure 5 After the wires are connected snap the control into place and route the wires around the screw boss See Figure 6 Place wires around screw boss Snap in place Figure 6 Route the wire harness and capillary tube through wireway under boss screw and snap into clip as shown in Figure 7 snap into clip thro
48. nnne RR E Ea END Evaporator Fan MoOlOT studens quit ease xpi donee adu E qun 50 cR m TO Fest Defrost THEO Stal Nm UTE To Remove Defrost Thermostat a aa Dero IRO NO How TO Remove Defrost Heater T Electrical Mechanical Control System Freezer Compartment Control NER T E Fresh Food Compartment Control AFAM ONION m lero 0 I mw EE OA Initial Start amp Power Interruptions eie TNT E 20 When Time OB SS lees decreas 20 iucrecuenhueco d e 21 System Diagnostics Control SyYSISM QR 21 Wild OAC Be SCG IAG E 23 Wiring Diagram Pictorial Dispenser and Relay 24 Wiring Diagram Dispenser and id Md UP 25 System Exploded Vi
49. part of the dispenser is free of the freezer door panel The main housing is part of the door panel and is not removable See Figure 17 Ice Door Closer Figure 19 Main housing for dispenser is part of the outer door panel Gear driver used to connect door closer to arm on door Figure 17 The ice door and actuator switches as well as the return springs can be serviced with the control module removed Figure 20 See Figure 18 The closer can be replaced by removing 3 screws and lifting Ice Door Return Springs closer from housing The door is held in place with a shaft at the top The spring that holds the door closed and sealed against the housing is over the shaft and can be replaced by using a small punch and removing the shaft See Figure 21 Switches Door Closer Figure 18 101 Use a small punch to remove shaft Figure 21 Tension is held against both the water and ice actuator by a stainless steel two bladed spring mounted behind the actuator switches The spring is held in place with 2 screws See Figure 22 TENSION SPRING FOR ACTUATORS FIGURE 22 The Actuators are held in place by stainless clamps at each end of the actuator and the two bladed spring in the middle See Figure 23 The actuators can be removed by removing the 4 screws and lifting the paddle ice chute out of the housing Spring and clamps used to hold actuators in place Figure 23 On models that only dis
50. several manufacturers The least expensive models are nonselective detectors that will detect any type of emission or vapor present regardless of its chemical composition Some nonselective detectors designed for use with R 12 may have a much lower sensitivity when used with R 134a However newly designed detectors with good R 134a sensitivity are now available Be sure to consult with the manufacturer before selecting or using anonselective detector with R 134a Halogen specific detectors use a specialized sensor that allows detection of compounds containing chlorine fluorine bromine and iodine without being activated by other species The major advantage of this type of PRESSURE UU GAUGE HAND SHUTOFF VALVE ig HEATED EE CHARGING Pp CYLINDER COMPRESSOR Figure E4 STAGE VACUUM PUMP detector is a reduction in the number of nuisance alarms Halogen specific detectors are generally more expensive than nonselective detectors but feature higher sensitivity R 134a PROPERTIES The properties of R 134a are very similar to those of R12 The principal data for the two refrigerants are shown in the chart below REFRIGERANTS Dichlorodifluoro 1 1 1 2 Tetra methane fluoromethane Molecular Weight g mol 120 93 102 3 Ozone Depletion Potential 1 ODP Solubility of Water in Refrigerant wt 77 F 56 HFC 134a CFC 12 PRESSURE TEMPERATU
51. the connector plug 12 Crimp the two solderless connectors to the two leads coming from the connector plug 13 Slip the heat shrink over the solderless connectors and heat that area with a heat gun until the heat shrink is tight around the solderless connectors 14 Hook the thermostat back on the evaporator near or at the same place it was before 15 Reverse Steps 1 7 to complete repairs 14 DEFROST HEATER 9 Unclip ground wire hooked to drain trough 10 Remove screw holding evaporator bracket through drain trough to cabinet 11 Remove rivet holding bracket to trough and set bracket aside for reuse 12 Remove screw holding drain trough to cabinet The length oftime the heateris energized dependsonthe 43 ift up and pull evaporator and drain trough out at amount of frost accumulation on the evaporator bottom How To Remove The Defrost Heater NOTE Use caution not to damage suction line or 1 Disconnectrefrigerator from electrical supply cap tube 2 Remove freezer section bottom shelves and baskets 14 Slide the drain trough off the evaporator The defrost heater is a radiant U shaped resistance heater rated at 450 watts The defrost heater is ener gized during that period of the cycle when the defrost thermostat contacts are closed 3 Remove ice container and rail assembly The 15 Remove the retainer clamp from bottom of multiconnector at the back of the rail assembly must evaporator holding the heat
52. the mechanism by the user See Figure F1 Water Fill Adjustment r Mounting Ice Make Plate ON OFF Switch hk UN Mounting Plate O O Screw Timing Gear Figure F1 ICE MAKER COMPONENTS Ice Mold The Ice Mold is die cast aluminum with the Ice Maker Thermostat bonded to its front surface The Mold has a semicircular interior partitioned into equal size compartments Water enters at the side of the Mold through a fill trough A film of silicon grease on the top edge of the Mold prevents siphoning of water by capillary action Mold Heater A Mold Heater rated at 85 watts at 115 volts 145 ohms 10 or 85 watt at 230 volts 379 ohms 10 and covered with an aluminum sheath is embedded in the grooved section on the underside of the Mold When the Mold Heater is energized the ice contact surface within the Mold is heated enough to allow harvest of the ice pieces The Mold Heater is wired in series with the Ice Maker Thermostat which acts as a safety device The heater is staked in place and is replaced as part of the ice maker Mold A thermal mastic sealer is placed between the heater and the Mold to ensure good thermal contact Ice Stripper Stripper is attached to the Mold to prevent ice pieces from falling back into the Mold It also serves as a decorative side cover Ice Ejector The Ejector blades are molded from Delrin and extend from a central shaft whic
53. while pressing the fresh food temperature DOWN COLDER key 5 times within 6 seconds Function Initiates a defrost cycle All other functions are disabled including alarm s enabling Show Room Mode See page 31 Changing between Fahrenheit to Centigrade on the display See page 31 CONTROL EXPLODED VIEW DIAGRAM GENESIS Control Box Retainer Filter Release Rod Filter Release Button 2 4 Front GENESIS SS Filter CONTROL Damper Assembly Control Box Evaporator Fan Motor Bracket Shroud Fan Orifice 39 Diagram C Service Mode Display Routine Test Number Test Variable Freezer Display Fresh Food Display Advance to 7 Dual Display EOL Tone Start Advance to Advance to Variable A Test 2 Advance to Back to Test 7 Start Variable Advance to Advance to Variable B Test 2 Advance to Back to Test 7 Variable A Variable B H Advance to EOL Tone Test 2 Variable A Variable A Ib 4 4 lt Single Display od Flash first character for 1 second Flash second character twice for 400mS 200 mS interval Back to first character and repeat 40 D AR 5 SECTION D AIR CIRCULATION AUTOMATIC DEFROST MODELS Principals Of Automatic Defrost Operation Automatic defrost refrigerators operate on the principle that moisture or frost transfers or migrates to the coldest surfaces evaporator in the
54. you can not get water out the door the test and operation of the diode is the same as for the ice maker except for the voltage readings On the water side you should read the same voltage at the coil of the secondary valve as you have at the outlet On the primary valve the voltage should read 60 to 80 V AC If the voltage is 10 orless at the primary butgoodatthe secondary you have a bad diode If the voltage is low at both the primary and secondary you have a bad connection or a bad relay switch in the door dispenser If you havethe same voltage at both coils the diode is shorted shorted diode will cause water come out the ice maker and dispenser at the same time Ifyou have a problem with the diodes order the diode kit part number 530441 8384 See Figure H8 The diodes are part of the wiring harness for the machine compartment If you do your voltage checks and find you have the correct voltage at the coils and the valve is not letting water through replace the valve To see which valve is bad disconnect the water line from the filter to the secondary valve at the inlet of the secondary valve Place the line in a bucket Run the ice maker through a fill and see if water will pass through the valve and the filter into the bucket If it does replace the secondary valve If it does not remove the primary valve disconnect the outlet line from the primary valve and run the ice maker through a fill If still no water replace the primary val
55. 4 Electrolux ELECTROLUX HOME PRODUCTS NORTH AMERICA Side by Side Refrigerator Built for Generations Gibson 3 ison For The Love Of Cooking Ke for Backed by the Platinum Advantage Warranty Built to Deserve it MAVI Sensible Dependable Affordable White VVestinghouse There s Extra Value In Everything We Do 5995413142 November 2004 SAFE SERVICING PRACTICES ALL APPLIANCES Toavoid personal injury and or property damage itis importantthat Safe Servicing Practices be observed The following are some limited examples of safe practices 1 DO NOT attempt a product repair if you have any doubts as to your ability to complete it in a safe and satisfactory manner 2 Before servicing or moving an appliance Remove the powercord from the electrical outlet trip the circuit breaker to the OFF position or remove the fuse e Turnoffthe gas supply Turnoffthe water supply 3 Never interfere with the proper operation of any safety device 4 USE ONLY REPLACEMENT PARTS CATALOGED FOR THIS APPLIANCE SUBSTITUTIONS MAY DEFEAT COMPLIANCE WITH SAFETY STANDARDS SET FOR HOME APPLIANCES 5 GROUNDING The standard color coding for safety ground wires is GREEN or GREEN with YELLOW STRIPES Ground leads are not to be used as current carrying conductors It is EXTREMELY important that the service technician reestabli
56. ATER SUPPLY LINE TO ICE MAKER Supply line installation must comply with all applicable plumbing codes Refer to the Ice Maker Installation Instructions in appendix A The tubing and any other plumbing materials required should be obtained locally The Ice Maker should be connected to a frequently used cold water line to ensure a fresh water supply NOTE A vertical cold water line should be selected for the water supply If a vertical line is not available a horizontal line may be used providing the connection is on the side ortop of the pipe but not on the bottom Scale and foreign material in the pipe could cause stoppage of water flow if the connection is on the bottom Be sure to leak test all connections after the water supply has been turned on TEST CYCLING ICE MAKER See ce Maker Testing Procedures on pages 66 75 It may be necessary on occasion to test cycle an Ice Maker to check its operation This can be done on the repair bench or while mounted in the Refrigerator If the Ice Maker is in an operating refrigerator take precautions against the formation of condensate by allowing the cold metal components to warm up before removing the front cover This can be expedited by cycling the assembly with the cover in place and the water supply valve closed Tomanually cycle the Ice Maker slowly turn the Ejector blades clockwise until the Hold Switch circuit to the Motor is completed When the Motor starts
57. Arm is cam driven and operates a switch that controls the quantity of ice produced Inthe Harvest Cycle the arm is raised and lowered during each of the two revolutions of the timing cam If the Sensing Arm comes to rest on top of ice in the storage compartment during either revolution the switch will remain open and stop the Ice Maker at the end of that revolution When sufficient ice is removed from the Storage Container the Sensing Arm lowers and ice production resumes To manually stop the Ice Maker raise the Sensing Arm until it locks in the upper position or turn the switch located on the housing at the left end of the icemaker to off Operation is resumed when the Sensing Arm is manually lowered or the switch is turned back to on Timing Switches See Figure F2 The three Timing Switches used are single pole double throw SPDT They are identical except for function and can be used interchangeably 1 Hold Switch Assures completion of a revolution once the Ice Maker operation has started 2 Water Fill Switch Opens the Water Valve during the Fill Cycle It is the only adjustable component in the Ice Maker 3 Shut Off Switch Stops Ice Maker operation when the Storage Container is full of Ice The switch is opened after the Sensing Arm is raised to its most upright position The switch is mounted to the top right wall of the Ice Maker Support Not shown in Figure F2 Mounting Plate Back View O Water Fill Swit
58. Container is Full 1 Check for loose linkage to the Ice Maker Control arm Shut Off Switch Switch should open when arm is in raised position Adjust if required 2 Check Shut Off Switch terminals C and NO for continuity with Ice Maker Control Arm raised Replace switch if continuity readings are indicating a closed circuit Complaint Ice Maker Produces Undersized Ice Pieces 1 Ensure that Ice Maker mold is level 2 Check for partial restriction in supply line or Water Valve Strainer 3 Ensure that the water pressure to Water Valve is sufficient 20 psi min 120 psi max 4 Ensure that the Water Valve Switch is adjusted for proper water fill 78 to 83 cc s 5 Check thermal bond between Thermostat and Mold If necessary rebond with thermal mastic sealer 83 ICE MAKER TESTING PROCEDURES Operating Cycle The operation of the Ice Maker water refilling and controlled ice storage require proper functioning and timing of all components Consider the following e Has refrigerator been properly installed connected to sources of electrical power and water e Has Freezer compartment Evaporator pulled down to temperature Have several ice making cycles been completed and is the Ice Maker in the Freeze Cycle sthe Ice Maker Thermostat single throw switch in series with the Mold Heater Dothe Ejector Blades make two revolutions per cycle Is ice stored on blades after harvest sthe Water Solenoid
59. E TANK UNLESS IT IS EQUIPPED WITH A PRESSURE REGULATOR NEVER PUT HIGH PRESSURE ON DOME OF COMPRESSOR IT COULD EXPLODE MAKE SURE GAUGE HOSES AND ALL FITTINGS ARE IN GOOD CONDITION AND DO NOTLEAK 5 Leave pressure on hot tube for 24 hours Any drop in pressure is indication of leak If dry nitrogen or carbon dioxide is not available follow steps 1 through 3 above then steps 4 and 5 below 4 Connectgaugesto charging hosefittings Pull vacuum on hot tube 5 Leave vacuum on each side of system for 24 hours Any loss of vacuum indicates leak COMPRESSORREPLACEMENT CAUTION NEVER install a new compressor without first checking for possible system contamination To check for contamination obtain oil sample from old compressor e fthe oil has burned odor but no color change or residue follow instructions in section Installing A New Compressoron page 45 e foilhasaburnedodoranda sugar or gritty feel as well as showing signs of contamination dark color follow instructions in next section To Flush The System Remove as much of contamination as pos sible from system before installing new compressor and filter drier To Flush The System NOTE It is recommended that system be flushed with dry Nitrogen However if refrigerantis used to flush the system you must look at the serial plate to see what type of refrigerant is used in the system This is the only refrigerant that can be used to flush the sys
60. Motor in reverse order To Replace Water Fill Switch 1 2 63 Remove front Cover Remove three screws that attach Mounting Plate to Support Housing Disconnect two Water Fill Switch wire leads Remove two switch mounting screws Remove switch Replace switch in reverse order ensuring that switch insulator is in place Check Water Fill Cycle and adjust as required To Replace Hold Switch 1 2 3 4 5 6 To 1 2 ol 6 T To 2 Remove front Cover Remove three screws that attach Mounting Plate to Support Housing Disconnect six Hold Switch wire leads Remove two Hold Switch mounting screws Remove Hold Switch Replace in reverse order Replace Ice Maker Control Arm Shut OFF Switch Remove front Cover Remove three screws that attach Mounting Plate to Support Housing Disconnect three Ice Maker Control Arm Shut Off Switch wire leads Raise Ice Maker Control Arm Lever Remove two Ice Maker Control Arm Shut Off Switch mounting screws Remove switch Replace switch in reverse order Replace Ice Maker Thermostat Remove front Cover Remove three screws that attach Mounting Plate to Support Housing Loosen two Thermostat retaining clip mounting Screws Disconnect two thermostat wire leads and remove thermostat Apply thermal mastic sealer to sensing surface of replacement thermostat to ensure a positive bond to mold Replace thermostat in revers
61. NESIS e ss CONTROL COND FAN P SEE COMPRESSOR P n WIRING f TN AUTO EMAKER ab 95 SEE DISPENSER ASS Y WIRING M WATER VALVE TOW MAIN WATER VALVE 2999 Fc anm DISPENSER WATER VALVE OE e e ACTUATOR ICE DOOR a MOTOR AUG 70 em HEATER ICE DOOR EVEL LIGHT i PO CRISPER LIGHT FRZR LIGHT FRE SAF EZER LIGHT ETY SWITCH FIN ry REFRIG LIGHT EFRIG LIGHT SWITCH 34 GENESIS WIRING DIAGRAM 5 50
62. PRESSOR BLACK LIGHT BLUE NEUTRAL YELLOW BLACK TO FOOD COMPARTMENT LIGHT SWITCH NOTE SWITCHES WILL CLOSE AND OPEN Figure 14 ONEATATIMETOPREVENTSTALLING IN AHALF OPEN POSITION ASARESULT OF A POWER OUTAGE 19 Defrost Control The ADC 11 Adaptive Defrost Control 2 is used on all Side by Sides with mechanical control system See Figure 15 In addition to controlling the defrost cycles the ADC supplies power to the evaporator fan motor compressor and condenser fan motor as well as the damper motor Figure 15 Voltage between number 1 BLK HOT and number 10 LT BLU Neutral on the ADC is 115 VAC 10 60 Hertz This supplies the power to operate the processes Evaporator fan motor and Damper motor The freezer cold control 4 supplies line voltage to the ADC relay common contact to run the compres sor and condenser fan motor as well as the defrost system It also supplies the signal to run the evaporator fan motor that is connected to 11 The board has a built in 6 minute delay on starting the compressor after the Defrost limit thermostat has shut the defrost heater off This is to allow the evaporator time to drain The food compartment cold control 9 also supplies the signal to the board to run the evaporator fan motor and tell the ADC to start the damper motor opening the damper door When the control contacts open braking the signal the ADC will turn the damper motor back on and close the damper door The d
63. RE CHART croaz wesws ores me s Cs me s ps wr ss we m pa m Cae ms Css ara we se mr 79 4 ss m mr ww ws we or os oso Las asx ore me aa 9 e woe s me es se we we ss o2 oor ire em Ls aso oe om es pom Ce e we ws 7 9 ee 9 m per we e me vas se e mee Cm far ome e ms C er e _ s o ovo s 295 Le ri oo n me ome ws we ns 65 FIGURES WITH ASTERISKS IN HG VACUUM FIGURES WITHOUT ASTERISKS PSIG 57 R 134A HEALTH AND SAFETY INFORMATION INHALATION TOXICITY HFC 134a poses no acute or chronic hazard when it is handled in accordance with DuPont recommendations and when exposures are maintained at or below the DuPont Acceptable Exposure Limit AEL of 1 000 ppm 8 and 12 hour Time Weighted Average or TWA An AEL is an airborne exposure limit established by DuPontscientists that specifies time weighted average TWA airborne concentrations to which nearly all workers may be repeatedl
64. TE Theend ofthe roller pin that protrudes through the roller has been flared to prevent it from slipping out You will have to squeeze it back together with a pair of pliers before it will slide out for removal 3 Squeeze flared end of roller pin together using pair of pliers 4 Pull roller pin free of roller andcompressor base Roller should fall free If not you may have to tap roller lightly with hammer to free it from compressor base 5 Reassemble in reverse order Figure B6 Compressor Base 65 Roller ML Roller Pin __ 1 2 gt CABINET TOUCH UP PROCEDURE Vinyl gaskets are used on all models Lacquer repairs can be made on all areas of the cabinet except any painted surface that comes in contact with the vinyl gasket Since prolonged contact of vinyl gaskets with lacquer will soften the lacquer repairs in these areas should not be attempted 10 Lacquer Refinishing The following steps to touch up or refinish a acrylic painted cabinet except in gasket contact areas 1 Sandoutspotto be repaired with 360 or 400 wet or dry sandpaper Finish sanding to feather edge with 600 wet or dry sandpaper Wipe area dry Hand rub with fine rubbing compound Dupont VZ109090r equivalent the area extending at least six inches beyond edges of lacquer repair spot Wipe com pound off and wash area with Naphtha Dry with clean cloth 2 Prepare bare metal with Sol Kleen cleaner and rust remover Reduc
65. _ Condenser Fan Silencer o gt 26 CONTROLS EXPLODED VIEW DIAGRAM REAR FILTER Damper Assembly s N Y Adaptive Defrost Control Insulator Fresh Food Compartment Control Rear Bracket Evaporator Fan Motor Front 4 Control Control Knobs Box Bushings Front Bracket Fan Blade Shroud Fan Orifice 2 CONTROLS EXPLODED VIEW DIAGRAM FRONT FILTER Retainer Filter Release Rod Damper Assembly Filter Release amp Y Button Front Filter Adaptive Defrost Control gt Insulator Fresh Food Compartment Control Rear Bracket Evaporator Fan Motor Front 4 Control Control Knobs Box Shroud Fan Orifice 28 ELECTRONIC CONTROL SYSTEM The ELECTRONIC control is located in the housing mounted in the food compartment along with the light and damper assembly See Figure 1 1 Genesis Electronic control 2 Food Compartment Damper Control 3 Food amp Freezer Compartment Thermistor Figure 1 To remove the Control Housing Assembly remove the three screws across the front control box and the two screws located in the rear control box After removing cover over water line on front filter models remove the screw from the back of the control box See Figure 2 Scr
66. aeesaeeenaessauseneeeseneens 80 To Replace lce Stripper MR TTD 81 To Replace Motor Switch Mounting 81 Replace 2619 421219 51 V E 81 Replace P 81 To Replace Water Fill Switch TE 81 To Replace Hold RU 82 To Replace Ice Maker Control Arm Shut Off Switch 82 To Replace Ice Maker Thermostat irri 82 Replace Thermal Cut Out 82 To Replace Mold Heater D E 82 FI VAIO O SIS PRETERITO Dm 83 Complaint Ice Maker Fails To Start 83 Complaint Ice Maker Fails To Complete 83 Complaint Ice Maker Fails To Stop At End Of Cycle 83 Complaint Ice Maker Continues To Eject When Container Is 83 Complaint Ice Maker Produces Undersized 8 83 Maker Testing OCC GUNS 84 84 Operating Cycle Illustrations Manual Cycle 2
67. ake sure refrigerant is circulating Reinstall evaporator cover and machine compartment cover HEAT EXCHANGER REPLACEMENT CAUTION Always use the TORCH GUARD heat shield behind evaporator before at tempting to solder The excessive heat from soldering will warp the plastic liner The original heat exchanger Suction Line amp Cap Tube Assembly in this product is enclosed in the insulation between the liner and the cabinet back Because of this the original part can not be removed There is a service kit to bypass the internal heat exchanger It will be necessary to run a new heat exchanger down the back of the product and bypass the internal heat exchanger Heat Exchanger Kit Contants 1 Heat Exchanger 6 Screws 1 Drier Filter 1 Armor Flex 1 Cover 1 Package Permagum 2 Tape 1 Instruction Sheet replace the heat exchanger 1 Recover refrigerant from sealed system 2 Disconnect wiring harness at liner plug 3 Remove defrostlimiter and disconnect defrost heater Cutsuction line off at liner Remove evaporator and save for reuse FIGURE 1 2 Old Heat Exchanger Location Drill 1 2 inch hole through cabinet 1 inch below old Heat Exchanger FIGURE 2 4 Remove fan motor and wiring 5 Cutheatexchanger offflush with liner See Figure 1 6 Remove evaporator and drain trough NOTE You do not need to remove rivet or defrost heater 7 Using a 1 4 drill bit drill hole through ca
68. ample is 158 cubic centimeters Subtracting 145 cc from 158 the adjustment needed is 13 cc Since one turn of the adjusting screw changes the fill 18 cc of a turn clockwise would reduce the fill about 13 cc the desired amount This example is for manual models only PARTS REPLACEMENT Disconnect electrical supply to refrigerator If the Refrigerator is operating and cold allowthe Ice Makerto warm up to room temperature before removing the front cover This prevents moisture from condensing on the metal components To Replace Front Cover See Figure F4 1 Ensure that Ice Maker is atroom temperature before removing Cover 2 Place straight blade of screwdriver in slot at bottom of Mold Support and pry Cover loose NOTE Ensure that the retaining tabs inside the Cover are located on the top and bottom when installing the Cover 3 Snap Cover in place Figure F4 Data Sheet Export Only Mounting Data Sheet Envelope Ice Maker Control Arm Cover To Replace Fill Trough and Bearings 1 Push Trough retaining tab back away from Mold 2 Rotate Trough counterclockwise until it is clear 3 Pull from back to detach from Mold and Ejector Blades 4 Replace in reverse order To Replace Ice Stripper 1 Remove Ice Maker from refrigerator 2 Remove retaining screw at back of mold 3 Pull back on Ice Stripper to disengage it from front of Mold Support housing 4 Replace in reverse order
69. binet from inside at location shown in Figure 2 8 Using a 1 2 drill bit open hole drilled in Step 7 to 1 2 from back of product See Figure 2 9 Removestubsofold heat exchanger from evaporator and install new heat exchanger into evaporator 10 Push heat exchanger through hole in cabinet See Push the heat exchanger through the hole in the cabinet Install the armorflex over the heat exchanger Seal hole using the permagum FIGURE 3 Using screws in kit attach cover to back of cabinet Line lower cover up with top lof machine compartment opening FIGURE 4 Using the permagum amp provided in kit seal 2 holeandendofold heat exchanger FIGURE 5 48 Using the permagum provided in kit seal hole and end of old heat exchanger FIGURE 6 Bend tubing as shown to fit inside machine compartment FIGURE 7 figures 3 amp 5 and set evaporator back in place 11 Slide Armor Flex over heat exchanger until cover is against hole at back of cabinet The excess cap tube can be wound around the suction line 12 Seal the hole on the inside and outside using Permagum See Figures 3 amp 5 13 Theone piece cover can now be installed over heat exchanger Place open end of cover with top of compressor compartment opening Attach cover to back of cabinet using screws provided There is no need to predrill holes as the screws are self cutting See Figure 4 14 Seal hole and end of o
70. bled Enabling Door Ajar Alarm Audio after Disabling Press and hold Freezer UP Key while pressing the Fresh Food DOWN Key 3 times Alarm Condition Alarm is enabled and active Alarm LED Green is ON and steady state Show Room Setting Activation Press and hold Fresh Food Temperature UP WARMER Key while pressing the fresh food temperature DOWN COLDER key 3 times within 5 seconds Both displays will flash 0 for 10 seconds While the displays are flashing press the Freezer Temperature UP key to confirm activation Deactivation Mode automatically deactivates at a power on reset Active Function Displays Freezer Fresh Food Temperature Keys Fresh Food Lights Alarm Key Key Tone ONLY Air Filter Key Key Tone and green LED toggles on amp off All other functions are disabled including alarm s en abling NOTE The Show Room mode which during activation doesn trecognize Alarm Power Off con ditions 31 Change Between Fahrenheit and Centigrade Models with mode Key Only To change from Fahrenheit to Centigrade press the mode key Advance into defrost cycle manually Activation Press and hold Freezer Temperature UP WARMER Key while pressing the fresh food temperature DOWN COLDER key 5 times within 6 seconds This will advance the processor into defrost cycle Deactivation Press and hold Freezer Temperature UP WARMER Key while pressing the fresh food temperature DOWN COLDER key 5 time
71. ce The Mold has a semicircular interior partitioned into equal size compartments Water enters at the rear of the Mold through a fill trough A film of silicon grease on the top edge of the Mold prevents siphoning of water by capillary action Mold Heater A Mold Heater rated at 115 volts 81 ohms 1096 or 230 volts 340 ohms 10 and covered with an aluminum sheath is embedded in the grooved section on the underside of the Mold When the Mold Heater is energized the ice contact surface within the Mold is heated enough to allow harvest of the ice pieces The Mold Heater is wired in series with the Ice Maker Thermostat which acts as a safety device The original heater is staked in place but can be removed for replacement The replacement heater is secured to the Mold by four flat head retaining screws that thread into holes in the Mold adjacentto the heater A thermal mastic sealer is placed between the heater and the Mold to ensure good thermal contact Ice Stripper An Ice Stripper is attached to the Mold to prevent ice pieces from falling back into the Mold It also serves as a decorative side cover Ice Ejector The Ejector blades are molded from Delrin and extend from a central shaft which turns in nylon bearings atthe front and rear Each blade sweeps an ice section out of the Mold The drive end ofthe Ice Ejector is D shaped Silicone grease is usedto lubricate the bearing surfaces Water Valve Assembly T
72. cement rennene 46 Heat Exchanger HeDIGGCOITIODIE 48 Perimeter Hot Tube ts 49 Condenser 51 PUES LIST ANS UU OUD MM RR mm 51 e FS CNN esre a E tcn uni du eM RUM NOD MU UO 51 Equipment Needed Tor Evacuation amp uan du E RR 52 Installing Evacuation amp Recharging Equipment de zl 52 o UB E DNI MONUI NEIN BU itu A 52 lent CIO BY c NN m 52 D RR A 53 R 134a Service Information m 54 Verify Refrigerant Type In The QUA Redi 54 Fe Ci CIN E TO TR 54 SIGNING AATTEENA EERON 54 Miscipility of R 134a and Ester Oll M n 54 Waterin Reiigeration Systeri NE ETT T E mem 55 Vacuum IVA INS ING C 55 Ez AKG E O E 56 iio
73. ch Figure F2 Thermal Cut Out TCO The Thermal Cut Out is a one time limit fuse used as a safety device It is located under the mounting plate in the head ofthe Ice Maker between the Thermostat and wire connector Ifthe Thermal Cut Out opens the cause of failure must be determined and corrected priorto replacing the TCO Normal causes of the TCO failing are a bad Thermostat or a shorted coil on the water valve Timing Cam amp Coupler Three separate cams are combined in one molded Delrin part 1 Inner operates Shut Off Switch lever arm 2 Center Cam operates Hold Switch 3 Outer Cam operates Water Fill Switch One Cam end is attached to a large Timing Gear The other Cam end is coupled to the Ejector Timing Gear This large molded plastic gear is driven by the Motor and in turn rotates the Cam and Ejector A D shaped hole in the gear fits over the Timing Cam Hub Spacer tabs on the backside of the gear prevent the gear from binding on the mounting plate Motor A low wattage stall type Motor drives the Timing Gear This gear turns the Timing Cam and Ejector Blades approximately one revolution every three minutes 1 3 RPM On Off Switch A single pole single throw switch mounted on the right side of the housing at the front of the ice maker This switch is used to turn the ice maker off Unlike the switch on the bail arm the On Off switch will stop the ice maker as soon as it is pushed it wil
74. ck leads together and separate them NOTE One black lead is connected to the Mold Heater Another is connected to the Thermostat and the third lead goes to the Hold Switch 6 Disconnect remaining Mold Heater lead connected to brown Motor lead and black Thermal Cut Out lead 7 Separate Mold from Support Housing NOTE careful not to destroy the thermostat gasket located between the mold and support housing 8 Remove hex head screw holding Ice Maker Leveling Bracket to Mold NOTE The Mold is crimped in six places holding the Mold Heater firmly in the Mold groove It may be necessary to use a hammer and screwdriver to remove the heater from the Mold groove 9 Use aflat bladed screwdriver to pry inoperative heater from Mold groove 10 Clean remaining thermal mastic sealer from Mold groove 11 Apply layer of thermal mastic sealer to Mold groove 12 Install replacement Mold Heater 13 Replace parts in reverse order Ensure that Thermo stat gasket is in place Bond the Thermostat to Mold with thermal mastic sealer NOTE For best operation the freezer temperature should be between 2 F to 4 F FAULT DIAGNOSIS Complaint Ice Maker Fails to Start 1 Check to see if Ice Maker Control Arm is locked in raised position 2 Check terminals from Cabinet wiring to Ice Maker for open circuit in wiring or components 3 Check operation of the Maker with test service cord 4 Check Mold temperatur
75. commended for silver soldering to surfaces to be joined and to surfaces immediately adjacentto joint Align tubing so no stress is on joint Do not move tubing while solder is solidifying or leaks will result CAUTION During application of heat use wet cloths to prevent heat from conducting to areas other than the soldered joint Use a sheet of metal or torch guard pad as a heat deflector to keep flame away from inflam mable materials and painted surfaces Use a torch of adequate capacity so joint can be quickly heated with a minimum of heat travel to other points Use a good grade of silver solder Solder connections If tubing is properly cleaned and fluxed solder will flow readily Use only enough solder to make a good bond Allow joint to cool then wash exterior with water to remove flux BASIC COMPONENTS The basic components of a refrigerator are a compressor condenser evaporator heat exchanger capillary tube and suction line drier and perimeter hot tube PERIMETER HOT TUBE Toreduce the possibility of condensation forming on the exterior ofthe cabinetin high humidity areas a perimeter hottube refrigeranttube has been installed in the unit The perimeter tube extends up the left side across the top of the freezer and down the center mullion and into the filter drier When the compressor operates warm refrigerant flows through the primary condenser then into the primary hot tube warming the cabin
76. drier inlet 5 Install copper bypass tube and replacement filter dryer as shown in figure below Use 45 silver solder for all connections Perimeter Clamps Copper By Pass Tube Tube Perimeter Tube New Filter Drier 6 or pierce three holes in cabinet to hold clamps Secure bypass tube just below cabinet edge with three clamps and screws provided NOTE When clamped in place the bypass tube should NOT touch any plastic lines such as water lines for ice makers and or filters as well as drain lines 7 Evacuate and recharge refrigeration system Refer to serial plate for correct charge INSTALLING THE HEATER WIRE STEP 2 1 Attach Vacuum Pump and Gauge Set to one end of Perimeter Hot Tube with an Adapter and Plastic Sleeve See illustration on next page 2 Cutoff waxed end of Fiberglass braid that is extended past end of heater wire and make knot in end just a little smaller than inside diameter of hot tube Insert knot on end of braid into open end of Perimeter Hot Tube 4 With braid inserted start Vacuum Pump and place your thumb over end of tube When good vacuum is obtained release your thumb and begin to feed braid into Hot tube Continue this process until string reaches Plastic Sleeve NOTE Take the time to remove all the bends from the heater caused from being rolled up by pulling the heater and braid through a shop rag with a small amount of silicone on the rag and laying
77. duct cover Disconnect connector and green ground lead connected to evaporator fan motor Evaporator fan motor assembly can now be pulled free Remove two screws holding fan motor bracket to shroud 10 Remove fan blade and slinger washer 11 Remove two screws holding front and rear motor brackets together Pull evaporator fan motor free 12 Reverse procedure to complete repairs 9 NOTE The Slinger washer on the fan motor shaft must be adjusted to within 1 16 to 1 8 from motor to prevent water from entering motor bearing NOTE When replacing the fan blade press the blade onto the motor shaft until the blade bottoms out on the shaft Figure C5 Evaporator Fan Motor Assembly DEFROST THERMOSTAT Figure C6 The defrost thermostat is a temperature sensing device Wired in series with the defrost timer and the evaporator defrost heater itsenses the rise in evaporator tempera ture during defrost cycle and cycles the defrost heater off after all frost is melted It is calibrated to permit a defrost cycle only when the temperature is below a preset temperature The contacts in the defrost thermo stat are set to open at 47 F and close at 25 F To Test The Defrost Thermostat 1 Measure resistance across two thermostat leads at the connector plug Atroom temperature resistance should be infinity The contacts are open 2 Place a couple ice cubes on sides of thermostat After a few seconds thermostat should res
78. e 98 MET m A 98 SelecNONIDISDOFISBl eii 98 Five Selection DISpENSET T EET DOTT 98 FOU SOIC ONT DISPENSE QE EE OTT 98 Three Selection Dispenser TE T I T TU 99 lo amd Water ONIY m P 99 ci avo e MB EID P 99 Models With Electronic COMTO M C 99 821574524 21210 e a E sn an EES 103 NOMS ISS HG m Tr 105 loRemove Control Board TET ee a E EREE EERE ar init E aia NER L EESE 105 SECTION H WATER SYSTEM SINS EE E E E T EE E EE EE E E E A E 107 2212 E 107 PureSource Water Filters EU m T Mm 107 LAW EE 108 mensi M ENT mmt 108 Rear Fillor SY TE omm t 109 NO Fito SY SION ETE TO TOL 109 Test The Water Fill System 2 Teka avatar rictu nudi ik edic xdi bn y vi 110 SECTIONA INSTALLATION INSTRUCTIONS UNCRATING Uncrating instructions are clearly printed on the ship ping carton Under no circumstances should a refrigera tor beuncrated until these instructions have been read Additional handling and installation informationis pro vided in the Installation Tips affixed to the refrigerator door and in the Owner s Guide located in one of t
79. e Combustible mixtures of air and HFC 134a will not form when liquid HFC 134a is pumped into closed vessel if initial air pressure in vessel is limited to one atmosphere absolute and final pressure is limited to 300 psig 2 170 kPa absolute If initial air pressure is greater than one atmosphere combustible mixtures may form as tank is filled Based on above information the following operating practices are recommended Leak Testing Equipment should NEVER be leak tested with a pressurized mixture of HFC 134a and air HFC 134a may be safely pressured with dry nitrogen Bulk Delivery and Storage Tanks should normally be evacuated at start of filling and should never be filled while under positive air pressure Tank pressure should never be allowed to exceed 300 psig 2 170 kPa when filling with HFC 134a Relief devices on either tanks or HFC 134a supply system usually preventthis Tank pressures should be monitored routinely Airlines should neverbe connected to storage tanks 99 Filling and Charging Operations Before evacuating cylinders or refrigeration equipment any remaining refrigerant should be removed by recovery system Vacuum pump discharge lines should be free of restrictions that could increase discharge pressures above 15 psig 205 kPa and result in formation of combustible mixtures Cylinders orrefrigeration equipment should normally be evacuated at start of filling and should never be filled
80. e termination thermostat is closed or open the compressor is activated and sets the next defrost time An electrical connection between the defrost heater and the defrost termination thermostat is coupled to the ADC for system data but also gives the technician the ability to check electrical continuity individually of either the defrost heater or termination thermostat from the ADC mounting area The ADC printed circuit board has component identifica tion and lead wire color name listed on the cover over of the heat resistant box the ADC is mounted into NOTE Because the evaporator fan motor operates through the ADC control you can not replace the ADC with a defrost timer To check input power to the board See Figure 14 1 Check voltage between 1 and 10 You should have 115 VAC 10 as long as the refrigerator is connected to house current If the freezer control contacts are closed there should have 115 VAC 10 between 10 and 4 If no voltage is present check control 21 Ifthe food compartment control contacts are closed there should be 115 VAC 10 between 9 and 10 If no voltage is present check control With the door open and the food compartment light switch contacts closed there should be 115 VAC 10 between 7 and 10 If no voltage is present check light switch NOTE Remember to initiate defrost with the light switch both the switch and the light bulb must be operating The board
81. e 6 small screws from the board See Figure 13 Remove screws 4 Unsnap Night Unplug the wire harness from touch socket panel to board Figure 13 Figure 10 Pull board straight out of housing Disconnect plug on left side of board Disconnect 4 wires to dispenser actuator Carefully unplug the wiring harness from the touch panelon switches See Figure 14 the front cover See Figure 10 This will give you access to the control board See Figure 11 Disconnect actuator Control Board switches Figure14 Figure 11 On models with no selector on the front panel when you With the board removed remove the 3 screws from the dis remove the front you can gain access directly to dispenser penser housing and pull the dispenser forward See Figure because you do not have a touch pad or board on dispenser 15 See Figure 12 Model without electronic control Remove SCrews Pull housing forward Figure 15 Figure 12 100 Remove water line from dispenser housing by pulling straight The door closer is mounted on the side of the housing See out See Figure 16 Figure 19 and connected to the door arm with a gear wheel to slow the closing of the door See Figure 20 This allows enough time for the ice to clear the chute The door will take approximately 20 seconds to close after the glass is removed from the actuator Remove water line Figure 16 With the water line removed the upper
82. e Cycle begins Ice Maker Exploded View Bearing amp Fill Trough Ice Ejector Shut off Arm Wiring Harness Connector Plug Leveling Bracket Ice Stripper 7 d Thermal Cutoff Assembly 2 Maker Mold With Heater 7 Cam Screw Thermostat 7 Screw I D Plate Plate 7 7 1 7 NS Ss mes Ti 1 7 dd z d p 7 P i Shut off a Arm Spring 2 P d NN CONST Spring Screw Shut off en Switch SPDT pF SPDT SS 4 di Screw Water Fill Switch SPDT Insulator Valve Switch Plate Fill Tube INSTALLATION PARTS 76 LINE 0 amp 8 POWER 8 NEUTRAL e ICE MAKER ea r 2 BLK lt BRN EB gt THERMAL m CUT OUT p a B M ee a e m JJ x RED 2 HOLD TT SWITCH u 1 P 4 THERMOSTAT O ui Q E cl CLP T Kp lt LLI 1 lt zj Cy SWITCH 6 GRN YEL p box LT BLU xz a P 2 1 MOLD MOUNTING WATER FILL PLATE SWITCH Seem MOUNTING PLATE mE HOUSING foo RED 77 77777770777 E NO NC Q SHUT OFF SWITCH Ice Maker Wiring Diagrams Enlarged view
83. e a bad Thermostat or a shorted coil on the water valve Timing Cam amp Coupler Three separate cams are combined in one molded Delrin part 1 Inner operates Shut Off Switch lever arm 2 Center Cam operates Hold Switch 3 Outer Cam operates Water Fill Switch One Cam end is attached to a large Timing Gear The other Cam end is coupled to the Ejector Timing Gear This large molded plastic gear is driven by the Motor and in turn rotates the Cam and Ejector A D shaped hole in the gear fits over the Timing Cam Hub Spacer tabs on the backside of the gear prevent the gear from binding on the mounting plate Motor A low wattage stall type Motor drives the Timing Gear This gear turns the Timing Cam and Ejector Blades approximately one revolution every three minutes 1 3 RPM Fill Trough The Fill Trough is molded nylon It supports the Inlet Tube and directs the water into the Mold It also forms a bearing for one end of the Ejector Blades Wiring A four prong plug connects the Ice Maker wiring to the cabinet wiring harness See Figure F3 The Ice Maker Assembly is wired across the line and will harvest in either the Refrigeration or Defrost Cycles A wiring diagram is located inside the front cover ofthe Ice Maker Ice Maker Connector Plug GRN YEL Connects to ground BLUE Connects to valve Connects to line Connects to neutral BLACK YELLOW Figure F3 INSTALLING W
84. e at a mounting screw If temperature is above 15 F freezer air temperature is not cold enough to switch Ice Maker Thermostat to closed position If Mold is below 9 F manually start Ice Maker by rotating Timer gear If motor fails to start check Motor for continuity If Motor starts Thermostat Shut Off Switch or Hold Switch is inoperative 5 Check Hold Switch first With Ejector blades in the starting position check terminals C and NC for continuity Replace switch if continuity readings are open Check Shut Off Switch linkage Then check terminals NO and C for continuity with Ice Maker Control Arm in lowest position Replace switch if continuity readings are open If Hold Switch and Shut Off Switch are operative then replace Thermostat Complaint Ice Maker Fails to Complete Cycle 1 With Ejector blades at 10 o clock position Hold Switch Plunger depressed Check terminals C and NO for continuity Replace switch if continuity readings are open 2 With Ejector blades at 12 o clock position check Shut Off Switch terminals C and NC for contin uity Replace Thermostat if continuity readings are open 3 With Ejector blades at 4 o clock position check Mold Heater and Ice Maker Thermostat for continuity Replace heater if continuity readings are open If heater shows continuity replace Thermostat 4 Check Motor operation with a test cord Replace Motor if it fails to start Complaint Ice Maker Fail to Sto
85. e cabinet except gasket contact areas All damaged areas should be repaired as outlined in steps 1 through 6 above The overall surface of the cabinet should be sanded thoroughly and cleaned as outlined in step 7 Thecabinet should be given two or more coats of touch up lacquer and polished as outlined in steps 8 and 9 SECTION C ELECTRICAL COMPONENTS ELECTRICAL GROUNDING All refrigerators are equipped with a power supply cord incorporating a three prong grounding plug and a ground wire which is attached to the refrigerator cabinet for protection against shock hazard Each electrical com ponent is either cabinet mounted or connected through a ground wire to the cabinet to complete the ground Certain components such as defrost timers may be double insulated and do not require a ground wire Ensurethe electrical wall receptacle is ofthe three prong type and is properly grounded in accordance with the National Electrical Code and or local codes COMPRESSOR ELECTRICAL COMPONENTS AND CIRCUITS The new series of very high efficiency compressor is equipped with all new electrical components consisting of a solid state PTC relay with a thermally operated overload protector and a run capacitor Solid State Relay The solid state relay has no moving parts It consists of a PTC resistor mounted in a plastic case with appropriate terminals PTC Positive Temperature Co efficient simply denotes a resistor which increases in resista
86. e cleaner with two parts water and apply with a clean wet rag Do not touch painted surface with this cleaner Stubborn or deep seated rust can be removed by applying cleaner with steel wool NOTE Prepare surface of bare metal with Sol Kleen regardless if rust is present 3 Before cleaner dries wipe surface dry with clean rag 4 Wipe over surface thoroughly second time with solution of 50 50 alcohol and water Wipe again with clean dry rags preferably new cheesecloth 5 Allow to dry for at least 10 to 15 minutes 6 Apply primer surfacer reduced by approximately equal parts of lacquer thinner to build bare metal area up to surrounding surface Any imperfections which primer has not filled should be knifed out with lacquer type putty glaze 7 lf no putty glaze is used allow to dry about minutes and if necessary sand out lightly with 360 wet or dry sandpaper If putty glaze is used allow about three hours before sanding with sandpaper and water Remove sanding residue thoroughly by wiping with clean rag soaked in naphtha Wiping surface with tack rag will remove dust and lint 8 Finish repair with two or more coats of lacquer reduce approximately one part of lacquer to 1 parts of thinner Finally apply mist coat of lacquer thinner to flow out surface 9 Patched area should be allowedto dry three or more hours before rubbing with compound or polish This procedure also applies to the complete refinishing of th
87. e order Screw E In Mounting 7 Plate 7 Uke 10 Plate Insulator Screw Screw Valve Switch Plate Cover j Y N water Fill Switch SPDT 64 To Replace Thermal Cut Out TCO l 2 Screw SPDT Remove front Cover Remove three screws that attach Mounting Plate to Support Housing Pull cable assembly free from support housing It will slide out easily Loosen screw securing clamp to TCO TCO should come free after tension from clamp is released Disconnect TCO from two wire nuts One end is connect to the cable assembly and the other end is connected to the motor and mold heater Replace with new TCO Reassemble in reverse order Wiring Harness Connector Plug Thermal Cutoff Assembly Ice Maker Control Arm Support a id 7 Maker WN A Am Spring Shut Off Switch SPDT Lever Arm Figure F6 To Replace Mold Heater 1 Remove front Cover 2 Remove Stripper Refer to Section To Replace Ice Stripper on page 63 3 Remove three screws that attach Mounting Plate to Support Housing 4 Remove three screws that attach Mold to Support Housing NOTE One of the three screws is attached to the two Green Yellow ground wires and another one is holding the Clamp in place The third screw is located in the lower right corner of the Support Housing 5 Unscrew wire nut holding three bla
88. e relay 8 Reverse this procedure to reassemble NOTE When replacing leads to the PTC relay ensure locking tabs snap into terminal Overload Protector The overload protector is completely thermally operated It will open from excessive heat or current Unlike prior overloads the internal bimetal is not self heating and is not a part of the electrical circuit The overload has a small built in coil heater that is in series with the compressor start and run windings See Figure C1 To Check Replace The Overload Protector 1 Disconnect electrical supply to refrigerator 2 Remove bale wire holding relay to compressor 3 Remove relay assembly from compressor 4 Use flat headed screwdriver to gently pry capacitor from relay assembly Use small flat bladed screwdriver to disconnect leads to relay assembly Note On some models you will have to remove bale wire and cover to gain access to relay and overload protector Use ohmmeter to check resistance between tab terminal and female pin terminal Overload protector should have less than 1 ohm of resistance at normal room temperature 7 If ohm readings are out of range install new Starter Overload Assembly NOTE The Overload Protector is built into the Starter Overload Assembly 8 Reverse this procedure to reassemble NOTE When replacing leads to the PTC Relay ensure the locking tabs snap back into the terminal Run Capacitor The run capacitor has perma
89. efrost thermostat is sensing the suction line temperature The contacts will open to shut off the defrost heater at 47 5 F The wire connected to the 12 position on the ADC receives a change in the signal from the defrost thermostat indicating the heater has cut off This change in signal change will start the 6 minute drip time before the compressor restarts The Food Compartment Door Switch has a wire connecting to 7 on the ADC Sensing is between the door switch and the light bulb This signal change is used to manually put the refrigerator into a defrost cycle and used to monitor door openings for the vacation mode The evaporator fan motor is connected to 11 on the ADC This will allow the fan to run when the food compartment control or the freezer control is calling for cooling The board also has a built in 7 20 minute delay on starting the evaporator fan motor after the Defrost thermostat has shut off the heater This is to allow the evaporator to drain and the temperature to drop slightly before starting the fan motor Output Voltage Output voltage to the defrost heater 2 and compressor 6 is equal to the input voltage from the freezer control 4 The PC board will withstand the following electrical loads for temperatures as high as 110 F Amps Duration of Load Reason for Load Locked Rotor 30 Minutes Indefinite The ADC will dissipate an average of no more than 0 4 watts The normal operating life
90. en both doors then remove toe grille 3 Close doors To Remove Refrigerator Door 1 Remove top hinge cover screw Remove cover 9 Cover Screw Cover Hinge Screws Top Hinge 2 Trace around hinge with soft lead pencil This will make it easier to realign doors when they are re placed 3 Remove top hinge 4 Lift refrigerator door off bottom hinge pin Set door aside 5 Remove bottom hinge if necessary 6 Reverse this procedure to reinstall refrigerator door To Remove Freezer Door 1 Disconnect water line that goes through lower hinge of freezer door at connection located under front of freezer grip water line firmly in one hand then with 3 8 wrench or fingers push in on gray collar to release water con nector 2 Remove top hinge screw on freezer door then remove Cover Disconnect wiring harness connector plug at top hinge place your thumbs on flat sides of each connector bending both sides back and forth then with firm grasp pull both pieces apart 4 Trace around hinge with soft lead pencil This will make it easier to realign doors when they are reinstalled 5 Remove top hinge allowing wiring harness to pull through hinge 6 Liftfreezer door off bottom hinge pin Lay door down flat to avoid kinking water line 7 Remove bottom hinge if necessary 8 Reverse this procedure to reinstall freezer door Door
91. er light This light will tell you when to replace the 6 Filter RESET Press and Hold five seconds to water filter reset light This light will tell you when to replace the water filter 7 LOCK Press to disable dispenser Child Lock 1 2 3 4 Figure 4 Figure 2 98 Three Selection Dispenser See Figure 5 I Cube Press to get cubed ice 2 Crush Press to get crushed ice 3 Light Press to turn on light in dispenser Ice and Water Only The last model will not have any selections you will get water or ice cubes depending which actuator you push your glass against See Figure 6 No Selections Figure 6 All models with a touch selection on the front will have a electronic control behind the front panel of the dispenser GAININGACCESS Two gain access to the control area you will need to pull the drip tray out first See Figure 7 To remove drip tray pull straight out Figure 7 With the drip tray removed remove the 3 screws at the bot tom ofthe front panel See Figure 8 Remove screws Figure 8 Lift up on the front panel there are tabs on the top of the panel that slide into holes in the door panel See Figure 9 Holes in outer door panel Figure 9 99 Swing panel out to side being careful not to pull the wires models with electronic control to gain access to the con out of the disconnect plug or the board itself trol snap the light socket loose and remove th
92. er in place be disconnected before rail assembly will comefree 16 Grab heater from bottom and pull free of the 4 Loosen the 2 screws holding ice maker to right side evaporator It s very snug so you ll need to use a of compartment just enough liftice makerfree The little force multiconnector must be disconnected before ice 17 Replace with new defrost heater maker will come free from compartment 18 Reassemble in reverse order 5 Remove two rail assembly supports two screws each one Remove fourscrews from evaporator cover Figure C8 Remove five screws on evaporator air duct cover Disconnect two leads to defrost heater NOTE This is a good time to test the heater Check resistance of defrost heater using a multimeter Resis tance should be very close to 30 ohms Replace defrost heater if resistance readings are out of range d Defrost Heater Evaporator Bracket 15 ELECTRICAL MECHANICAL CONTROL SYSTEM The Freezerand Refrigerator controls are located in the same housing mounted in the food compartment along with the light Damper and Automatic Defrost Control ADC See Figure 1 1 Food Compartment Damper Control 2 Cold Control Food Compartment 3 Cold Control Freezer Compartment 4 ADC II Control Figure 1 Toremove the Control Housing Assembly remove the three screws across the front control box and the two screws
93. esent the heater is open If the heater is not operating and there is no voltage between 12 and 10 the limit switch is open Toopen the damper door the ADC will get 115 VAC 10 NOTE Some models are not equipped with a Run capacitor from the food compartment cold control on number 9 terminal The ADC will then supply 115 VAC 10 to the number 3 contact starting the damper motor and opening the damper If the food compartment control contacts are closed you should have 115 VAC 10 between 9 and 10 If not check the control and wiring to the control If voltage is present between 9 and 10 you should have 115 10 between 3 and 10 supplying voltage to the damper motor switches and damper motor opening the damper door If no voltage is present replace the ADC If voltage is present check for voltage at damper switches If voltage is present and the motor will run replace the damper Toclose the damper door the ADC will use 115 VAC 10 from the food compartment cold control on number 9 terminal The ADC will then supply 115 VAC 10 to the number 8 contact starting the damper motor and closing the damper If the food compartment control contacts are open you should nothave 115 10 between 9 and 10 If voltage is present checkthe control and wiring to the control If no voltage is present between 9 and 10 you should have 115 VAC 10 between 8 and 10 supplying voltage to the damper motor switches and da
94. et 3 Measure resistance again This time reading should be 0 Contacts have closed 4 If you get resistance readings that differ from this procedure replace defrost thermostat Contacts are probably burnt To Remove The Defrost Thermostat 1 Disconnect refrigerator from electrical supply 2 Remove freezer section bottom shelves and baskets 3 Remove ice container and rail assembly The multiconnector at the back of the rail assembly must be disconnected before rail assembly will come free 4 Loosen the 2 screws holding ice maker to right side of compartment just enough liftice maker free The multiconnector must be disconnected before ice Evaporator Cove maker will come free from compartment 5 Remove tworail assembly supports two screws on each one 6 Remove four screws from evaporator cover Figure C7 7 Remove five screws on evaporator air duct cover 8 Cutthe two leads coming from the thermostat close to the base You must leave enough wire coming from the connector to allow for splicing the new thermostat in 9 Remove faulty thermostat NOTE The Defrost Thermostat Replacement Kit comes with a new thermostat 2 solderless connectors and two pieces of heat shrink to allow for splicing the new thermostat to the connector plug Defrost 10 Crimp the two solderless connectors to the two Thermostat leads on the new thermostat 11 Slip the two pieces of heat shrink onto the two leads coming from
95. et front exterior 43 The perimeter hot tube is not replaceable In the unlikely event of aleak in the hot tube a kitis available to bypass the hot tube in the sealed system A electrical heater wire must be installed within the tubing Refer tothe appropriate parts list of the model being serviced for the correct kit part number REFRIGERANT CYCLE The refrigerant cycle is a continuous cycle that occurs whenever the compressor is in operation Liquid refrigerant is evaporated in the evaporator by the heat that enters the cabinet through the insulated walls and by the heat from product load and door openings The refrigerant vapor is then drawn from the evaporator through the suction line to the compressor Compres sion raises the pressure and temperature of the vapor in the compressor and the vapor is then forced through the discharge valve into the discharge line and into the condenser Air passing over the condenser surface removes heat from the high pressure vapor which then condenses to a liquid The liquid refrigerant then flows from the condenser to the evaporator through the small diameter liquid line capillary tube Before it enters the evaporator the liquid refrigerant is sub cooled in the heat exchanger by the low temperature suction vapor in the suction line LOW OR HIGH SIDE LEAK OR UNDERCHARGE A loss of refrigerant can result in any of the following Excessive or continuous compressor operation Above norma
96. etting Lower Limit 33 F 1 C Each key press Temperature UP or DOWN displays temperature setting Actual temperature will be displayed after 10 sec of no key press and during normal operation Air Filter Control Not on all Models Pressing the Air Filter key activates the Fresh Food Filter and turns the Air Filter LED tricolor on Press Filter key again to deactivate and turn the Air Filter LED tricolor off When activated the Air Filter Fan Motor is on until the customer turns off the motor and Air Filter LED Air Filter Fan Motor run time is monitored during activa tion as to determine and display Air Filter Status via LED color Green 0 to 3600 minutes run time Amber 3600 to 4344 minutes run time Red 4344 minutes run time 32 Air Filter Status is reset by pressing and holding Air Filter key for 5 seconds Fast Freeze Fast Ice Mode Fast Freeze Freezer Temperature Set Pointis adjusted to 6 F when this option is selected from the IWD Ice and Water Dispenser Set Point will return to the previous setting after the mode terminates in 14 hours Fast Ice Freezer Temperature Set Pointis adjusted to 6 F when this option is selected from the IWD Set Point will return to the previous setting when the mode terminates in 12 hours Over Temperature Shut Off Compressor operation is terminated at ambient tem peratures over 85 C 185 F Compressor operation continues at 65 C 149
97. eventthe stopping of the motor in a 1 2 open position as a result of a power outage as the damper is opening or closing When both switches have reached the NC position the damper will be all the way open and the motor will stop The damper will remain open and the fan motor will continue to run aslong as the food compartment control calls for cooling Once the food compartment control is satisfied the contacts in the cold control will open This will break the signal to the ADC and start the damper motor running again closing the damper and shutting off the freezer fan motor As the damper motor closes the damper the switches onthe damper will change from the NC to the NO position oneatatime When both switches have reached the NO position the damper will be all the way closed and the motor will stop CONTROL HOUSING WIRING 12 BLUE WITH BLACK TRACER DEFROST THERMOSTAT 10 LIGHT BLUE NEUTRAL PINK DAMPER CLOSED O RED COMPRESSOR ORANGE FREEZER COLD CONTROL 2 BROWN DEFROST HEATER 1 BLACK LINE 1 HOT 3 PURPLE WITH WHITE TRACER DAMPER 5 NUMBER 5 IS OPEN 9 WHITE WITH VIOLET TRACER FOOD COMPARTMENT COLD CONTROL RED WITH WHITE TRACER EVAPORATOR FAN N REFRIGERATOR DAMPER MOTOR L1 CONTROL FRONT SWITCH PUR WHITE N DAMPER NC EVAP FAN MOTOR OPEN PNK DAMPER CLOSED TO DEFROST HEATER TO DEFROST A D C ADAPTIVE THERMOSTAT DEFROST CONTROL TO COM
98. ew DIAG AI UT OT 26 Controls Exploded View Diagram Rear Filter 2 onora a SUP RED DD chm ta EROS es ame q aus eue aqu cm SM EE DUREE 27 Controls Exploded View Diagram Front Filter i us socucse utin io eitis 28 zeige niebe ci ND T UU UU 29 Bree A 30 Alas and eges E E E E 31 SOW OOM oC INOS 31 Change Between Fahrenheit and 31 Advance Into Defrost Cycle tran 31 32 Wiring Diagram Schematic 34 Winng Diagrami IGT OM lI 35 Wiring Diagram Dispenser and Relay x scncancteniceiveanensietdespeameincondsieondncadentducognaddyawiitadnincesbuetepstdieneeanedsaredounaous 36 Service Diagnostics Mode Genesis Electronic 37 System Exploded View Ein sii tu Een eto ues 39 Service Mode Display ROUNE usse idee abu ERR 40 SECTION D AIR CIRCULATION Principles of Automatic Defrost ODBFAHOLD Dp ond ss MEE 41 EE E TE eee
99. ew at Rear of Front Filter Side Screws Figure 2 29 The 2 housings will separate at the left back of the front housing by sliding the rear housing to the right until the buttons line up with the larger hole in the slots See Figure 3 Figure 3 Electronic Control The Control is mounted on the left as shown in Figure 4 and it controls the cycling of the compressor condenser fan motor damper motor and evaporator fan motor as well as the defrost cycle The door alarms are also part of this control See figure 4 The freezer and food compartmentthermistor plug into the back of the control at the top and the main electrical connector is plugged in at the bottom left corner of the control To remove the control from the housing disconnect the two thermistors from the top of the control and disconnect the lower wiring harness Push the front of the control box forward to clear the display windows and slide the control straight up and out of the housing Reinstall in reverse order Thermistor Freezer Control with Plastic Tube Food Compartment Thermistor Genesis Electronic Control Figure 4 ELECTRONIC CONTROL SYSTEM FOR GENESIS CONTROL REFRIGERATORS Freezer Temp A DESCRIPTION Damper Assembly Motorized door 115 VAC 10 located between the freezer section and the fresh food section in the back of left side of control box of the refrigerator This control system uses the same damper as the e
100. ezer compartment control call for cooling on ELECTRICAL MECHANICAL CON TROL models On ELECTRONIC CONTROL the ther mistors sense the temperature ofthe compartment and send the information to the electronic control If the temperature in the food compartment is too warm the control will open the damper door and startthe evapora tor fan Itthe freezer is too warm the control will start the compressor as wellas the condenser and evaporator fan motors During the defrost period the compressor and circulating fan do not operate The ADC Adaptive De frost Control opens the electrical circuit to the fan motor compressor on Electrical Mechanical Control mod els The Electronic Control opens the electrical circuit to the fan motor and compressor on Electronic Control models 41 ELECTRICAL MECHANICAL CONTROL AIR FLOW Automatic Damper Control Behind control box FREEZER REFRIGERATOR CONTROL CONTROL ICE MAKER OUTLET MEAT AIR KEEPER RETURN DUCT VENTS Air Flow Behind Cover An Air Flow In Cabinet RETURN DUCT Figure D1 ELECTRONIC CONTROL AIR FLOW Automatic Damper Control Behind control box FREEZER REFRIGERATOR CONTROL CONTROL x P lt ICE MAKER OUTLET MEAT AIR KEEPER RETURN DUCT VENTS Air Flow Behind Cover Air Flow In Cabinet RETURN ir Flo
101. f Water F Toachieve the required 29 9 inch 500 micron vacuum a properly maintained two stage vacuum pump in good condition is required A two stage pump can reach a deeper vacuum than a single stage because the exhaust from the first pumping stage is discharged into the second pumping stage This meansthe second stage begins pumping at a lower pressure so a lower ultimate vacuum can be achieved See 2 Stage Vacuum Pump Figure E3 55 2 Stage Vacuum Pump Figure E3 VACUUM PUMP MAINTENANCE Itis absolutely essential to maintain your vacuum pump according to the manufacturer s instructions including required oil changes at the recommended intervals Vacuum pump oil should always be changed after evacuating a contaminated system Vacuum pump performance should be checked periodically with a micron gauge Vacuum pump suppliers may or may not recommend changing the vacuum pump oil to the same type that s in the system being evacuated Some manufacturers may recommend a vacuum pump that s dedicated to R 134a systems Robinair has stated that their current and discontinued vacuum pump models using mineral oil currently specified for use in their vacuum pumps can be used to evacuate R 134a Ester oil systems Robinair also states that it is acceptable to alternate between evacuating R 12 mineral oil and R 134a Ester oil systems without adversely effecting the vacuum pump s performance For other brands of vacuum pump
102. gure 3 point 12 Place cap tube in new evaporator and weld in place 13 Place suction line in new evaporator and weld in place PIP n Now make your weld on the suction line Make your weld on the cap tube first Cut the cap tube at this point ji ue a wy ne A FIGURE2 11 FIGURE 4 6 Removedraintrough and evaporator from inside the freezer 7 Clean end of suction line and cap tube Straighten line and slightly bendtoward frontof cabinetto aid in installing shield 8 Cutasmall X inheatshield then slide cap tube and suction line through hole Pack heat shield in back corner of liner See Figure 3 Note You may need to use a small pair of vise grips on the suction line to help hold the heat shield in place Removethe heat shield and reinstall the evapora tor clamp 31 44 93 2 NE USISIILILJDISSSST Pd bh 47 14 With a sharp knife cut along a seam on the heat shield from center hole to edge of shield Slide shield from between liner drain trough and suction line assembly 15 Push evaporator back in place and reinstall plastic clamp at top See Figure 4 16 Slide fan and bracket assembly in place and connect defrost heater Mount limit switch on evaporator Plug wiring harness into connector on liner 17 Replace Drier Filter Pump down and recharge system 18 Allow product to run and m
103. h closed C to NO Hold Switch closed C to NC Water Fill Switch open 0f 0n Thermal Cul 001 Switch BLACK 3 LT BLUE Hold LT BLUE nm Water Valve A5 CEC V VY Y Y MOLD HEATER 85 Walls Woler Fill Switch Ice Maker Electric 2 NEUTRAL Ice Maker connected to electricity Mold temperature below 15 F Motor starting to rotate Power on heater Thermostat closed Control Arm in the down position ON OFF switch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill Switch open Off On Thermal Cul 001 Switch BLACK 3 LT BLUE Hold LT BLUE A Shut Off Waler Valve A5 ea V MV Y Y MOLD HEATER 85 Walls Woler Fill Switch Ice Maker Electric 3 85 Section F Ice Maker 0f 0n On Thermal Cul Qul Swilch But 9 C 3 BLACK LT BLUE Ice Maker Electric 4 0f 0n On Thermal 1 01 Switch BLACK BLACK e 3 LT BLUE Ice Maker Electric 5 Ice Maker connected to electricity Mold temperature below 15 F Motor rotating Power on heater Thermostat closed Control Arm swinging up ON OFF switch in the ON position Shut Off Switch closed C to NC Hold Switch closed C to NO Water Fill Switch open LT BLUE Hold Swilch Off Switch WOLD HEATER 85 Wells Woler Fill Swilch Ice
104. h turns in nylon bearings atthe front and rear Each blade sweeps an ice section out of the Mold The drive end ofthe Ice Ejector is D shaped Food Grade Silicone grease is used to lubricate the bearing surfaces Water Valve Assembly The Water Valves are solenoid operated and when energized releases water from the water tank in the food compartment into the Ice Mold The amount of water released is directly proportional to the length of time the Water Valve Switch is energized A flow washer inside the Water Valve maintains a constant rate of water flow over a supply line pressing ranging from 20 to 100 psig It will not compensate for pressures below 20 psig or greater than 100 psig A No 80 mesh screen placed ahead of the flow washer filters out foreign materials The solenoid coil draws 10 to 115 watts of power The coil is wired in series with the Mold Heater across the supply voltage Thermostat The Thermostat is a single pole single throw SPST bimetallic disk type thermal switch It automatically starts the Harvest Cycle when the ice is frozen The Thermostat closes ata temperature of 18 F 6 Wired in series with the Mold Heater the Thermostat acts as a safety device against overheating in the event of mechanical failure A thermal mastic bond is provided where the Thermostat is mounted against the Mold A gasket prevents water from leaking into the support housing Sensing Arm amp Linkage The Sensing
105. he drawers inside the refrigerator Pay particular attention tothe information regarding hand trucking leveling and door alignment MODEL AND SERIAL NUMBER Model and Serial Numbers are found on the Serial Plate located on the ceiling of the refrigerator compartment just behind the compartment light Or on the right side at the top See Figure A1 AIR CIRCULATION Proper air circulation must be maintained for efficient refrigerator operation Refer to the Owner s Guide for recommended clearances Install the refrigerator out of direct sunlight and away from the range dishwasher or other heat sources NOTE Do not install the refrigerator where the temperature will drop below 55 F 13 C or rise above 110 F 43 C because the compressor will not be able to maintain proper temperatures Allow an extra 3 8 on the top and sides and 1 from the back for ease of installation proper air circulation and plumbing and electrical connections Ifthe hinge side of the unit is placed against a wall allow a 72 minimum between hinges and wall to permit proper door swing NOTE Do not block the toe grille on the lower front of the refrigerator Sufficient air circulation is essential for proper operation of the refrigerator ELECTRICAL INFORMATION The refrigerator must be plugged into its own 115 Volt 60 Hz AC only electrical outlet The circuit should be protected by a 15or20 Amp circuit breakerortime delay type fuse
106. he Water Valve is solenoid operated and when energized releases water from the supply line into the Ice Mold The amount of water released is directly proportional to the length of time the Water Valve Switch is energized A flow washer inside the Water Valve maintains a constant rate of water flow over a supply line pressing ranging from 15 to 100 psig It will not compensate for pressures below 15 psig or greater than 100 psig ANo 80 mesh screen placed ahead of the flow washer filters out foreign materials The solenoid coil draws 10 to 115 watts of power The coil is wired in series with the Mold Heater across the supply voltage 60 Thermostat The Thermostat is a single pole single throw SPST bimetallic disk type thermal switch It automatically starts the Harvest Cycle when the ice is frozen The Thermostat closes ata temperature of 18 F 6 Wired in series with the Mold Heater the Thermostat acts as a safety device against overheating in the event of mechanical failure A thermal mastic bond is provided where the Thermostat is mounted against the Mold A gasket prevents water from leaking into the support housing Sensing Arm amp Linkage The Sensing Arm is cam driven and operates a switch that controls the quantity of ice produced Inthe Harvest Cycle the arm is raised and lowered during each of the two revolutions of the timing cam If the Sensing Arm comes to rest on top of ice in the storage compartment
107. heck with the manufacturer of your vacuum pump for refrigerant and oil compatibility issues CAUTION If you use a vacuum pump with mineral oil to evacuate an R 134a system it is ABSOLUTELY ESSENTIAL to have a shut off valve between the pump and your manifold gauge set as shown on page 53 Figure E2 The hand valve must be closed during all times when the vacuum pump is not operating This will prevent the migra tion of mineral oil vapor into the R134a Ester oil system If the vacuum pump should stop during evacuation for any reason the hand pump shut off valve must be closed immedi ately CAUTION Insure that your refrigeration hoses are specified for use with R 134a refrigerant Research has shown that compounds in stan dard refrigeration hoses may enter sealed systems and ultimately restrict the cap tube in an R 134a system Equipment Needed for Evacuation amp Recharging e Heated charging cylinder e Standard 3 port manifold gauge set 4 charging hoses Tee fitting with valve core stem removed Robinair No 40396 Hand shut off valve Robinair No 40380 e Two stage vacuum pump Process tube adapter kit Robinair No 12458 e Tubing cutter e Pinch off tool capable of making leak proof seal Complete brazing torch set e Small3 corner file Grit cloth or Scotch Brite e 45 silver solder and flux Installing Evacuation and Recharging Equipment 1 Disconnect refrigerator from electrical supply 2 If compressor wa
108. id or light VOLTAGE TESTING The power to the control board from the power board can be tested by checking between GND and V IN test points on the power board To do the rest of the test you will use the GND terminal and the terminal marked for the component you are testing your readings will be 5 VDC or 2 until you make a selection At the time you press the actuator your voltage will drop to less than 1 VDC on the pin listed to test the component but the voltage will remain around 5 VDC on the remaining pins See Figure 38 Bend a piece of wire around hook on face and push into center hook slot to hold front face while testing voltage Figure 37 TO REMOVE CONTROL BOARD To remove the control board from the front remove the screws and lift straight up Slide the board out from between the cover and the push buttons When you install the new board make certain you line the pads on the cover with the switches on the board See Figure 39 Reinstall front frame on freezer door making sure you plug wire harness from power board into control board before you slide the front frame into slots at top 105 Test Points on Power Board wire connector sas Power to control GND amp V IN 8 9 to 12 2 VDC Light GND amp LIGHT less than 1 VDC Water GND amp WATER less than 1 VDC Auger Motor GND amp AUGER less than 1 VDC Cube Ice Solenoid GND amp CUBE less than 1 VDC Figure 38 106
109. id Guide 09 ic 1 Disconnect refrigerator from electrical supply 0 79 2 Slide Ice Container forward and off of Rail Assembly Remove two 2 screws mounting the rail assembly to the Evaporator Cover Lift up on Rail Assembly and pull forward freeing it from mounting brackets 4 Disconnect Molex connector located at back of Rail Assembly and pull Rail Assembly free 5 Disconnect yellow and light blue wires con nected to lamp socket located behind Motor Motor Cover 3 Figure G3 Cover 6 Press in two tabs on bottom of lamp socket Socket base and push through mounting hole See Figure G4 7 Replace lamp socket in reverse order Light Bulb Ice Auger amp Crusher Assembly Motor C remove Ice Auger amp Crusher Assembly 1 Remove four 4 screws holding Ice Container Front to Ice Container 2 Remove two 2 screws on underside of Ice Container holding Crusher Housing to container 3 Remove screw holding Control Rod to container located on underside of container 4 Remove three 3 Hex head screws holding Crusher Housing to Front Plate See Figure G5 5 Remove E ring and washer on front of Crusher Housing See Figure G5 6 Slide Control Rod free of Crusher Housing Crusher Gate Crusher Blade 1 Blade 2 Crusher Blade 3 S Crusher Housing S 4 Fixed bf CAI Auger Nut e Q To replace Crusher Blades CAUTION The Crusher Blades are very sharp
110. ing the Freezer Tempera ture DOWN Colder key 3 times within 5 seconds d HOLD E PrecisionTemp CONTROL ma 3 TIMES The freezer display will show 1 The fresh food display will be blank Each press of the freezer temperature up Warmer or the freezer temperature DOWN Colder key will step you through the service menu tests 1 through 7 Each press of the fresh food temperature UP Warmer or fresh food temperature DOWN Colder key will step you through variables of each test Note If you are in test 1 and press the freezer up key you will go to test 7 If you are in at the start of test 1 and press the food compartment up key it will beep at you Freezer Temp Fresh Food Temp Deactivation Press and hold Freezer Temperature UP key for 5 seconds the control will beep and service mode is deactivated Mode automatically deactivates after 5 Minutes of no key entry Service Test Menu Test 1 Firmware Version Variable 1 Display main software version Test 2 Evaporator Fan Test Variable 1 Motor runs continuously Freezer Temp Fresh Food Temp lt Precisioniemp CONTROL Test 3 Note products with two position read out in the freezer and food compartment the one or two digit temperature will appear in the food display to give you the test temperature Freezer Temp Fresh Food Temp PrecisionTemp CONTROL Test Numbe
111. ion Shut Off Switch closed C to NC Hold Switch closed C to NO Water Fill Switch open Qf 0n On Thermal Cut Out Switch BLACK Q l Q Q 3 LT BLUE Hold LT BLUE Sub Off NO Thermostat witch BLUE WHIT gt MOLD HEATER 85 Walls Waler Fill Switch Waler Valve EAT ATA V V V V Ice Maker Electric 10 NEUTRAL Ice Maker connected to electricity Mold temperature above15 F Motor is rotating Mold heater is off Thermostat open Control Arm is swinging down ON OFF switch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill Switch open Off On On Thermal Cut Out LN gt BLACK Q C J LT BLUE Hold LL BLUE Swilch Shut Off NO Thermostat Switch BLUE WHIT O VNANV WMV Water Valve MOLD HEATER 85 Walls Water Fill Swilch Ice Maker Electric 11 89 Section F Ice Maker NEUTRAL Ice Maker connected to electricity Mold temperature above15 F Motor is rotating Mold heater in series with Water Valve Thermostat open Control Arm is swinging down ON OFF switch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill Switch closed 0f 0n tOn Thermal Cut Out BLACK Switch guu A O LT BLUE at Shut Off Thermostat Snitch e nd MOLD HEATER is 85 Walls W
112. is looking for the change from L1 when the switch is closed and Neutral through the light bulb when the switch is open Tocheck output power from the board See Figure 14 1 there is voltage coming in from the freezer or food compartment control there should be 115 VAC 10 between 10 and 11 to operate the evaporator fan motor unless itis in defrost or within the 7 minute delay after defrost If no voltage is present replace the board If there is voltage coming in from the freezer control there should be 115 VAC 10 at either 2 to 10 if the relay is set in defrost or 6 to 10 if the relay is set for the compressor to run If there is voltage between 6 and 10 the compressor and condenser fan should be running If they are not check the voltage at the compressor If voltage is present follow procedure to check compressor If voltage is not present check wiring between ADC and compressor NOTE To change relay from compressor run to defrost open door and push light switch in and out 5 times within 6 seconds The relay contact should open from Number close to number 2 shutting off the compressor and supplying power to the defrost heater If there is 115 VAC 10 between 2 and 10 there should be power to the defrost heater If the limit switch is closed the heater should be on Ifthe heater is not operating check the voltage between 12 and 10 If the heater is not working but line voltage is pr
113. l E cy H Cr H H Lu Lu ig 23 ux Pu und ca Ce ea Ll Sd 51 S6 M NO NO NC A Ling E ini F E on FAST FREEZE FAST ICE CUBE CRUSH LIGHT RESET LOCKOUT ELECTRO MECHANICAL DISPENSE RED BLK 120 VAC WATER DISP SWITCH ICE DISP SUITES COMM COMM NO NC NO o NC PURPLE AUGER TAN WATER VALVE P T C STARTER WITH RUN CAPACITOR START 6 3 gt 60909 De 27 ue 2 ud RUN 5 _ 1 0 600603 De L OVERLOAD MOTOR STARTER a 5 E CAPACITOR 15 ONLY USED WITH SOME P T C MODELS 36 SERVICE DIAGNOSTICS MODE GENESIS ELECTRONIC CONTROL With a series of key presses a service technician will be able to view data via the display and exercise loads to help troubleshoot the product Following 1s a list of capabilities View Firmware Version What version of software Indicate an open or shorted sensor condition Test Manually test sensors Run evaporator fan at high and low speeds Operate damper to full open full close and mid positions Turn defrost heater on Turn compressor on To enter the test mode press and hold the Freezer Tempera ture UP Warmer key while press
114. l freezer and or food compartment temperature Apartially frosted evaporator depending on amount of refrigerant loss Low suction pressure vacuum 5 Low wattage The condenser will be warm to cool depending on the amount of refrigerant lost When refrigerant is added the frost pattern will improve the suction and discharge pressures will rise the condenser will become hot and the wattage will in crease In the case of a low side refrigerant leak resulting in complete loss of refrigerant the compressor will run but will not refrigerate Suction pressure will drop below atmospheric pressure and air and moisture will be drawn into the system saturating the filter drier lf there is reason to believe the system has operated for a considerable length of time with no refrigerant and the leak occurred in the evaporator excessive amounts of moisture may have entered the system In such cases the compressor may need to be replaced to prevent repetitive service If a slight undercharge of refrigerant is indicated and no leak can be found after a thorough leak test the charge can be corrected without changing the compressor If a high side leak is located and some refrigerant remains in the system it is not necessary to change the compressor TESTINGFORREFRIGERANT LEAKS Ifthe system is diagnosed as short of refrigerant and the system has not been recently opened there is probably a leak in the system Adding ref
115. l not allow the ice maker to complete the revolution Wiring A four prong plug connects the Ice Maker wiring to the cabinet wiring harness See Figure F3 The Ice Maker Assembly is wired across the line and will harvest in either the Refrigeration or Defrost Cycles A wiring diagram is located inside the front cover ofthe Ice Maker Ice Maker Connector Plug GRN YEL YELLOW Connects to ground Connects to valve Connects to line Connects to neutral BLACK LT BLUE Figure F3 19 INSTALLING WATER SUPPLY LINE TO ICE MAKER Supply line installation must comply with all applicable plumbing codes Refer to the Ice Maker Installation Instructions in appendix A The tubing and any other plumbing materials required should be obtained locally The Ice Maker should be connected to a frequently used cold water line to ensure a fresh water supply NOTE A vertical cold water line should be selected for the water supply If a vertical line is not available a horizontal line may be used providing the connection is on the side ortop of the pipe but not on the bottom Scale and foreign material in the pipe could cause stoppage of water flow if the connection is on the bottom Be sure to leak test all connections after the water supply has been turned on TEST CYCLING ICE MAKER See ce Maker Testing Procedures on pages 84 93 It may be necessary on occasion to test cycle an Ice Maker to
116. ld heat exchanger with Permagum See Figure 6 15 Replace Drier Filter 16 Evacuate and recharge system 17 Bend remaining tubing to fit into machine compartment opening being careful notto set up any excess noise from line vibration See Figure 7 18 Run product to make sure refrigerant is circulating 19 Reinstallevaporatorand machine compartment cover PERIMETER HOT TUBE REPAIR KIT Effective July 1 1992 Section 608 ofthe Clean Air Act prohibits Individuals from knowingly venting ozone depleting compounds used as refrigerants into the atmosphere while maintaining servicing repairing or disposing of refrigerant equipment A hot tube repair kit is used to bypass a leaking Perimeter Hot Tube Yoder Loop The Perimeter Hot Tube must be bypassed in the sealed refrigeration system and alow wattage heater wire installed inside the tube This heater will prevent condensation from forming on the exterior front edge of the cabinet 2 53 4 49 Hot Tube Heater Kit Contants 1 Plastic Sleeve 1 Heater Wire 1 Harness Adapter 2 Wire Connectors 1 Copper Bypass Tube 1 Drier Filter 3 Clamps 3 Screws BYPASSING PERIMETER HOT TUBE STEP 1 1 Disconnectservice cord from power supply Recoverrefrigerant from system Remove filter drier Using tubing cutter cut and de burr tubing from perimeter hot tube at points shown in figure below Cut at weld between condenser and hot tube Cut at filter
117. lectromechani cal control system covered in pervious section Freezer Temperature Control Electronic thermostat regulating the temperature of the frozen food section ANegative Temperature Coefficient Thermistor monitors Freezer Compartment Temperature Loads controlled are the compressor condenser fan and evaporator fan motor Fresh Food Temperature Control Electronic thermostat regulating the temperature of the fresh food section A Negative Temperature Coefficient Thermistor monitors Fresh Food Compartment Tem perature Loads controlled are the damper motor and evaporatorfan motor Defrost Heater A 450 watt heating element 115VAC locate in the evaporator assembly to melt frost during the defrost cycle Thedefrostheateris connected to the NO contact of a relay Defrost Heater Operation is detected and internally monitored by the microprocessor Defrost Termination Thermostat DTT Bimetal disc thermostat attached via a clamp to the evaporator tubing During the defrost cycle the device is a closed circuit between the defrost heater and Neutral The DTT is designed to open at a predetermined tem perature ending the defrost cycle Compressor Motorized pump 115 that creates the high and low pressures required for heat exchange The Compressor is controlled by a relay Evaporator Fan Motorized Fan 115 VAC that circulates freezer and fresh food section air The evaporator fan motor speed is controlled via
118. ll start in one minute Vacation Mode When the defrost interval has reached 12 hours or less and the door has not been opened in the last 24 hours the ADC places the product in vacation mode Once in vacation mode the defrost heater will be turned on after 96 hours Should the door not be opened but the heater runs for longer than 16 minutes then the ADC control restarts in 6 hours Once the ADC control unit has entered vacation mode ifthe food dooris opened and the compressor run time since the last defrost has been at least 5 hours a defrost is initiated after one hour of compressor run time since the initial door opening The maximum defrost cycle must be terminated after 30 minutes After each defrost termination there must be 6 minute delay before compressor start except no time delay when the defrost heater has been on for 30 minutes System Diagnostics An electrical connection between the light switch and refrigerator light bulb is coupled to the ADC system board providing a manual method of initiating defrostand back to compressor The actuation code will be a minimum of 5 depressions of the light switch within a 6 second time period If a defrost is initiated manually and the termination thermostatis closed the heater will be actuated until the termination thermostat opens A 6 minute drip time follows before actuating the compressor and setting the next defrost time When terminating the defrost manually and th
119. loot e a NON RIBBED ONE P L I BLACK YEL RED LT BLU Jae i YEL BLK g lg ODES TO BE ui LIGHT SWITCH E 39 LARIZED AS S S REFRIG 215 6 OWN alls YELLOW EU RED DRAIN ICE WATER T ROUGH nee MAKER DISPENSER DEFROST Dy VALVE THERM B TWO LT BLU 2 BLACK Les i ue Ig mou gc UN Um 1 LL cr BROWN BLU WHT LT BLUE i BLUE i aA TO gc FRZR FRZ m aM uo BE ou M YELLOW WATER D FAN GRN YEL B E LIGHT 5 5 SES Ts 1 5 EIE uu RED WHT YEL RED B ou lt lt SS ste ILT BLU AETERNUS 6 YEL RED 7 9 1 3 241622001 35 GENESIS WIRING DIAGRAM T T RONIC DISPENSER BLACK DISPENSER BLU MHT CUBE LIGHT WHITE RED BLK 120 VAC PURPLE AUGER BROWN WATER DISP DC POWER SUPPLY LT BLUE NEUTRAL ICE DISP SWITCH AND RELAYS Pang SWITCH AN WATER VALVE NO NC NO NC ORG WHT FAST FREEZE ICE SLATE ORANGE z Lu Lu os Lu Lu M C a Mme A ne LE Ex Lu oO ce ul en zs E o cr Lu 2 E p Li y zx m LO a Lu 114 tii LLI Ce Lu wu gt Cr C 1 a Lu be ig o
120. mper motor closing the damper door If no voltage is present replace the ADC If voltage is present check for voltage at damper switches If voltage is present and the motor will run replace the damper 22 LIN EUTRAL T 5 gt ZER CONTROL pe TR ESH FOOD JS tO 1 JOOR PER LIGHT REFRIG LIGHT SWITCH 23
121. n dedicated and properly identified recovery bags and tanks It will be necessary to check with the manufacturer of your recovery equipment to determine R 134a compatibility Some recovery equipment manufacturers have changeover instructions for switching between refrigerant types Protect yourself and your equipment by following all manufacturer guidelines Also ensure that your refrigeration hoses are specified for use with R 134a refrigerant Research has shown that compounds in standard refrigeration hoses may enter sealed systems and ultimately restrict the cap tube in an R 134a system R 134a REFRIGERATION SYSTEMS The sealed refrigeration system will consist ofthe same basic components being utilized in the R 12 systems There is a 10 to 15 discharge pressure increase using R 134a with a 5 to 10 decrease in suction pressure when compared to the same product with an R 12 system operating at 90 F 32 C ambient temperature conditions Lower suction pressures result from the lower density of R 134a refrigerant which effects refrigerantflow rate R 134a systems commonly operate in a 1 2 vacuum on the suction side Products using R 134a refrigerant will generally have a longer capillary tube to maintain a similar flow rate and some models will have a larger condenser to reduce the discharge pressures and lower start up sound transmission MISCIBILITY OF R 134a AND ESTER OIL A special synthetic oil known as Ester oil is
122. nce as its temperature is increased The self heating PTC resistor used in the solid state relay has the unique characteristic of changing from low to very high resistance very abruptly thus serving as an on off switch See Figure C1 The solid state relay plugs directly onto the compressor start and run terminals Relay terminals 1 2 and 5 are connected within the relay as are terminals 3 and 6 A run capacitor is connected to relay terminals 2 and 3 so it is connected in parallel with the PTC resistor One side of the 120 VAC power is connected to relay terminal 1 The other side of line is connected to the overload protector See figure C1 P T C Relay With Run Capacitor fe Q O c 2 x P T C Relay Overload Comp Motor Capacitor Is Only Used With Some P T C Models Figure C1 11 To Check Replace Relay 1 Disconnect electrical supply to refrigerator 2 Remove bale wire holding relay to compressor 3 Remove relay assembly from compressor See Figure C2 Figure C2 4 Use small flat bladed screwdriver to disconnect leads to relay assembly 5 Use flat headed screwdriver to gently pry capacitor from relay assembly 6 Use ohmmeter to check resistance between terminals 5 and 6 Resistance should be 3 to 12 ohms at normal room temperature Shorted relay will read 0 ohms Open relay will read very high or infinite resistance 7 If ohm readings are out of range replac
123. necting ice amp water switches Wires to light socket Connector Door Harness Relays K4 K3 K2 K1 Transformer Figure 29 103 Door wiring harness will connect to the main harness at the plug under the top hinge cover Figure 30 The labeling is as follows 1 NEUTRAL one side of line to power the board 2 CUBE connected to solenoid for ice cubes 3 AUGER connected to auger motor 4 FICE fast ice fast freeze feature 5 WATER connected to water valve yellow coil 6 120 V AC other side of line to power the board See Figure 31 Connector on Control Board NEUTRAL FICE WATER AUGER 21 120 Figure 31 The relays mounted on board are numbered See Figure 32 Controls the Light in the Dispenser K2 Controls the Water to the Door K3 Controls the Solenoid for Cube Ice K4 Controls the Auger motor Diodes RELAYS K4 K3 K2 K1 Transformer Figure 32 The power supply onto the board is 120 VAC The transformer is mounted on the board and is used to reduce the operating voltage See Figure 32 There are 4 diodes mounted on the board to convert the AC current to DC current Touch Board See Figure 33 The operating voltage for the control board is 8 to 13 V DC Control Board Figure 33 The control board is mounted on the front face and can be serviced by removing the front face and removing the 4 screws
124. nently attached terminals which are connected to relay terminals 2 and 3 NOTE Some models are not equipped with a Run capaci tor To Check Replace The Run Capacitor 1 2 Disconnect electrical supply to refrigerator Remove bale wire holding relay to compressor Use small flat bladed screwdriver to disconnect leads to relay assembly Use flat bladed screwdriver and gently pry capacitor from relay assembly Discharge capacitor by shorting across terminals with 500K 1 watt resistor for one minute Use ohmmeter set on the Ohms times 1000 scale if available to check resistance across capacitor wire terminals C2 IN The needle should jump towards zero ohms and quickly move back to infinity If the needle does not move the capacitor is open If the needle reads a constant value at or near zero ohms the capacitor is shorted out If the needle jumps toward zero and then moves back to constant high resistance not infinity the capacitor has a high resistance leak 6 If ohm readings are out of range replace capacitor 7 Reverse procedures to reassemble Compressor Start Circuit When the compressor circuit is first energized the solid state relay haslow resistance 3 12 ohms and both the run and start windings are energized to start the compressor The run capacitor is being bypassed by the relay and ithas a minor function during compressor starting See Figure C3 12
125. nto the ice maker and coming out the door at the same time If the diode fails in the open position the coil on your secondary valve will open but the coil on the primary valve will not As a result you will not get water to the ice maker or dispenser Both diodes can be checked with an ohmmeter to see if they are opened or shorted The coils on all water valves can be checked with an ohmmeter to see if the coils are opened or shorted If the coil checks bad replace the coil If the coils check good and water pressure is between 20 120 psi and the valve will not allow water to flow through replace valve It is not necessary to replace the whole valve assembly if one coil is bad The two valves can be separated by inserting a screwdriver at point A in Figure H1 PureSource Water Filters Next Generation models can have either a Front Filter see Figure H2 or a Rear Filter see figure H3 The water filter must be changed at a minimum of twice a year But under certain water conditions such as large concentrations of calcium alkali or other particulate matter in the water a filter may require changing more frequently A good way to judge whether the filter needs to be replaced is when the water flow to the dispenser starts slowing down and there has been no change to the water pressure to the product Operating water pressure should be a minimum of 20 120 psi PureSource2 Front Filter Retainer Figure H2 Filter Release Rod
126. nues to flow through the compressor motor windings which become in effect electric resistance heaters The heat produced begins to vaporize the excess refrigerant liquid causing a rapid increase in system pressure If the compressor protective devices fail the pressure within the system may rise to extremes far in excess of the design limits Under these conditions the weld seam around the compressor shell can separate with explosive force spewing oil and refrigerant vapor which could ignite To eliminate this exceedingly rare but potential hazard never add refrigerant to a sealed system If refrigerant is required evacuate the existing charge and recharge with the correct measured amount of the refrigerant specified for the system 42 SOLDERING WARNING WEAR APPROVED SAFETY GLASSES WHEN WORKING WITH OR ON ANY PRESSURIZED SYSTEM OR EQUIPMENT HAVE AN APPROVED DRY TYPE FIRE EXTINGUISHER HANDY WHEN USING ANY TYPE OF GAS OPERATED TORCH All joints to be soldered must have proper fit Clearance between tubes to be soldered should be from 001 to 006 It is not practical to actually measure this however you do not want a dry fit or loose fit Tubing joints should overlap about the distance oftheir diameter exceptfor restrictor tubes which should be inserted 1 25 Clean all joint areas with fine steel wool or preferably an abrasive cloth such as grit cloth No 23 or Scotch Brite Apply athin film of liquid flux re
127. ocess tube at this time 12 Solder all connections according to soldering procedure outlined on page 43 13 Remove original filter drier CAUTION DO NOT unbraze old filter drier from system This will vaporize and drive moisture from desiccant back into system The old filter drier should be cutoutof system 14 Install new filter drier at condenser outlet 15 Evacuate and charge system using recommended procedure described under Evacuating and Re charging Screws Motor Bracket uci 27 7 JBr cket Grommets 7 oa 7 Wiring Harness Motor Bracket Shoulder Screw a Filter Drier ni Compressor 7 Capacitor 27 2 g Clamp Compressor Mounting PTC Starter Grommets a Roller Mounting Pins 16 Reconnect compressor terminal leads in accordance with refrigerator wiring diagram 17 Reassemble unit EVAPORATOR REPLACEMENT CAUTION Always use the TORCH GUARD heat shield part number 5304418872 behind evaporator before attempting to solder The excessive heat from soldering will warp the plastic liner The evaporator is located in the lower section of the freezer and is secured to the drain pan by a bracket at the top Styrofoam blocks are located on each side directly across from each other to ensure proper air flow through the evaporator The heat exchanger on this style of refrigera
128. of power Recover refrigerant by using an EPA approved recovery system Using a cornered file score a groove around capillary tube as close to old filter drier as possible Break capillary tube along score mark from filter drier Cut condenser outlet tube at filter drier Discard filter drier Thoroughly clean condenser outlet tube and capillary tube Place inlet connection of filter drier over condenser tube approximately 74 and solder Insert capillary tube input end into filter drier outlet Do notallow tube to bottom against screen Solder carefully so that solder does not plug capillary tube Install process tube adaptor to filter drier Evacuate and charge system using the recom mended procedure described under Evacuating and Recharging on page 51 10 Reassemble unit EVACUATING AND RECHARGING CAUTION Checkthe serial plate forthe correct refrigerant type It is extremely important to verify the type of refrigerant in the system before starting any sealed system repairs CAUTION With the possible exception of the vacuum pump all service equipment that comes in contact with R 134a during evacuation and recharging must be dedicated Accordingly R 134a will require a dedicated charging cylinder manifold gauge set process tube adaptors and hoses Any residual mineral oil on other tools tubing cutter etc must be thoroughly cleaned off before using on R 134a Ester oil systems It will be necessary to c
129. oler Fill Switch M V NN Water Valve Ice Maker Electric 12 NEUTRAL Ice Maker connected to electricity Mold temperature 15 Motor is rotating Mold heater off Thermostat open Control Arm is swinging down ON OFF switch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill Switch open Off On 0n Thermal Cut Out IL 9 C BLACK Q Q 3 LT BLUE Hold um Switch Shul Off Thermostat wild BLUE WILLT 94 MOLD HEATER 85 Walls Woler Fill Swilch YUU V Water Valve J jt jt jJ Ice Maker Electric 13 90 Section F Ice Maker NEUTRAL Ice Maker connected to electricity Mold temperature above15 F Motor not rotating Mold heater off Thermostat open Control Arm in down position ON OFF switch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NC Water Fill Switch open 0f 0n On Thermal Cul Qul Switch BLACK l Q Q 3 LT BLUE ii Shut Off NO Thermostal BLUE WHIT p DOES Waler Valve eo M M NN MOLD HEATER 85 Walls Woler Fill Switch Ice Maker Electric 14 Operating Cycle Illustrations Mechanical Ice Storage Bin Ice Storage Bin Freezer Cycle Start of Harvest Cycle 1 Mold is filled with wa
130. on Coil is Installed Over Terminals and Plug Top of Terminal on Left Side of Plug Installed Correctly Figure H9 111 Water lce E Selector Switch N on Dispenser Dispenser Fill Solenoid Actuator Single Coil Valve Switch Water Fill Solenoid Dual Coil Valve Ice Maker Fill Switch Ice Maker Fill Solenoid Dual Coil Valve VOLTAGE READINGS AT GREEN COIL OF SECONDARY VALVE When Ice Maker is Filling Voltage at Outlet Voltage at Coil 120 VAC 100 10 VAC Normal 100 VAC 85 10 VAC Normal at 105 VAC Will require use of 50 watt coil 100 120 VAC 20 76 VAC Bad connection Fill Switch or Heater in Ice Maker VOLTAGE READING AT YELLOW COIL OF SECONDARY VALVE When Filling A Glass With Water 120 VAC 119 10 VAC Normal 100 VAC 99 10 VAC Normal 100 120 VAC 0 90 VAC Bad connection or bad Fill Switch VOLTAGE READING AT COIL OF PRIMARY VALVE When Ice Maker is filling 120 VAC 56 10 VAC Normal 100 VAC 48 10 VAC Normal 100 120 VAC 10 43 VAC Bad connection Fill Switch or Heater in Ice Maker 100 120 VAC 0 VAC Open Diode if current is normal at secondary coil NOTE You must remember that with the current flowing to the Primary Valve Coil through the Diode you are getting 30 cycle instead of 60 cycle current at the coil of the Primary Valve Because of this your volt meter will only read about 1 2 the voltage that is going to the coil The change in the cycle of current does not effect the
131. on is having difficulty breathing administer oxygen If breathing has stopped give artifi cial respiration SPILLS OR LEAKS If a large release of vapor occurs such as from a large spill or leak the vapors may concentrate near the floor or low spots and displace the oxygen available for breathing causing suffocation Evacuate everyone until the area has been ventilated Use blowers or fans to circulate the air at floor level DO NOT reenter the affected area unless you are equipped with a self contained breathing apparatus or unless an area monitor indicates that the concentration of HFC 134a vapors in the area is below the AEL Always use Self contained breathing apparatus or an airline mask when entering tanks or other areas where vapors might exist Use the buddy system and alifeline Refer to the Material Safety Data Sheet MSDS for HFC 134a for more information HFC 134a vapors have aslightly sweet odor that can be difficult to detect Therefore frequent leak checks and the installation of permanent area monitors may be necessary in enclosed spaces Refer to ASHRAE Standards 15 and 34 for refrigeration machinery rooms To ensure safety when working with HFC 134a in enclosed areas 1 Route relief and purge vent piping if present outdoors away from air intakes 2 Make certain area is well ventilated using auxiliary ventilation if necessary to move vapors 3 Make sure area is clear of vapors prior to beginning w
132. or leads 5 Remove two Motor mounting screws 6 Replace Motor in reverse order To Replace WaterFill Switch 1 Remove Ice Maker from Freezer Remove Ice Maker from Freezer 4 2 Remove front Cover 3 Remove three screws that attach Mounting Plate to Support Housing Disconnect two Water Fill Switch wire leads Remove two switch mounting screws Remove switch Replace switch in reverse order ensuring that switch insulator is in place 7 Replace with new TCO 8 Reassembleinreverse order NOOA To Replace Mold Heater 1 Remove Ice Maker from Freezer 8 Check Water Fill Cycle and adjust as required 2 Remove front Cover To Replace Hold Switch 3 Remove Stripper Refer to Section To Replace Ice Stripper on page 81 1 Remove Ice Maker from Freezer 4 Remove three screws that attach Mounting Plate to 2 Removefront Cover Support Housing 3 Remove three screws that attach Mounting Plateto Remove three screws that attach Mold to Support Support Housing Housing 4 Disconnect six Hold Switch wire leads NOTE One of the three screws is attached to the 5 Remove two Hold Switch mounting screws two Green Yellow ground wires and another one is 6 Remove Hold Switch holding the Clamp in place The third screw is 7 Replaceinreverse order located in the lower right corner of the Support ToReplace Ice Maker Control Arm Shut OFF Switch Housing 1 Remove Ice Maker from Freezer Un
133. ork 4 Install air monitoring equipment to detect leaks SKIN AND EYE CONTACT Atroom temperature HFC 134a vapors have little orno effect on the skin or eyes However in liquid form HFC 134a can freeze skin or eyes on contact causing frostbite Following contact soak the exposed area in lukewarm water not cold or hot If medical treatment cannot begin immediately apply a light coat of a nonmedicated ointment such as petroleum jelly If the exposed area is ina location where the presence of the ointment would be awkward such as on the eye apply a light bandage In all cases of frostbite seek medical attention as soon as possible Always wear protective clothing when there is a risk of exposure to liquid HFC 134a Where splashing is possible always wear eye protection and a face shield 58 COMBUSTIBILITY OF HFC 134a HFC 134ais nonflammable at ambienttemperatures and atmospheric pressure However tests have shown HFC 134a to be combustible at pressures as low as 5 5 psig 139 3 kPa absolute at 177 C 350 F when mixed with air at concentrations generally greater than 60 volume air Atlower temperatures higher pressures are required for combustibility HCFC 22 is also combustible at pressures above atmospheric in the presence of high air concentrations Test results and calculations have shown At ambient temperature all concentrations of HFC 134a in air are nonflammable at pressures below 15 psig 205 kPa absolut
134. p at End of Cycle With the Ejector blades in the starting position check the Hold Switch terminals C and NO for continuity Replace the switch if the continuity readings are indicat ing a closed circuit Complaint Ice Maker Continues to Eject When Container is Full 1 Check for loose linkage to the Ice Maker Control arm Shut Off Switch Switch should open when arm is in raised position Adjust if required 2 Check Shut Off Switch terminals C and NO for continuity with Ice Maker Control Arm raised Replace switch if continuity readings are indicating a closed circuit Complaint Ice Maker Produces Undersized Ice Pieces 1 Ensure that Ice Maker mold is level 2 Check for partial restriction in supply line or Water Valve Strainer 3 Ensure that the water pressure to Water Valve is sufficient 20 psi min 120 psi max 4 Ensure that the Water Valve Switch is adjusted for proper water fill 90 105 cc s 5 Check thermal bond between Thermostat and Mold If necessary rebond with thermal mastic sealer 65 ICE MAKER TESTING PROCEDURES Operating Cycle Illustrations Manual Cycle Operating Cycle To manually cycle Ice Maker The operation of the Ice Maker water refilling and 4 Remove Cover from Ice Maker head controlled ice storage require proper functioning and 2 Inserta Phillips into screw on timing gear timing of all components 3 Turn gear clockwise until Motor starts to run Consider the following
135. partment houses the compressor condenser and fan motor All cabinet seams have special sealing materials applied as vapor barriers prior to installation of the inner liner and foam insulation COMPRESSOR MOUNTING All basic Construction Counter Depth models Side by Sides will have a dynamic condenser and a unitary drain pan assembly that is mounted to the bottom of the refrigerator cabinet just behind the toe grille See Figure B1 Drain Pan Figure B1 he compressor is mounted on rubber grommets with metal inserts then bolted to the baseusingthree Hex head 14 28 shoulder screws See Figure B2 Shoulder Screws INSULATION AND INNER LINER Thecabinet wrapper and compartment liner are bonded together with a core of Urethane foam insulation to from a slim three ply wall of single unit construction Figure B2 The one piece freezer and the one piece food inner liners are vacuum formed of tough corrosion proof ABS HIPS plastic material The liners are not removable CABINET DOORS AND GASKETS The exterior door panels are made from one piece of heavy gauge deep drawn cold rolled steel A wide flange at the periphery is formed integral with the exterior door panel Next generation model doors are filled with rigid Urethane foam insulation prior to assembly of the inner panel and door gasket The door inner panels are vacuum formed from high strength plastic
136. pen Neutral Thermal Cut out Mold Heater Shut Off Switch Hold Switch i VU VM I Ice Maker Electric 2 Water Fill Water Valve Switch Ice Maker connected to electricity Mold temperature below 15 F Motor starting to rotate Power on Heater Thermostat closed Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill switch open Control Arm in the down position Neutral Thermal Cut out Mold Heater Shut off O Switch Hold Switch Water Fill Water Valve Switch 67 Ice Maker connected to electricity Mold temperature below 15 F Motor rotating Power on Heater e Thermostat closed Shut Off Switch closed C to NC Neutral Hold Switch closed C to NO Water Fill Switch open Control Arm swinging up Thermal Cut out Mold Heater Shut Off Switch 000001 Switch WY I Ice Maker Electric 4 Water Fill Water Valve Switch Ice Maker connected to electricity Mold temperature below 15 F Motor stalls as finger hits ice cubes Power on Heater Thermostat closed Shut Off Switch closed C to NC Hold Switch closed C to NC Water Fill Switch open Control Arm swinging down Neutral Thermal Cut out Mold Heater Shut Off Switch 000001 Switch WY I Ice Maker Electric 5 Water Fill Water Valve Switch 68 Ice Maker connected to electricity Mold tempera
137. pense water and ice cubes the dis penser will come apart the same way as models with a control board The difference is there 1s no light in the housing and the wiring to the actuator switches is connected directly the plug in the door wiring harness See Figure 24 Connector from door harness to actuator switches Figure 24 The original heater for the ice chute and housing are foamed in place with the one piece door It is connected to the door wiring See Figure 25 harness by a plug coming out of the inner door panel with 2 black wires connected to it See Figure 25 Ifthe heater fails it will be necessary to install an external heater on the housing chute opening in place of the internal heater The replacement heater will connect to the same plug as the original heater See Figure 26 Check across the two black wires to test the internal chute heater Plug for chute heater Figure 25 102 Connect wire adaptor to heater and plug into door harness t h S 4 ry F LM Ji Attach service heater in this location Figure 26 The ice door will be replaced with a new door See Figure 27 Ice Door Figure 27 The ice door can be installed in the field with the internal chute heater to control moisture on the outside of the door This may appear in certain areas with high humidity FAST FREEZE FAST ICE The Fast Freeze Acceler Freeze
138. r On products with one position read out in the freezer and food compartment the first number of the temperature will be constant for 1 second the second number if needed of the temperature will flash twice in one second It will alternate back and forth to give you the test temperature Temperature Freezer Temp Fresh Food Temp v PrecisionTemp v Test Number Temperature Variable 4 Freezer sensor circuit condition Flash 1 Freezer sensor OK Flash 2 Freezer sensor open Flash 3 Freezer sensor shorted Variable 5 Disables buffer to allow technician to place his finger on the freezer sensor and observe an immediate temperature rise Test 4 Note On products with two position read out in the freezer and food compartment the one or two digit temperature will appear in the food display to give you the test temperature 37 Freezer Temp Fresh Food Temp v Test Number Temperature On products with one position read out in the freezer and food compartment the first number of the temperature will be constant for 1 second the second number of the temperature will flash twice in one second It will alternate back and forth to give you the test temperature Freezer Temp Fresh Food Temp PrecisionTemp CONTROL Test Number Temperature Variable 4 Fresh Food sensor circuit condition will be displayed in Fresh Food Window Flash 1 Fresh Food sensor OK Flash 2 Fresh Food
139. r This term usually applies to procedures implemented at the field job site or at a local service shop Reclaim To reprocess refrigerant to new product specifications by means which may include distillation Will require chemical analysis of the refrigerant to determine that appropriate product specifications are met This term usually implies the use of processes or procedures available only at a reprocessing or manufacturing facility SAFETY WARNINGS Compressor Testing Whenever testing a compressor extreme caution should be used to prevent damaging the terminals A compressor with a damaged terminal or a grounded winding can expel a terminal from its insulated housing when the compressor is energized If this happens a mixture of refrigerant and oil will be released that could be ignited by an external heat source open flame heater etc Also if there is airin the system when this happens aspark atthe compressor shell could ignite the refrigerant and oil mixture Charging Sealed Systems Overcharging a refrigeration system with refrigerant can be dangerous Ifthe overcharge is sufficient to immerse the major parts of the motor and compressor in liquid refrigerant a situation has been created which when followed by a sequence of circumstances can lead to the compressor shell seam separating A hydraulic block occurs preventing the compressor from starting This condition is known as locked rotor Electric current conti
140. r harness located in back of fan motor Remove fan motor and fan blade After refrigerantis completely recovered disconnect inlet and discharge lines from condenser Remove white condenser retainer clip from fan bracket and condenser Lift front of condenser and the two rubber groments out of retainer in base plate Remove old condenser out the back of cabinet Install replacement condenser Remove original filter drier CAUTION DO NOT unbraze the old filter drier from the system This will vaporize and drive moisture from the desiccant back into the system The old filter drier should be cut out of the system Install new filter drier at condenser outlet Evacuate and charge the system using recom mended procedure described under Evacuating and Recharging page 51 Reassemble unit FILTER DRIERINSTALLATION Any time the sealed system is opened and the refriger ant charge is removed the liquid line filter drier must be replaced and the system thoroughly evacuated before recharging CAUTION DO NOT unbraze the old filter drier from the system This will vaporize and drive moisture from the desiccant back into the system The old filter drier should be cut out of the system CAUTION Use only a 15 gram XH9 liquid line filter drier part number 5303305677 when servicing refrigerator and freezer systems This filter drier is compatible with either R 12 or R 134a refrigerant Disconnect unit from source
141. r to give the refrigerant a chance to disperse throughout the system Otherwise the compressor could be damaged by attempting to pump excessive quantities of liquid Preparing The Charging Cylinder 52 Make certain that hand shut off valve vacuum pump is closed Closehigh side manifold gauge valve Setcharging cylinder scale to pressure indicated on cylinder pressure gauge Observe refrigerant level in sight glass Subtract amount to be charged into system and note shut off point Opencharging cylinder valve slowly and allow proper charge to enter system 6 As soon as refrigerant in sight glass has gone down to predetermined level close charging cylinder valve WARNING DISCONNECT THE CHARGING CYLINDER HEATER AT THIS TIME TO PREVENT THE CYLINDER PRESSURE FROM EXCEEDING ITS MAXIMUM LIMITS 7 Allow system to sit for five minutes 8 Turnonrefrigerator compressor Run compressor for a few minutes and monitor system pressures 9 When satisfied that the unit is operating correctly clamp the high side process tube with the pinch off tool while the unit is still running 10 Slowly open the high side manifold gauge valve to allow the compressor to remove any refrigerant trapped in the high side hose and the process fitting TEE FITTING EVAPORATOR i m i HOT TUBE FILTER DRIER CONDENSER PROCESS TUBE ADAPTERS Figure E2 o9
142. reen coil of the secondary valve if the problem is with the ice maker or the yellow coil of the secondary valve if the problem is with the water dispenser If you are using a good meter you will read between 0 and 10 volts with a open diode on the primary valve but you will have over 90 at the secondary In checking the voltage on a ice maker fill you must keep in mind that the coils of the water valves are in series with the heater on the ice maker The resistance of the heater will cause a drop in voltage Example if you have 110 to 120 at the outlet with the product running between 92 and 101 will be present at the green coil of the secondary valve The production valves use 20 watt coils on the two sides of the secondary valve to open the valve The Brown coil on the primary valve is a 15 W coil On a Ice Maker Fill if you are getting 10 volts or less at the primary valve but you are getting 85 to 105 atthe secondary you have a bad diode If you are getting 48 or 70 volts at the primary valve and 90 or higher at the secondary this is normal With the current flowing to the primary coil through the diode you are getting 1 2 wave signal instead of 60 cycle current at the coil of the primary valve Because of this your meter will only read about 1 2 the voltage that is present at the coil If the voltage is low at both the primary and secondary you have a bad connection or a bad fill switch in the ice maker If the ice maker is operating but
143. remains closed To adjust the Water Fill Switch first determine how much water is needed The adjusting screw is calibrated so that one complete revolution changes the water fill about 18 cubic centimeters Turning the screw clockwise decreases the fill while turning counter clockwise increases the fill EXAMPLE An Ice Makeristest cycled and the water fill sample is 93 cubic centimeters Subtracting 80 cc from 93 the adjustment needed is 13 cc Since one turn ofthe adjusting screw changes the fill 18 cc 34 of a turn clockwise would reduce the fill about 13 cc the desired amount This example is for manual models only PARTSREPLACEMENT Disconnect electrical supply to refrigerator If the To Replace Front Cover See Figure F4 1 Remove ice for freezer 2 Ensurethat Ice Makeris atroomtemperature before removing Cover 3 Place straight blade of screwdriver in slot at bottom of Mold Support and pry Cover loose NOTE Ensure that the retaining tabs inside the Cover are located on the top and bottom when installing the Cover 80 5 Snap Coverin place To Replace Fill Trough and Bearings 1 Remove Ice Maker from Freezer 2 Push Trough retaining tab back away from Mold 2 3 Rotate Trough counterclockwise until it is clear Pull from back to detach from Mold and Ejector Blades 4 Replace in reverse order To Replace Ice Stripper 1 Remove Ice Maker from Freezer 2 3 Remove retaining screw a
144. rigerant without first locating and repairing the leak or replacing the com ponent will not permanently correct the difficulty The leak must be found Sufficient refrigerant may have escaped to makeitimpossibletoleaktest effectively In such cases add a 2 line piercing valve to the compressor process tube Add sufficient refrigerant vapor to increase the pressure to 40 to 50 Ib per sq in Check the low side for leaks Run the compressor 2 or 3 minutes and check the high side for leaks Recover refrigerant using an EPA approved recovery system NOTE The line piercing valve clamp on type should be used for test purposes only It must be removed from system after ithas served its purpose CHECKING FOR INTERNAL HOT TUBE LEAKS Before checking for internal leaks check all accessible system components and joints for leaks If an internal hot tube leak is suspected it must be confirmed Use the following procedure 1 Recover refrigerant by using EPA approved recovery system 2 After system refrigerant is completely recovered disconnect drier from hot tube Pinch off and sol der end of hot tube closed 3 Cutline from condenser to hot tube and solder a Ya charging hose fitting to open end of hot tube or put compression fitting on tube 4 Connect pressure gauge and access valve to hot tube and pressurize to 250 psig using dry nitrogen or carbon dioxide WARNING NEVER PRESSURIZE WITH OXYGEN NEVER OPEN A HIGH PRESSUR
145. s check with the manufacturer for restrictions and guidelines when using with R 134a CAUTION If you use a vacuum pump with mineral oil to evacuate an R 134a system itis ABSOLUTELY ESSENTIAL to have a shut off valve between pump and your manifold gauge set as shown in Figure E4 The hand valve mustbe closed duringalltimes when vacuum pump is not operating This will prevent migration of mineral oil vapor into R134a Ester oil system If vacuum pump should stop during evacuation for any reason the hand pump shut off valve must be closed immediately TEE FITTING FILTER CONDENSER COMPOUND PROCESS TUBE ADAPTERS Evacuating and Recharging Connections REFRIGERANT LEAKS A system with R 134a and Ester oil will become saturated with moisture much faster than a system with R 12 and mineral oil The compressor in an R 134a system will have to be replaced if the product has hada low side leak R 134a refrigerant molecules are smaller than R 12 molecules This means that R 134a will pass more minor leaks and the rate of flow will be greater than for R 12 Therefore it is now more important than ever to follow good brazing practices Use a good grade of silver solder 45 silver solder is recommended LEAK DETECTION R 134a system leaks can be pinpointed by means ofan electronic leak detector or by bubble solution Electronicleak detectors for R 134a serviceare currently available from
146. s replaced install correct sized process tube adaptor on process tube If compressor was not replaced cut process tube with tubing cutter leaving as much tube as possible and install correct size process tube adaptor 3 Install correct sized process tube adaptor on high side process tube 4 Attachrefrigeration service gauge manifold to system in following order e Low side compound gauge hose to suction side process tube adaptor e High side pressure gauge hose to high side process tube adaptor e Center port manifold hose before hand shut off valve to charging cylinder e Center port manifold hose after hand shut off valve to vacuum pump Evacuating System WARNING R 134A SYSTEMS ARE PARTICULARLY SUSCEPTIBLE TO MOISTURE CONTAMINATION WHICH CAN ONLY BE PREVENTED BY EVACUATING THE SYSTEM FOR MINIMUM OF 30 MINUTES TO ATTAIN A MINIMUM 29 9 INCH 500 MICRON OR LOWER VACUUM achieve the required levels of evacuation a properly maintained two stage vacuum pump in good condition is required It is absolutely essential to maintain your vacuum pump according to the manufacturer s instructions including required oil changes at the recommended intervals Vacuum pumpoil should always be changed after evacuating a contaminated system Vacuum pump performance should be checked periodically with a micron gauge 1 Make certain that charging cylinder valve hand shut off valve and manifold gauge valves are closed
147. s within 6 seconds This will advance the processor out of defrost cycle by making the control work as if the defrost limit switch had opened You will still have the 6 minute drip time before the compressor starts and one additional minute before the evaporator fan will restart Or just let the refrigerator alone and it will go through a normal defrost cycle and start running after defrost limit switch has turned off the heater and the controller has allowed for a normal drip time Mode CO FO OPERATION Control system Two Position Read out for Freezer and Food Compartment Freezer Temperature UP key increments temperature setting one degree F or C each key press Setting Upper Limit 6 F 14 C One key press past 6 F Off All Loads Damper Closed Displays will show of Temperature DOWN key decrements temperature set ting one degree F or C each key press Setting Lower Limit 6 F 21 C Each key press Temperature UP or DOWN displays temperature setting Actual temperature will be dis played after 10 seconds of no key entries and during normal operation Displays are off when Fresh Food Door is closed Communications remain active Default 0 F 18 C Fresh Food Temperature UP key increments temperature setting one degree F or C each key press Setting Upper Limit 47 F 8 C Temperature DOWN key decrements temperature set ting one degree F or C each key press S
148. screw wire nut holding three black leads 2 Removefront Cover together and separate them 3 Removethree screwsthatattach Mounting Plate to NOTE One black lead is connected to the Mold Support Housing Heater Another is connected to the Thermostat and 4 Disconnect three Ice Maker Control Arm Shut Off the third lead goes to the Hold Switch Switch wire leads 5 Raiselce Maker Control Arm Lever 7 Disconnect remaining Mold Heater lead connected 6 Removetwo Maker Control Arm Shut Off Switch to brown Motor lead and black Thermal Cut Out mounting screws lead 7 Removeswitch 8 Separate Mold from Support Housing 8 Replace switch in reverse order NOTE careful not to destroy the thermostat To Replace Ice Maker Thermostat gasket located between the mold and support 1 Remove Ice Maker from Freezer housing 2 Removefront Cover 9 Remove hex head screw holding Ice Maker 3 Remove three screws that attach Mounting Plate to Leveling Bracket to Mold Support Housing 4 Loosentwo Thermostat retaining clip mounting NOTE The Mold is crimped in six places holding Serene the Mold Heater firmly in the Mold groove It may be 5 Disconnect two thermostat wire leads and remove ROREM n i pd s Ue remove the heater from the Mold groove denial Mas te se alate lain SUNGER 2 10 Use a flat bladed screwdriver to pry inoperative replacement thermostat to ensure a positive bond heater from
149. sensor open Flash 3 Fresh Food sensor shorted Variable 5 Disables buffer to allow technician to place his finger on the Fresh Food sensor and observe an immediate rise in temperature Test 5 Damper Motor is a 115 VAC motor Variable 1 Damper to full open Variable 2 Damper to mid position Variable 3 Damper to full closed Freezer Temp Fresh Food Temp lt gt Precisioniemp CONTROL The display will show the FULLOPEN following symbols to CLOSED indicate the door position Test 6 Defrost Variable 1 Will turn on defrost heater This will continue until servicer advances to another test or 5 minutes have passed with out a key entry NOTE If the defrost limit switch opens during the time the heater is on the letter d will be displayed Ifthe DLS is closed a straight line will be displayed Test 7 Compressor and condenser fan Variable 1 Run compressor and condenser fan motor The display will show the letter when the low voltage section of the board is supplying a signal to the relay on the board that completes the 115VAC to the compressor and condenser fan motor NOTE Diagram C on page 16 will show key com mands for service 38 Manual Defrost Activation Press and hold Freezer Temperature UP WARMER Key while pressing the fresh food temperature DOWN COLDER key 5 times within 6 seconds Deactivation Press and hold Freezer Temperature UP WARMER Key
150. sh all safety grounds prior to completion of service Failure to do so will create a hazard 6 Priorto returning the product to service ensure that e All electrical connections are correct and secure Allelectricalleads are properly dressed and secured away from sharp edges high temperature components and moving parts e Allnon insulated electrical terminals connectors heaters etc are adequately spaced away from all metal parts and panels e All safety grounds both internal and external are correctly and securely connected Allpanels are properly and securely reassembled ATTENTION This service manual is intended for use by persons having electrical and mechnical training and a level of knowledge of these subjects generally considered acceptable in the appliance repair trade Electrolux Home Products Inc cannot be responsible norassume any liability for injury or damage of any kind arising from the use of this manual 2004 Electrolux Home Products Inc TABLE OF CONTENTS SAFE SERVICING PRACTICES SECTION A INSTALLATION INSTRUCTIONS Weiss MM E m Model and Serial Number RERO ge ced ue E E O E EE O ESC iCal TEOMA OM EE E E
151. starts Thermostat Shut Off Switch or Hold Switch is inoperative 5 Check Hold Switch first With Ejector blades in the starting position check terminals C and NC for continuity Replace switch if continuity readings are open Check Shut Off Switch linkage Then check terminals NO and C for continuity with Ice Maker Control Arm in lowest position Replace switch if continuity readings are open If Hold Switch and Shut Off Switch are operative then replace Thermostat Complaint Ice Maker Fails to Complete Cycle 1 With Ejector blades at 10 o clock position Hold Switch Plunger depressed Check terminals C and NO for continuity Replace switch if continui ty readings are open 2 With Ejector blades at 12 o clock position check Shut Off Switch terminals C and NC for contin uity Replace Thermostat if continuity readings are open 3 With Ejector blades at 4 o clock position check Mold Heater and Ice Maker Thermostat for continu ity Replace heater if continuity readings are open If heater shows continuity replace Thermostat 4 Check Motor operation with a test cord Replace Motor if it fails to start Complaint Ice Maker Fail to Stop at End of Cycle With the Ejector blades in the starting position check the Hold Switch terminals C and NO for continuity Replace the switch if the continuity readings are indicating a closed circuit Complaint Ice Maker Continues to Eject When
152. sure there is no leak in seam or tubing Reinstall rubber plug 1 Disconnect electrical supply to refrigerator Remove compressor access panel Recoverrefrigerantby using EPA approved recovery system Remove condenserfan mounting screws Unplugfan motorharness located in back offan motor Remove fan motor and fan blade Remove leads from compressor motor terminals Remove mounting clips and washers Co N 45 Bracket Grommet Condenser Motor Motor Silencer Support 22 Fan Blade Ms 2 di 2 1 Figure E1 9 After refrigerant is completely recovered cut suc tion and discharge lines as close to compressor as possible Leave only enough tubing to pinch off and seal defective compressor Plug or tape any open system tubing to avoid entrance of moisture and air into system Remove inoperable compressor and transfer mounting parts to new compressor 10 Install new compressor in exact same manner as original compressor 11 Reform both suction and discharge lines to align with new compressor If they are too short use additional lengths of tubing Joints should overlap 0 5 to provide sufficient area for good solder joint Clean and mark area where tubing should be cut Cut tubing with tubing cutter Work as quickly as pos sible to avoid letting moisture and air into system NOTE If low side process tube is too short silver solder four inch piece of tubing onto pr
153. t 61 EN ss de SVEN CS NETTE TET me 61 Thermal eiii o 61 GAC NR TNT 61 M REUNIR 61 61 alls 61 idle MET TT 61 Installing Water Supply Line to Ice 62 Test Cycling lce Makel RTT Tm 62 Water Valve Switch Water 62 Pars Replacement 62 T cs cic 62 To Replace Fill 63 To Replace lce Stripper EO E Sextet PS 63 To Replace Motor 8 Switch Mounting 63 209 E ET 63 e 63 To Renace 63 sede 64 To Replace Ice Maker Control Arm Shut Off Switch
154. t back of mold Pull back on Ice Stripper to disengage it from front of Mold Support housing 4 Replace in reverse order To Replace Ejector Blades 1 Remove Ice Maker from Freezer 2 3 Remove front Cover Remove three screws holding Mounting Plate in place Carefully remove Mounting Plate disengaging end of Ice Maker Control Arm and Ejector Blades from Motor coupling noting relative position of Ice Maker Control Arm Spring Remove Fill Trough and bearing Turn blades to 12 O clock position Slide Ejector Blades back and up to remove Replaceinreverse order Lubricate bearing ends of Ejector with Silicone grease OND To Replace Motor and Switch Mounting Plate 1 Remove Ice Maker from Freezer 2 Remove front Cover 3 Remove three screws that attach Mounting Plate to Support Housing 4 Carefully remove Mounting Plate disengaging end of Sweep Arm and noting relative position of Sweep Arm Spring 5 Transfer Motor Switches Cam Gear and Water Fill Adjusting Spring and Arm to replacement Mounting Plate 6 Attach new Mounting Plate to Support Housing with three screws NOTE Ensure that the wiring harness is properly positioned and the Sweep Arm is in place 81 7 Check Water Fill Cycle and adjust as required 8 Replace front Cover To Replace Motor 1 2 Remove front Cover 3 Remove three screws that attach Mounting Plate to Support Housing Disconnect two Mot
155. tem and it must be recovered CAUTION Use extreme care when using Dry Nitrogen to flush systems Pressure in nitrogen cylinder could be as high as 2000 psi Nitrogen cylinder must be equipped with approved pressure regulator and pressure relief valve Ensure that your hoses have adequate ratings for pressure involved and that all of your equipmentis in good condition CAUTION The end of the flushing hose on this tank regulator must be equipped with a hand shut off valve Robinair No 40380 Close hand shut off valve and adjust nitrogen regulator to correct pressure before proceeding with flushing procedure 44 To Use Dry Nitrogen To Flush The System 1 Removecompressor andfilter drier Connect process coupling to outlet tube of condenser 2 Fasten cloth over other end of coil to prevent old oil from spraying over room 3 Connect hand shut off valve on flushing hose to process coupling 4 Slowly open hand shut off valve and allow nitrogen to flow through condenser until discharge is clear CAUTION DO NOT exceed 300 PSIG 5 Disconnect cap tube from evaporator Flush evaporator in Same manner as condenser CAUTION DO NOT exceed 150 PSIG 6 Flush cap tube This is only possible if you have proper service valve adaptor CAUTION DO NOT exceed 300 PSIG 7 Reassemblesystem To Use Refrigerant To Flush The System CAUTION Refrigerant used for flushing must be recovered into a recovery system Me
156. ter MUS ocM ee 2 Thermostat is open 2 Mold heater amp Motor is energized 3 All components are de energized 3 Ejector begins to turn 91 Section F Ice Maker Ejector T Ice Storage Bin Harvest Cycle Holding Switch in normally open position Heater remains energized Control Arm is rising Step 3 Ejector E Q gt X 2 Ice Storage Bin Harvest Cycle 1 Completing 1st revolution of Ejector 2 Water Fill Switch closes but heater remains on preventing water fill Step 5 92 Ejector ONV WE J PA 2 Water J Ice Storage Bin Harvest Cycle 1 Ejector reaches ice 2 Motor stalls until ice loosens 3 Heater remains energized Step 4 Ejector Ice 2 2 7 gt Ice Storage Bin Harvest Cycle End of 1st revolution Hold Switch opens Since Thermostat is still closed 2nd revolution of Ejector begins Step 6 Section F Ice Maker Ejector 5 Ice Storage Bin Ice Storage Bin End of Harvest Cycle Harvest Cycle During end of 2nd revolution Mold Heater resets Thermostat Mold Heater de energized If container is full Control Arm opens Shut Off Switch Hold Switch closes Mo
157. ter amount of refrigerant used for flushing with your charging cylinder DO NOT OVERFILL THESYSTEM 1 Disconnect the suction and discharge lines from the compressor and remove the filter drier Connect process coupling to outlet and inlet tube of condenser 2 Connect hose to outlet process coupling and charging cylinder Connect another hose to inlet coupling and recovery system 3 Open charging cylinder and allow refrigerant to flow through condenser until discharge into bag is clear NOTE To flush evaporator and heat exchanger you must remove evaporator from inside product to disconnect cap tube 4 Disconnect capillary tube from evaporator Flush evaporator in Same manner as condenser 5 Flush cap tube This is only possible if you have proper service valve adaptor 6 Reassemblesystem Installing a New Compressor NOTE Entirely new compressors have been developed for use with R 134a and Ester oil refrigeration systems Both compressor and electric motorhave been modified Old compressors intended for R 12 refrigerant must not be used for new systems charged with R 134a Replacement of compressor and installation of filter drier must be done in a continuous sequence so system is exposed to atmosphere no longer than necessary Allreplacementcompressors are shipped with rubber plugs in the suction discharge and process tubes and contain the correctoil charge and a holding charge of inert gas Compres sorsha
158. there is little or no current to the start windings The overload protector will open due to high locked rotor run winding current With a shorted relay or capacitor the compressor will start and the overload protector will open With an open or weak capacitor the compressor will start and run The compressor however will be operating at reduced efficiency of energy usage COMPRESSOR ELECTRICAL CHECK If the compressor will not run make a voltage check across powerlead terminals on the PTC Relay See Figure C4 The voltmeter should show line voltage ifthe thermostat knob is in normal operating position and not in the OFF position If this check does not show a live circuit the control thermostat and defrost timer wiring should be checked for loose and or broken connections A control thermostat check can be made by using a piece of wire as a temporary bridge across two thermo statterminals Ifthe compressor starts and runs with the bridge the control thermostat is at fault and should be replaced If the voltage check shows power supply at the PTC Relay terminals use a test cord to check the compres sor If the compressor does not start and run with the test cord check the line voltage to see if there is more than 10 variation from the rated voltage If voltage is correct and the compressor will not start and run replace the compressor If the compressor starts and runs with the test cord replace the PTC Relay
159. tor energizes Mold Heater remains energized Shut Off Arm raises and lowers Ice dumps into bin Step 9 Ejector 4 em 2 ion Water x 4 Ice Ice Storage Bin Ice Ice Storage Bin Fill Cycle End of Fill Cycle Hold Switch goes to normally closed position Water Fill Switch opens Freeze Cycle begins 1 Near completion of 2nd revolution of Ejector Water Fill Switch closes and water fills mold 93 Section F Ice Maker WIRING DIAGRAM SERVICE START FEATURE ON OFF SERVICE V V V V Waler Valve WATER FILL 4 SWITCH li BLACK E T AS ri VUE THERMOSTAT vO I a ov Mall l V AS T IT T YELLOWGREEN YELLOWGREEN SERVICE START FEATURE LINE 115 Volt 60 HZ NEUTRAL X 2 0f 0n On Thermal Cut Out Switch ACK E BROWN ll t i L7 i E LI BLUE e 5 RED Hold ue 9 Switch 5 E C Shut Off z KL Thermostat x pe RED e O pe lt MOLD HEATER z 9 zi LE x Waler Fill 5 Switch
160. tor is in the insulation between the food liner and the cabinet back You will not be able to remove the heat exchanger with the evaporator Because of this all line welds will be made inside the freezer The evaporator kit contains a heat shield to protect the liner from damage when brazing Evaporator Kit Contains 1 Heat Shield 1 Instruction Sheet 1 Evaporator 1 Drier Filter Disconnect refrigerator from electrical supply Remove all freezer section shelves and baskets Remove bottom evaporator cover Disconnect wiring harness at liner plug Remove defrost limiter and disconnect defrost heater See Figure 1 Dope 46 Cut a small hole in the middle of the shield Disconnect plug and remove limit switch FIGURE3 Slide fan and bracket out of liner Place shield over the heat exchanger Place new evaporator V in drain trough and FIGURE 1 a a slide in place over E heat shield 9 Cutsuction line in front of weld atevaporator Using 9 Removerivetinretainer attop of old evaporator Slide afile score and break the cap tube just in front of the evaporator outtop of drain trough weld See Figure 2 10 Transfer defrost heater from old evaporator to new evaporator then slide evaporator into top of drain trough To replace the 11 Slide evaporator and drain trough in place and push evaporator cut drain trough over heat shield This will help hold suction line at this shield in place See Fi
161. traight down position and you will feel the OFF position Start here Press cap tube with plastic shield in channel on diffuser Figure 10 When the control is off the damper should close and the fan should shut off if the compressor is not running To replace the Fresh Food Compartment Control re move screw and drop housing follow freezer control instructions Snap control out of housing then remove damper control and cap tube for control Connect wiring to new control as shown in Figure 11 Invensys White Black Figure 11 Place control metal wing in solid clip first then snap other side in place Route wires and cap tube behind boss See Figure 12 Route wires amp tube behind boss Ey VN 4 2 M a A EC Tw Place the air damper in the housing and reinstall housing in the fresh food compartment E i 18 Air Damper Control Theairdamperis used to control the fresh food compart ment temperature by controlling air flow into the food compartment from the freezer See Figure 13 Damper Control When the food compartment control calls for cooling the contacts in the control will close sending a signal to the ADC The ADC then will startthe damper motor running to open the damper See Figure 14 Asthe damper motor opens the damper the switches on the damper will change from NO normally open to the NC normally closed position one ata time to pr
162. ture below 15 F Ice breaks loose and Motor starts to rotate again Power on Heater Thermostat closed Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill Switch closed but shorted out by Thermostat Neutral Control Arm is down Thermal Cut out Mold Heater Shut Off Switch Hold Switch C Ice Maker Electric 6 Water Fill Water Valve Switch Ice Maker connected to electricity Mold temperature below 15 F Motor is rotating Power on Heater Thermostat closed Shut Off Switch closed C to NO Neutral Hold Switch closed C to NC Water Fill Switch open Control Arm is down Mold Heater Shut Off Switch Switch VWVWW I Water Fill Water Valve Switch 69 Ice Maker connected to electricity Mold temperature below 15 F Power on Heater Thermostat closed Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill Switch is open Control Arm is swinging up Neutral Thermal Cut out Mold Heater Shut Off Switch Hold Switch Water Fill Water Valve Switch Ice Maker connected to electricity Mold temperature below 15 F Motor is rotating Power on Heater Thermostat closed Shut Off Switch closed C to NC Neutral Hold Switch closed C to NO Water Fill Switch open Control Arm is swinging up Thermal Cut out Mold Heater Shut Off Switch JUUUL 7 Hold Switch Maker
163. ugh wireway under boss Figure 7 17 Snaps wires and capillary tube into clip behind defrost control Place the plastic tube over the end ofthe control cap tube until it is even with the end of the tube Make a 90 bend in the tube at the end of the plastic sleeve See Figure 8 Install plastic tube over control cap tube Figure 8 Tape freezer cap tube to damper control and install damper into rear control box See Figure 9 Slide the end of the cap tube in the slot under the air duct which runs from the freezer to the fresh food compartment until the seal on the damper housing contacts the liner Install the screws to hold the control housing in place lU Pus Tape control cap tube to bottom of damper control Push control into housing Figure 9 Fresh Food Compartment Control The Fresh Food Compartment Control is located on the right side on the front control box The cap tube for the control runs alongside the freezer cap tube back to the damper control Like the freezer control the last 8 inches is covered with a plastic sleeve The end ofthe captube with the sleeve is snapped into a channel in the air diffuser in front of the damper control See Figure 10 The Fresh Food Compartment Control will have an OFF position for the servicer to use in testing but the word OFF will not show on the dial plate To turn the control OFF turn knob counterclockwise past WARM to the s
164. used as a lubricant in refrigeration systems operating on R 134a Ester oils are produced from alcohols and fatty acids and are available in several different variants Ester oils have a pleasant aroma reminiscent of fruit Esteroils generally include various types of additives for improving certain properties such as viscosity temperature sensitivity etc These additives are often aggressive and skin contact with Ester oils should therefore be avoided One of the most important requirements made on a refrigerant system is that the oil mix with the refrigerant Since mineral oil and ordinary synthetic oil DO NOT mix with R 134a Ester oil is used for lubrication Ester oil dissolves in R 134a Ester oil is broken down by chlorine and cannot be used with R 12 R 12 contains chlorine or any other compound containing chlorine Therefore R 134a refrigeration systems virtually no tolerance for chlorine molecules from CFC refrigerants R 134a is an HFC and contains no chlorine CAUTION During R 134a service it is extremely important to avoid using equipment that may contain residual amounts of mineral oil CFC s or HCFC s which could enter and contaminate the sealed system For example hoses that were used for a refrigeration system operating on R 12 may contain small quantities of mineral oil which can block the capillary tube in a system operating on R 134a As little as one milligram may be sufficient to cause
165. ve If water is coming through replace the water filter Place a glass against the actuator and push in to see if water will pass through the valve and the filter into the bucket If it does replace the secondary valve If it does not remove the primary valve disconnect the outlet line from the primary valve and place a glass against the actuator and push If still no water replace the primary valve If wateris coming through replace the water filter 110 Low No Voltage One point we need to cover in our testing is good connections at all points in the ice and water At Coil s wiring There are anumber of connections in the wiring of a refrigerator On the ice maker the wiring runs through the plug by the compressor up to the ice maker back down to the same plug and into the diode harness On the water dispenser the wiring runs from the plug by the compressor to the plug at the top of the freezer door down to the dispenser and back down through the same plugs to the diode harness bad connection at any of the plugs or wire terminals can stop the valves from operating One of the problems we have found is at the connector on the water valve coils is pushed on with the valve terminal over top the terminal in the plug See Figure H9 The Diode kit part number is 5304418384 this kit will contain Crimp Connectors Pieces of heat shrink Instruction sheet Diode Harness Figure H8 Terminals in Connector Terminals on Coil Terminal
166. vealow side process tube attachedtothe compressor shell A high side process tube is attached to the filter drier WARNING DO NOT OPERATE RECIPROCATING COMPRESSOR WHEN CHARGING LIQUID REFRIGERANT INTO SYSTEM THROUGH ITS PROCESS TUBE Replacement compressors for refrigerator may have an oil cooler even ifthe original compressor did not Ifthe productis notequippedforanoil cooler leavetheplasticcaps in place and install the compressor connecting only to the suction and discharge lines ofthe new compressor Before installing the replacement compressor remove the discharge plug and check for the pop sound of the inert gas leavingthe compressor CAUTION DO NOT use compressor if you do not hear this sound Ifthecompressorchecks OK reinstallthe plug Do notremove any ofthe plugs again until the compressor is in position and you are ready to braze the lines CAUTION On R 134a systems compressor must NOT be left open to atmosphere for more than 10 minutes to prevent moisture contami nation of oil A new compressor which is cold e g after having been kept inacoldservice van should be leftto warm to the surrounding temperature beforethe plugsonthe compressorconnections areremoved Thiswillhelp prevent condensation from forming inthe oil and the compressor Also avoid opening the system when any of the components or lines are cold NOTE RELEASE holdingcharge release slowlytoavoid oil discharge on new compressor to en
167. w In in DUCT SECTION E REFRIGERATION SYSTEM NOTICE Instructions given here are furnished as a guide Persons attempting to use these instructions to make repairs to the sealed refrigeration system should have a working knowledge of refrigeration and previous training on sealed system repair and an EPA certification for servicing refrigeration systems IMPORTANT NOTICE Effective July 1 1992 the United States clean air act governs the disposal of refrigerants such as R 134a Therefore when discharging or purging the sealed system use an epa approved refrigerant recovery system as outlined in the final rule on the protection of stratospheric ozone and refrigerant recycling which was published in the Federal Register May 14 1993 NOTE Frigidaire does not permit the use of recovered refrigerant in the servicing of our products for in warranty and out of warranty repairs or for products covered by service contracts Therefore only new refrigerant or refrigerant that has been reclaimed back to new specifications by a refrigerant manufacturer is to be used DEFINITIONS Recovery To remove refrigerant in any condition from a system and store it in an external container without necessarily testing or processing it in any way Recycling To clean refrigerant for reuse by oil separation and single or multiple passes through devices such as replaceable core filter driers which reduce moisture acidity and particulate matte
168. while under positive air pressure Final pressures should not exceed 300 psig 2 170 kPa Filled cylinders should periodically be analyzedfor air nonabsorbable gas or NAG Refrigerant Recovery Systems Efficient recovery of refrigerant from equipment or con tainers requires evacuation atthe end ofthe recovery cycle Suction lines toa recovery compressor should be periodically checked for leaks to prevent compressing air into the recovery cylinder during evacuation In addi tion the recovery cylinder pressure should be moni tored and evacuation stopped in the event of a rapid pressure rise indicating the presence of noncondensable air The recovery cylinder contents should then be analyzed for NAG and the recovery system leak checked if airis present DO NOT continue to evacuate a refrigera tion system that has a major leak THERMAL DECOMPOSITION HFC 134a vapors willdecompose when exposed to high temperatures from flames or electric resistance heaters Decomposition may produce toxic and irritating compounds such as hydrogen fluoride The pungent odors released will irritate the nose and throat and generally force people to evacuate the area Therefore it is important to prevent decomposition by avoiding exposure to high temperatures SECTION ICE MAKER LEFT SIDE MOUNT ICE MAKER ICE MAKER FOR SIDE BY SIDE MODELS The automatic Ice Maker is mounted in the freezer compartment Itis attached to the freezer compartment s
169. wired in series with the Mold Heater Operating Cycle Illustrations Manual Cycle To manually cycle Ice Maker 1 Remove Cover from Ice Maker head 2 Insert a Phillips into screw on timing gear 3 Turn gear clockwise until Motor starts to run Water Fill lt Mounting Ice Make Plate ON OFF Screws Switch Mounting Plate Screw Operating Cycle Illustrations Electrical The following wiring diagrams illustrate the electrical operation of an Ice Maker This procedure is on the Internet at http www frigidaire com tip LINE NEUTRAL Ice Maker connected to electricity Mold temperature above 15 F Thermostat open Motor not rotating Mold Heater off Control Arm in the down position ON OFF switch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NC Water Fill Switch open 0f 0n On Thermal Cul Qul BLACK Swilch But amp 9 C e 9 3 LT BLUE BLACK RED LT BLUE RED MOLD HEATER 85 Wells Ice Maker Electric 1 LT BLUE Off Ji jt Jt j V NV NV WV Waler Valve BLACK Woler Fill Z YELLOW RED Section F Ice Maker NEUTRAL Ice Maker connected to electricity Mold temperature below 15 F Thermostat closes Motor starting Heater starting to heat Control Arm in the down position ON OFF switch in the ON position Shut Off Switc
170. y exposed without adverse effects The AEL for HFC 134a has the same value as the Threshold Limit Values TLVs established for CFC 12 and HCFC 22 TLVs are established by the American Conference of Governmental and Industrial Hygienists ACGIH However inhaling high concentrations of HFC 134a vapor may cause temporary central nervous system depression with narcosis lethargy and anesthetic effects Other effects that may occur include dizziness a feeling of intoxication and a loss of coordination Continued breathing of high concentrations of HFC 134a vapors may produce cardiac irregularities cardiac sensitization unconsciousness and with gross overexposure death Intentional misuse or deliberate inhalation of HFC 134a may cause death without warning This practice is extremely dangerous If you experience any of the initial symptoms move to fresh air and seek medical attention CARDIAC SENSITIZATION If vapors are inhaled at a concentration of 75 000 ppm which is well above the AEL the heart may become sensitized to adrenaline leading to cardiac irregularities and possibly to cardiac arrest The likelihood ofthese cardiac problems increases if you are under physical or emotional stress Medical attention must be given immediately if exposed to high concentrations of HFC 134a DO NOT treat with adrenaline epinephrine or similar drugs These drugs may increase the risk of cardiac arrhythmia and cardiac arrest If the pers

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