General Icemaker Information Letter In Door Ice & Ice
Contents
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3. NOTES 1 Optics Diagnostics will not respond for 5 minutes after the ice maker begins a harvest cycle To reset the control wait until the ice maker parks then switch off the Ice maker by means the User Board for 5 seconds and repeat the test To determine if the icemaker is in the harvest mode press in the door switch and look at the status LED When the door switch is pushed in during a harvest the status LED will flash on and off one pulse every second If the IDI control is in the diagnostics mode it cannot enter the harvest mode 2 The ice bin must be on the door and the ice level below the notched openings OPTICS DIAGNOSTICS PROCEDURE FOR WER SbS DESIGN BOARDS STEP STATUS LED POSSIBLE CAUSES ACTION The flapper door on Two 2 pulses followed the emitter is blocking Go to step 2 by a one 1 second the infrared beam delay repeated The optics are faulty Go to step 2 Ice maker is in the harvest mode The To confirm press in harvest mode consists and hold the freezer 1 Open the Freezer of a five 5 minute door switch If in the door period that starts harvest mode the when the bimetal Status LED will flash No lamp closes and the ice once every second maker begins to run Replace the receiver Faulty status LED and emitter boards Two 2 pulses followed Replace the emitter and 2 Press in the emitter by a one 1 second The optics are faulty
4. boards flapper door to clear the delay repeated optics beam The optics are Close the freezer door working properly LED is on steady TROUBLE SHOOTING CHART for OPTICS DIAGNOSTIC CORRECTIVE TEST RESULT POSSIBLE CAUSE ACTION Dirt on optics Clean dirt from optics Frost on optics Clean frost from lenses lenses Flapper door is open Hold the emitter door 2 LED pulses and is blocking the closed and the status repeated emitter beam LED should be on Optics Diagnostic Mode optics test only steady Failed optics Replace emitter and receiver boards and retest No LED pulses Ice maker is in 5 minutes harvest cycle To verify press in on door switch Status LED should flash at 1 second intervals Incorrect wiring at emitter or receiver board Correct wiring and retest Optics performing self tests will not perform diagnostic tests during this time Make sure ice maker is parked Switch OFF the by means the User Board for 5 seconds to reset optics control and retest LED is defective Replace emitter and receiver boards and retest 5 second LED on steady Flapper door is held closed Normal with flapper door closed POWER UP DIAGNOSTIC MODE TEST WARNING Electrical Shock Hazard Voltage is present during these tests 1 Switch OFF the Ice Maker using the User
5. As the heater melts the outer layer of the ice the motor rotates a rake which sweeps the ice cubes out of the mould and into the storage bin Due to the placement of the storage bin on the freezer door the sensing of the ice level is made by an electronic control that performs this function and two additional functions It controls power to the ice maker and performs system diagnostic which includes a power up test and service diagnostic The electronic control consists of two separate printed circuit boards mounted on opposite sides of the freezer liner just inside the door The board mounted on the freezer door hinge side of the cabinet is referred to as the emitter board and the board mounted on the mullion side is referred to as the receiver board When the Ice Maker thermostat closes and signals the ice is ready to be harvested the emitter board sends out an infrared IR pulse If the path of the pulse is unobstructed to the receiver board the phototransistor on the receiver board will sense the pulse The control will then energise a relay which applies power to the ice maker And a harvest begins The ice maker loads the motor the heater and water valve is controlled by the stamped circuit module which is part of the ice maker The electronic control will check periodically to see if the ice maker is at the home park position when the ejector stops at the 2 o clock position If the ejector is at the home position
6. Board push button 2 Slide the ice maker out of the mounting rails remove the cover leaving the wiring harness connected 3 Connect jumper test holes T and H to bypass the bimetal thermostat and start a harvest Motor Jumper Points T and H 4 Make sure there is a clear path across the bin for the infrared beam to travel to the receiver sensor Close the freezer door and switch on the system using the User Board ON OFF push button then wait 5 seconds to allow the optics relay to close 5 Open the freezer door and observe the ice maker A harvest should be in progress i e the ice cube rake is turning NOTE If holes T and H are properly jumpered and the ice maker will not run stop the test and check the ice maker 6 Remove the jumper before the fingers reach 10 00 Reinstall the ice maker 7 Switch OFF the Ice Maker immediately after the water fills 8 With the freezer door closed switch ON the Ice Maker 9 Wait 5 seconds to a maximum of 50 seconds then open the freezer door and watch the Status LED for one of the following codes Status LED Output Codes 4 PULSES repeated once indicates the relay is defective Replace both the emitter and receiver boards 3 PULSES repeated once indicates the optics and relay are okay but the ice maker is not being sensed or will not operate If this happens Check the bail arm switch to make sure it is On Check the ice maker circuit and the connections back to the rec
7. Ice Valve command lasts more than 20 seconds the Ice Maker equipment will be switched OFF until the following points are satisfied 1 Alarm reset alarm and buzzer OFF Ice Maker OFF When engaged this alarm the buzzer will sound and the Ice Mode LED s will blink alternately 2 The mains power has been removed 3 The mains power has been re applied Note a If the customer tries to switch ON the Ice Maker before to executing point 2 the alarm will re start again and the relay will remain in the OFF state b If after point 3 the situation persist i e the failure has not been fixed during the service intervention the above alarm will restart TIP The above situation could occur when the VIOLET wire Ice Valve feed back is short circuited with a main Line harness failure So be prepared also to check the wiring loom Diagnostics WARNING Electrical Shock Hazard Voltage is present during these tests OPTICS DIAGNOSTIC MODE TEST The service diagnostics mode only checks the functionality of the optics To enter this mode open the freezer door anytime when power has been applied for at least one minute The status LED should flash twice then pause for 1 second then repeat this sequence as long as the door is open If the user pushes in the flapper door on the emitter the optics path should be cleared and the LED should be on solid The service diagnostics mode cannot be entered if the icemaker is in the middle of a harvest
8. near this value or 10 ohms Module must be separated from heater before testing MODULE SPECIFICATION MOLD HEATER 185 Watts 300ohms THERMOSTAT Bimetal Close 17 F 3 F 8 C Open 32 F 3 F 0 C WATER FILL 140cc MOTOR 3 Watts 21000 ohms MODULE Stamped circuit Plug in connectors CYCLE One revolution ejects amp water fill Frequently Asked Question 1 Does the Ice button on the user board close a relay on the main control board The User Board has got a microprocessor that detects which of the 13 push buttons has been depressed and communicates this code to the Main Board So keep in mind there are no wiring connection between relay Ice Maker and User Board 2 Does this relay supply the emitter board and the receiver board NOT COMPLETELY CORRECT It supplies the Neutral to the Receiver board and to the Ice Maker 3 On the receiver board the relay closes to supply the Ice Maker Module and remains closed while the infrared beam is not broken NOT COMPLETELY CORRECT The relay closes every 40 minutes if the infrared beam is not broken Hence it remains closes only if the bimetal inside the Ice Maker is closed resistance load check This situation allows a harvest about 5 minutes So usually the receiver board relay is closed 5 minutes every 40 minutes if some condition are true 4 Which board controls the 40 minutes delay in harvesting why is there a del
9. then off for a second and repeats 4 flashes relay problem The relay that supplies power to the icemaker is cycled during the power up test If the relay doesn t close it doesn t pass the test receiver board is defective d If multiple failure modes exist the status LED will only display one of them If the freezer door is open when power is applied diagnostics are skipped and the main routine is started Once the door is closed again and the power up diagnostics have indicated that all tests passed the IDI control will begin to monitor the icemaker TROUBLE SHOOTING CHART for POWER UP DIAGNOSTIC TEST RESULT POSSIBLE CAUSE CORRECTIVE ACTION 4 LED pulses repeated Replace emitter and receiver Defective receiver relay once boards and retest Ice Maker in park T ositionemd bimetalis Install jumper in ice maker holes p T and H and retest open Ice Maker bail arm Bail arm not used in these models switch in OFF position but switch must be ON 3 LED pulses repeated Ice Maker is not Switch ON the Ice Maker by p p powered means the User Board and retest Thermal fuse in Ice Replace ice maker harness and Ice Maker Maker harness is open retest Control Circuit Incorrect wiring at emitter or receiver board Correct wiring and retest Problem with Ice Maker See Ice Maker Checks below 2 LED pulses Optics board defective Replace emitter and receiver boar
10. water fill tube and check for seeping valve Water valve has failed Replace water valve Ejector bar does not stop at home position Thermostat jumper not removed Remove thermostat jumper DETAILED INFORMATION ON THE ICE MAKER To better understand the icemaker operations please refer to the following information This will allow you to deal with the system in case the above TEST PROCEDURE fails ICE MAKER MODULE TEST POINTS The design of this Ice maker allows all of the components to be tested without removing the Ice maker or moving the refrigerator away from the wall to access the water valve Removing the cover you wiil see the test points identified on the module N Neutral side of line M Motor connection H Heater connection T Thermostat connection L L1 side of line V Water valve connection H T Thermostat L H Heater L M AC Motor L N V N 220Vac Valve ICE MAKER MODULE DETAILED OPERATION When the thermostat has sensed low temperatures about 8 C the thermostat called also Bimetal closes At this time the current has a path through the thermostat to motor because the contact b is connected to the contact c see wiring diagram below Neutral from Main Board pin 15 Line from Receiver board relay VIOLET BLUE GREEN BROWN Main Board Side by Side 4 poles Ice Maker Side by Side Contact A 12 poles WD H
11. Whirlpool Europe Service Consulting Center lt gt Whirlpool IGNIS General Icemaker Information Letter In Door Ice amp Ice Maker system Side by Side production Cassinetta Index Forward Theory of Operation Schematic Diagram Ice Valve Feed back Description Optics Diagnostic Mode Test Optics Troubleshooting Chart Power Up Diagnostic Mode Test Power Up Troubleshooting Chart Ice Maker Module Test Points Ice Maker Module Detailed Operation The Ice Maker Module Cycle Testing when Ice Maker is plugged in Testing when Ice Maker is unplugged Module Specification Frequently Asked Questions Optics Test Flow Chart Power Up Test Flow Chart FORWARD This Service Manual provides the technician with information on the operation and service of the Whirlpool amp Bauknecht In Door Ice System Rounded door TRIM KIT and Flat models are covered It is to be used as a Service Manual For specific information on the model being serviced refer to the Instructions For User provided with the Refrigerator Freezer The Wiring Diagrams used in this document are typical and should be used for service training purposes only Always use the Wiring Diagram supplied with the product when servicing the unit GOALS AND OBJECTIVES The goal of this document is to provide detailed information that will enable the service technician to properly diagnose malfunctions and repair the In Door Ice System The objecti
12. ay and can it be overridden The delay in harvesting is controlled by the Receiver board it is at the moment 40 minutes it can be overridden at power up components diagnostic if the Ice Maker internal bimetal is closed etc 5 Can the output from the switch on the user board be tested The ON OFF Ice Maker push button is not connected by wiring to the Main Board it is connected to the User Board microprocessor by PCB trace and once de pressed its code is sent to the Main Board by means the communication wires RX and TX This allows to engage disengage the relay that supplies the Neutral side of the Line to the system So you can test it unless the communication is not working by means MULTIMETER You should see main voltage between pole 15 or 16 connector 16 poles and poles from 1 to 5 same connector 16 poles when the relay is engaged Ice Maker push button ON and no any voltage when the relay is not engaged Ice Maker push button OFF 6 How would the output from the relay and other outputs from the main control board be tested My opinion is to TEST it by means MULTIMETER or a LAMP usually there is Main Voltage signal to check 7 How does the receiver or other component detect the closure of the icemaker thermostat to energise the relay The icemaker thermostat closes by itself when it reaches the required temperature the receiver every 40 minutes closes the internal relay if the infrared beam is not broken and by means inte
13. blade Park Stop Position about 2 o clock Start position Bimetal Closes Motor ON Heater ON 6 Ejector Stalls On Ice Motor ON Heater On d 1 2 Minute To 5 Minutes Thermostat Opens In This About 4 o clock Position Range Of Operation Then Heater goes OFF 6 o clock position Testing when Ice Maker is plugged in to the power Test points L amp N will verify 220 Volts to Ice Maker module Make sure your test probes go into the test points gt Test points T amp H will verify if the bimetal thermostat is open or closed Short T amp H with an insulated piece of wire 14 ga to run the motor If the motor doesn t run replace the module assembly If the motor runs replace the bimetal thermostat If you leave the jumper in for a half of a revolution you can feel the heater in the moid heat up if it s good Remove the jumper and the water valve will be energized in the last half of the revolution Make sure that the freezer temperature is cold enough to close the bimetal NOTE Do not short any contacts other than those specified Damage to Ice Maker can result Testing when Ice Maker is unplugged Test points L amp H will check the resistance of the heater 300 ohm Replace the mold and heater assembly if not near this value or 10 ohms Ejector blades should be at the end of the cycle position Test points L amp M will check the resistance of the motor about 21500 ohms Replace module assembly if not
14. ds and retest 5 second LED on steady Ice Maker control circuit is functioning normally None required No LED pulses Optics performing self tests will not perform diagnostic tests during this time Make sure ice maker is parked Unplug refrigerator for 5 seconds to reset optics control and retest Ice Maker Checks No power applied to Ice Maker module Optics check not run before testing Ice Maker Run optics test and recheck ice maker Freezer door not closed after Optics test Close freezer door to start harvest Optics path not clear Clear optics path Optics test failure Replace emitter and receiver boards and retest Ice Maker is not powered Checks poles relay output on the Main Board Thermal fuse in Ice Maker harness is open Replace ice maker harness Wiring harness problem Check continuity in wiring harness Ejector bar does not move Motor has failed Replace ice maker module Heater is not on Thermostat jumper not making contact Reposition jumper Heater has failed Replace ice maker No water fill Thermostat jumper was left installed past 11 00 position Remove jumper by 10 00 position of ejector bar Water valve wiring connection problem Check wiring to valve Customer s water supply is problem Check for proper water supply Frozen water fill tube Defrost the
15. eater 300 ohm Ice valve feed back 16 poles 3 HORAS Bimeta Shut Off 7 Ww pin 8 VIOLET T Switch NT Thermosta On Dn e off up 4 1 BROWN pin 4 BLACK Water valve Contact C 6 poles BLACK Cyl Contact D Motor AC 21K ohm The motor is linked with the drive gear From the module there are copper contact a b c and d that ride on copper strips on the backside of the drive gear As the drive gear rotates these contacts from the module will make or break a circuit track to the copper strips to generate the Ice maker cycle When the bimetal opens the motor runs anyway because the c and d contacts are connected together these contact will be connected together until the blades are at Home Park position contacts c not more connected to contacts d During the rotation the contacts b and a will be connected together about 7 5 seconds to drive water valve in this case the current has a path through the heater Contact D Contact C Timer Holding Switch Contacts rotate clockwise and tracks are static Water Valve Contact B Heater Thermostat Ice Maker cycle what happens during blade rotation PLASTIC WHEEL VIEW Water valve energized 7 5 seconds 140cc Fill about 11 00 o clock Ejector
16. eiver board and neutral Check the ice maker components 2 PULSES repeated once indicates the optics are blocked or defective Clear the optics path and repeat the Optics Diagnostics Procedure Replace both boards if necessary STEADY LIGHT for 5 seconds indicates the relay and optics are okay and the receiver senses the ice maker NO LIGHT Switch OFF the Ice Maker using the User Board for 5 seconds and repeat the test See note on next page FURTHER NOTE During the first minute after Ice Maker power is cycled from OFF to ON the IDI control will go through a power up diagnostics routine if the freezer compartment door is closed when power is first applied The freezer door can be opened at any time during the first minute to check the status LED located on the receiver which will indicate the results of the power up test The results of the power up tests are displayed on the status LED as follows a LED on solid for 5 seconds all tests pass b LED flashes twice then off for one second and repeats 2 flashes optics problem Sending a pulse from the emitter to the receiver performs the optics test If the receiver gets it the test passed C LED flashes 3 times then off for a second and repeats 3 flashes icemaker problem The icemaker test is performed by checking for a load lt 10Mohm between the AC line to the icemaker pin 4 and neutral pin 8 If a load is present the icemaker test is passed LED flashes 4 times
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18. rnal resistor feed back the receiver microprocessor detects the load resistance value two different value are possible depending if the bimetal is closed or not If the bimetal is closed the relay stays engaged to allow the harvest about 5 minutes till the Ice Maker reaches the park position 8 How does the receiver or other component detect the park position of the ice maker to de energise the relay The receiver detects the same value as for bimetal closed when the motor is The park position automatically stop the Ice Maker if the bimetal is open and opens the connection between the receiver relay output and the Ice Maker motor So the receiver by means the feed back internal resistor detect the end of the harvest 9 What are all the circumstances that would cause the receiver relay to open cutting the voltage to the ice maker This is the factor that causes most difficulty when testing Knowing whether a no voltage situation is correct due to the normal function of the boards or if one of them is faulty Mainly the relay opens when it doesn t detect anymore the Ice Maker motor connection that at the beginning is allowed by the bimetal in closed position and during the harvest time by means the internal Ice Maker contacts c amp d these are connected together until the park position Of course the infrared beam mustn t be broken etc yas 100p ay aaejday 4384331 sjeuiuuaBuut 184480 Jie das S8Jl YOPWAS 100p ay
19. the relay will de energize and remove power from the ice maker until the next harvest To prevent an early harvest from occurring after the last harvest is completed a minimum of 40 minutes must pass before another harvest will be initiated Schematic diagram of the icemaker related circuits through the user main control emitter and receiver boards 7 5 secondi CLOSED mechanical contact Line x Ice Maker Bimetallo o Line Heater Feed back LED Cathode Emitter Board Receiver IR Neutral User Interface dis Lj Line Line Water Filter N L Indicator Main Board Ice Valve IT black b h Feed back Rel Main plug 220Vac Ice valve 2 Ice Make Neutral Ice Valve Feed back Description The feedback Ice Valve mainly gives the information to the microprocessor on how many times the Ice Valve has been engaged This value is recorded by the microprocessor and it is multiplied by the valve flow rate in order to record how many litres of water flows through the valve and consequently through the filter So the Water Filter Indicator can be updated accordingly The feedback is also used by the Main Board in order to understand if the Ice Maker is stuck at water fill position and to avoid water overflow The following describes how the feed back works If the
20. ves of this document are to Successfully troubleshoot and diagnose malfunctions Successfully perform necessary repairs Successfully return the In Door Ice System to proper operational status IMPORTANT Electrostatic Discharge ESD Sensitive Electronics ESD problems are present everywhere ESD may damage or weaken the electronic control assembly The new control assembly may appear to work well after repair is finished but failure may occur at a later date due to ESD stress Use an anti static wrist strap Connect the wrist strap to the green yellow ground connection point or to an unpainted metal surface in the appliance OR Touch your finger repeatedly to a green yellow ground connection point or to an unpainted metal surface in the appliance Avoid touching electronic parts or terminal contacts Handle the electronic control assembly by the edges only Theory of operation The IDI Ice Maker system consists of the following an Ice Maker an electronic ice level sensor an external water valve and a freezer door compartment mounted ice storage bin The Ice Maker control module is a stamped circuit that provides power and control for the ice making loads which consist of the motor heater and water valve The Ice harvesting process begins when the ice maker thermostat closes and signals that the harvest temperature has been reached The closed thermostat applies power to the ice maker motor and to the heater
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