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Electrolux Side by Side Refrigerator, Service Manual

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Electrolux Side by Side Refrigerator Service Manual Download Page 136

129

Section H - Water System

at the top of the freezer door down to the dispenser and back up through the same
plugs to the diode harness. A 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.)

Summary of Contents for Side by Side Refrigerator

Page 1: ...5995393583 0311 Dishwasher Service Manual Side by Side Refrigerator ...

Page 2: ...R ROLLERS 9 To Remove Front Roller Assembly 9 To Remove Rear Roller 9 CABINET TOUCH UP PROCEDURE 10 Lacquer Refinishing 10 SECTION C ELECTRICAL COMPONENTS 13 ELECTRICAL GROUNDING 13 COMPRESSOR 13 Electrical Components and Circuits 13 Solid State Relay 13 To Check Replace Relay 14 Overload Protector 14 To Check Replace Overload Protector 14 Run Capacitor 15 To Check Replace Run Capacitor 15 Compres...

Page 3: ... Fresh Food Door Sensor 23 Air Filter 23 Sensors 23 Fresh Food Lights 23 Alarm 24 Control Main Board 24 Control User Interface 24 Numeric Display 24 Fahrenheit Centrigrade Temperature 24 Showroom Setting 24 ALARMS AND SIGNALS 25 Temperature Alarm 25 Alarm Condition 25 Door Ajar LED flashing green 25 Door Ajar High Temp 26 Power Failure flashing yellow 26 Power Failure High Temp 26 High Temp 26 Ala...

Page 4: ...Test 2 Evaporator Fan Test 38 Test 3 Freezer Temperature Last 24 Hours 38 Test 4 Fresh Food Temperature Last 24 Hours 39 Test 5 Damper Motor is a 12 Volt DC Stepper Motor 39 Test 6 Defrost 40 Test 7 Compressor and Condenser Fan On 40 Test 8 Default Settings Clear Service Data 40 Manual Defrost 41 Function 41 Show Room Mode 41 Changing Between Fahrenheit to Centigrade On The Display 41 Diagram C Se...

Page 5: ...MENT 58 HEAT EXCHANGER REPLACEMENT 60 PERIMETER HOT TUBE REPAIR KIT 62 Bypassing Perimeter Hot Tube Step 1 62 Installing the Heater Wire Step 2 63 Installing the Heater Wire Step 3 64 CONDENSER REPLACEMENT 65 FILTER DRIER INSTALLATION 66 EVACUATING AND RECHARGING 67 Equipment Needed For Evacuation Recharging 68 Installing Evacuation Recharging Equipment 68 Evacuating System 68 Charging the System ...

Page 6: ...ition 81 SECTION F ICE MAKER 83 REAR MOUNTED ICE MAKER FOR COUNTER DEPTH MODELS 83 Front Cover 83 Ice Mold 83 Mold Heater 84 Ice Stripper 84 Ice Ejector 84 Water Valve Assembly 84 Thermostat 84 Sensing Arm Linkage 85 Timing Switches 85 Thermal Cut Out TCO 85 Timing Cam Coupler 86 Timing Gear 86 Motor 86 On OFF Switch 86 Wiring 86 Installing Water Supply Line to Ice Maker 87 Test Cycling Ice Maker ...

Page 7: ... 95 Operating Cycle Illustrations Electrical 95 Operating Cycle Illustrations Mechanical 102 Ice Maker Wiring Diagrams 105 SECTION G ICE WATER DISPENSER 107 ICE DISPENSER CONTAINER RAIL ASSEMBLY 107 Dispenser Auger Motor Solenoid Assembly 107 To Remove Auger Motor 107 To Test Auger Motor 108 To Remove Solenoid Assembly 108 To Test Solenoid Assembly 108 To Remove Lamp Socket and Light Bulb 109 ICE ...

Page 8: ...tem 126 Resistance Check 127 Voltage Check for Water to Ice Maker 127 Digital Meter 127 Voltage Drop From Heater 127 Different Voltage Readings Between Primary Secondary Valve Coils 127 No Water At Door 128 Diode Kit 128 Checking Water 128 Ice Maker Valve 128 Chilled Water Valve 128 Low No Voltage At Coil s 128 ...

Page 9: ...arrying conductors It is EXTREMELY important that the service technician reestablish all safety grounds prior to completion of service Failure to do so will create a hazard 6 Prior to returning the product to service ensure that All electrical connections are correct and secure All electrical leads are properly dressed and secured away from sharp edges high temperature components and moving parts ...

Page 10: ...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 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...

Page 11: ...n a solid floor Adjust the front rollers to level the 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 Open refrigerator and freezer doors 2 Remove toe grill by removing two screws and pulling it straight out See Figure A2 3 Adjust rollers by turning each ...

Page 12: ... 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 connector NOTE If installation requires the remo...

Page 13: ...m 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 Lift freezer 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 Screws Water Line T...

Page 14: ...han freezer door raise left corner of cabinet by adjustingroller 4 If refrigerator door is lower than freezer door raise right corner of cabinet by adjusting roller 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 bo...

Page 15: ...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 The compre...

Page 16: ... 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 Counter Depth model doors are filled with rigid Urethane foam insulation after assembly of the inner panel and prior to the installation of the door gasket The door inner panels are vacuum formed from high strength plastic ADJUSTABLE DOOR BINS Some models ...

Page 17: ...rse order To Remove Rear Roller See Figure B6 1 Disconnect refrigerator from electrical power 2 Raise and support cabinet 3 Squeeze flared end of roller pin together using pair of pliers or vise grips 4 Pull roller pin free of roller and compressor 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...

Page 18: ...urface with this cleaner Stubborn or deep seated rust can be removed by applying cleaner with steel wool 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 equa...

Page 19: ... also applies to the complete refinishing of the cabinet except gasket contact areas All damaged areas should be repaired as outlined in steps 1 through 6 on the previous page The overall surface of the cabinet should be sanded thoroughly and cleaned as outlined in step 7 The cabinet should be given two or more coats of touch up lacquer and polished as outlined in steps 8 and 9 ...

Page 20: ...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 Coefficient simply denotes a resistor which increases in resistance as its temperature is increased The self heating PTC resistor used in the solid state relay h...

Page 21: ...m readings are out of range replace relay 8 Reverse this procedure to re assemble Overload Protector The overload protector is completely thermally operated It will open from excessive heat or current Unlike prior overloads the internal bi metal 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 ...

Page 22: ...ly 3 Use flat bladed screwdriver and gently pry capacitor from relay assembly 4 Discharge capacitor by shorting across terminals with 500K 1 watt resistor for one minute 5 Use ohmmeter set on the Ohms times 1000 scale if available to check resistance across capacitor wire terminals The needle should jump towards zero ohms and quickly move back to infinity If the needle does not move the capacitor ...

Page 23: ...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 correcting the power factor of the compressor motor See Figure C4 Compressor Operating Characteristics When the compressor electrical circuit is...

Page 24: ...ic control system wiring should be checked for loose and or broken connections You can jump from J42 to J41 with a piece of wire as a temporary bridge If the 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 compressor If the compressor does not start a...

Page 25: ...emove the cover 4 Remove the two bottom screws on evaporator air duct cover This will allow you to pick the cover up to gain access to the fan assembly 5 Disconnect connector Evaporator fan motor assembly can now be pulled free 6 Remove back bracket holding fan motor by pushing in and releasing tabs 7 Remove fan blade and slinger washer 8 Pull evaporator fan motor free 9 Remove rubber bushings fro...

Page 26: ...e 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 di...

Page 27: ...heater is energized during that period of the cycle when the defrost thermostat contacts are closed The length of time the heater is energized depends on the amount of frost accumulation on the evaporator How To Remove The Defrost Heater 1 Disconnect refrigerator from electrical supply 2 Remove freezer section bottom shelves and baskets 3 Remove ice container and rail assembly The multiconnector a...

Page 28: ...h 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 13 Lift up and pull evaporator and drain trough out at bottom NOTE This is a good time to test the heater Check resistance of defrost heater using a multimeter Resistance should be very close to 30 ohms Replace defrost heater if resistance readings are...

Page 29: ...Temperature Control An electronic thermostat regulates the temperature of the frozen food section A Negative Temperature Coefficient Thermistor monitors freezer compartment temperature Loads controlled atr the compressor condenser fan and evaporator fan motor enabling and speed See Diagram A Fresh Food Temperature Control An electronic thermostat regulates the temperature of the fresh food section...

Page 30: ...115 VAC that circulates air through the condenser coils Either a Relay or Triac depending on compressor used controls condenser Fan Motor Fresh Food Door Sensor Magnetically activated reed switch Switch will detect Fresh Food Door state Air Filter Motorized Fan 12VDC that circulates air through a filter in the Fresh Food Section The Filter Fan Motor is controlled via a power transistor Not on all ...

Page 31: ...netically activated reed switch that detects Fresh Food Door state Fahrenheit Centigrade Temperature Somemodels Allows customer to change temperature readings from Fahrenheit to Centigrade and back Showroom Setting Active functions Displays Freezer Fresh Food Temperature keys Fresh Food Lights Alarm Key Key Tone ONLY Air Filter Key Key Tone and Green LED toggles on and off All other functions are ...

Page 32: ...arm condition Alarm LED steady green Press and hold reset 3 seconds you will hear one beep to turn all alarm functions Off Press and hold reset 3 seconds you will hear one beep to turn all alarm functions On Default at POR power on reset is On Door Ajar LED flashing green If either door is open for 5 minutes this light blinks and control beeps Condition is reset if the opened door is closed or res...

Page 33: ...have exceeded recommended limits See Example 6 See Owners Manual NOTE If the user unplugs the unit and the setpoints have been reached when the product is plugged back in POR the Power Off indicator will be on If the user has the product unplugged long enough to cause a unsafe temperature condition the High Temp indicator will also be on when the product is plugged back in Alarm Reset Example 5 Do...

Page 34: ...er 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 Off All other functions are disabled including alarm s enabling Fresh Food Lights Fresh Food Lights are enabled and disabled depending on the Fresh Food Door Sensor state Light on maximum is 10 minutes Interior lights will shut off afte...

Page 35: ...st cycle 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 OPERATION UPDATED REVISION L User Interface Ver A Two Position Read Out for Freezer and Food Compartment Freezer Temperature UP key increments temperature setting up one degree F or C f...

Page 36: ...ter key again to deactivate and turn the Air Filter LED tri color off When activated the Air Filter Fan Motor will run continuously until it is turned off Air Filter Fan Motor run time is monitored during activation as to determine and display Air Filter Status via LED color Green 0 3600 hours run time Amber 3600 4344 hours run time Red 4344 hours or more run time Air Filter Status is reset by pre...

Page 37: ...per Limit 9 Temperature Warmer key decrements setting one number 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 Colde...

Page 38: ...31 Section C Electronic Controls Number Setting to Temperature Conversion 1 47 F 8 C 2 44 F 6 5 C 3 43 F 5 5 C 4 41 F 4 C 5 37 F 3 5 C 6 36 F 3 C 7 35 F 2 5 C 8 34 F 2 C 9 33 F 1 C Default 5 1 ...

Page 39: ...32 Section C Diagrams Diagram A Control System ...

Page 40: ...33 Karl Truitt 3 03 Diagram B Controller User Interface Board Reference ONLY See Drawing J2 Version A Version B Reed Switch J2 Reed Switch Pin 1 Pin 1 J1 J1 Section C Diagrams ...

Page 41: ...34 SectionC WiringDiagrams ...

Page 42: ...35 Section C Wiring Diagrams ...

Page 43: ...to 115 psig 621 to 793 kPa 130 to 155 psig 896 to 1069 kPa Wattage last 1 3 of cycle 120 to 150 130 to 160 Amps running 1 0 to 1 4 1 1 to 1 5 Base Voltage 115 vac 127 vac max 115 vac 127 vac max DEFROST SPECIFICATIONS Thermostat Heater Cabinet Size Cut In Cut Out Watts Ohms 23 25 F 4 C 47 F 8 C 450 30 Electronic Timer ADC Defros 24 minutes every 6 to 96 hours of compressor run time CONDENSER FAN M...

Page 44: ...s Number of compressor cycles last 24 hours Compressor Run Time last 72 hours Average Compressor Speed Variable Speed Compressor 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 Temperature UP Warmer key while pressing the Freezer ...

Page 45: ...rs Defrost temperature omitted Variable 1 Display Minimum Temperature Coldest temperature Variable 2 Display Maximum Temperature Warmest temperature Variable 3 Display Average 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 if needed of the temperature will flash twice in one ...

Page 46: ...Variable 4 Fresh Food sensor circuit condition will be displayed in Fresh Food Window Flash 1 Fresh Food sensor OK Flash 2 Fresh Food 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 12 volt DC Stepper motor Variable 1 Damper to full open Va...

Page 47: ...ter C when the compressor and condenser fan are running Test 8 Default Settings Clear Service Data Variable 1 Display 1 Indicates default settings have been changed and or there is service data in memory Variable 2 Display 0 Indicates Factory Defaults resets temperature settings to 0 and 37 F and service data memory cleared To reset temperatures to factory default clear the service memory and enab...

Page 48: ... cycle All other functions are disabled including alarm s enabling Show Room Mode See page 27 Changing between Fahrenheit to Centigrade on the display See page 28 Diagram C Service Mode Display Routine Test Number Freezer Display Test Variable Fresh Food Display Start Advance to Test 7 Advance to Test 7 EOL Tone EOL Tone Variable B Variable A Advance to Test 2 Advance to Test 2 Advance to Test 2 A...

Page 49: ...unplug the ribbon cable from the front membrance of the control board The control board can now be lifted out of the control housing Reconnect ribbon cable and push the new control board down into place using caution not to damage the board on the retainer With the board snapped all the way down in place reinstall the control box in the top of the food compartment in reverse order from the removal...

Page 50: ...mage and help with the installation Start the control box into the opening and reconnect the wiring using caution to make sure they are all the way plugged in Now you can push the control box back in place and reinstall the screw There is a 3 amp fuse mounted on the control board that is used to protect the board from voltage surges To replace the fuse remove the control board and lift the fuse ou...

Page 51: ...back of the liner See figure 3 Snap the new sensor into the bracket plug it into the connector and push the bracket straight back into the holes in the liner The freezer compartment temperature sensor is located inside the housing that supports the ice bucket and has the auger motor and solenoid mounted into it See figure 5 To replace remove the ice bucket then remove the two screws at the bottom ...

Page 52: ...aced Follow control board replacement instructions The magnet that operates the Reed Switch is located at the top of the food door inner door panel The magnet can be replaced by removing the screw located at the bottom of the bracket Then lift the magnet and cover off the door panel On some models it will be necessary to remove the top bin to get to the magnet The bin will lift off in the same man...

Page 53: ...derser Fan Silencer Speed Nut Bracket Bracket Bracket Condenser Roller Pin Rear Roller Roller Pin Front Roller 22 23 23 PTC Starter Clamp Run Capacitor Drier Filter Shoulder Screw Power Cord Shoulder Screws Compressor Defrost Drain Pan Defrost Thermostat ...

Page 54: ...tment through a duct located in the separating wall in the bottom rear left hand corner of the cabinet interior The air is then drawn up through the fin and tubes of the evaporator surface The cold air is forced into a fan cover and discharged into the top of the freezer and out the air discharge under the ice maker See Figure D1 If the food compartment control is calling for cooling the automatic...

Page 55: ...THIS IS A BLANK PAGE ...

Page 56: ... 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...

Page 57: ...hell seam separating A hydraulic block occurs preventing the compressor from starting This condition is known as locked rotor Electric current continues 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 fa...

Page 58: ...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 To reduce the possibility of condensation forming on the exterior of the cabinet in high humidity areas a perimeter hot tube refrigerant tube has been installed in th...

Page 59: ...or continuous compressor operation 2 Above normal freezer and or food compartment temperature 3 A partially frosted evaporator depending on amount of refrigerant loss 4 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 con...

Page 60: ...ystem 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 solder end of hot tube closed 3 Cut line from condenser to hot tube and solder a charging hose fitting to open end ...

Page 61: ...ext section To Flush The System Remove as much of contamination as possible from system before installing new compressor and a new two stack filter drier CAUTION NEVER install a new compressor without first checking for possible system contamination NOTE It is recommended that system be flushed with dry Nitrogen However if refrigerant is used to flush the system you must look at the serial plate t...

Page 62: ...same manner as condenser 6 Flush cap tube This is only possible if you have proper service valve adaptor 7 Reassemble system To Use Refrigerant To Flush The System 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 proced...

Page 63: ...r than necessary All replacement compressors are shipped with rubber plugs in the suction discharge and process tubes and contain the correct oil charge and a holding charge of inert gas Compressors have a low side process tube attached to the compressor shell A high side process tube is attached to the filter drier Replacement compressors for refrigerator may have an oil cooler even if the origin...

Page 64: ...d 1 Disconnect electrical supply to refrigerator 2 Remove compressor access panel 3 Recover refrigerant by using EPA approved recovery system 4 Remove leads from compressor motor terminals 5 Remove mounting clips and washers 6 Remove inoperable compressor and transfer mounting parts to new compressor 7 Drain oil from old compressor and mark with approved tag that oil has been removed 8 Remove suct...

Page 65: ...terminal leads in accordance with refrigerator wiring diagram 16 Reassemble unit Shroud Fan Blade Condenser Motor Silencer Speed Nut Bracket Grommet Bracket Grommets Motor Bracket Motor Bracket Motor Support Screws Condenser Wiring Harness Clamp Grommets Roller Roller Mounting Pins Roller Compressor Mounting Grommets PTC Starter Clamp Capacitor Filter Drier Shoulder Screw Washer Spacers Compressor...

Page 66: ...s will be made inside the freezer The evaporator kit contains a heat shield to protect the liner from damage when brazing 1 Disconnect refrigerator from electrical supply 2 Remove all freezer section shelves and baskets 3 Remove bottom evaporator cover 4 Disconnect wiring harness at liner plug Remove defrost limiter and disconnect defrost heater See Figure 1 Evaporator Kit Contains 1 Evaporator 1 ...

Page 67: ...to new evaporator then slide evaporator into top of drain trough 11 Slide evaporator and drain trough in place and push drain trough over heat shield This will help hold shield in place See Figure 3 12 Place cap tube in new evaporator and weld in place 13 Place suction line in new evaporator and weld in place 14 With a sharp knife cut along a seam on the heat shield from center hole to edge of shi...

Page 68: ...he liner and the cabinet back Because of this the original part cannot 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 Make your weld on the cap tube first Now make your weld on the suction line FIGURE 4 Remove the heat shield Heat Exchanger Kit Contents 1 He...

Page 69: ...ack 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 Figues 3 5 13 The one 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 ...

Page 70: ... 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 a low wattage heater wire installed inside the tube This heater will prevent condensation from forming on the exterior front edge of the cabinet Bypassing Perimeter Hot Tube Step 1 1 Disconnect service cord from pow...

Page 71: ...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 Cut at filter drier inlet Cut at weld between condenser and hot tube New Filter Drier Clamps Perimeter Hot Tube Perimeter Hot Tube Copper By Pass T...

Page 72: ...rness adapter into refrigerator circuit as shown in Figure 3 3 Cut off braid at start of heater Strip insulation back about 5 16 inch Be careful not to damage heater resistance wire Splice heater wire ends to loose leads of adapter harness with furnished wire connectors 4 Dress wires away form Condenser Fan Blade and any sharp edges 5 Secure wires with electrical tape as necessary 6 Reinstall Back...

Page 73: ...clip from fan bracket and condenser 9 Lift front of condenser and the two rubber groments out of retainer in base plate 10 Remove old condenser out the back of cabinet 11 Install replacement condenser 12 Remove original filter drier 13 Install new filter drier at end of hot tube 14 Evacuate and charge the system using recommended procedure described under Evacuating and Recharging on pages 27 28 1...

Page 74: ... allow tube to bottom against screen Solder carefully so that solder does not plug capillary tube 8 Install process tube adaptor to filter drier 9 Evacuate and charge system using the recom mended procedure described under Evacuating and Recharging on page 67 When using the two stage drier filter add an additional 1 4 ounce of refrigerant to what s required on the serial plate charge 10 Reassemble...

Page 75: ...will be necessary to check 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 32 Figure E2 The hand valve must be closed during all times when the vacuum pump is not opera...

Page 76: ...cess 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 Attach refrigeration service gauge manifold to system in following order Low side compound gauge hose to suction side process tube adaptor High sid...

Page 77: ...stop vacuum pump System is now ready for charging 6 If a leak is 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 lbs psig 7 Leak test low side Close compound gauge Run compressor for a few minutes and leak test high side When leak is found recapture refrigerant using EPA appr...

Page 78: ...ocess tube with the pinchoff 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 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 s...

Page 79: ...eration System 2 STAGE VACUUM PUMP Figure E2 HEATED CHARGING CYLINDER GAGE MANIFOLD PRESSURE GAUGE COMPOUND GAUGE HAND SHUTOFF VALVE TEE FITTING EVAPORATOR CONDENSER COMPRESSOR FILTER DRIER PROCESS TUBE ADAPTERS HOT TUBE ...

Page 80: ... 134a Refrigeration Systems The sealed refrigeration system will consist of the 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 dens...

Page 81: ...and cannot be used with R 12 R 12 contains chlorine or any other compound containing chlorine Therefore R 134a refrigeration systems have virtually no tolerance for chlorine molecules from CFC refrigerants R 134a is an HFC and contains no chlorine 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 ...

Page 82: ...ughly 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 To achieve 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 fi...

Page 83: ...s 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 pumps 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 it is ABSOLUTELY ESSENTIAL to have a shut off...

Page 84: ...gned 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 a non selective detector with R 134a Halogen specific detectors use a specialized sensor that allows detection of compounds containing chlorine fluorine bromine and iodine wi...

Page 85: ...117 2 10 23 3 1 9 4 5 105 40 6 134 3 126 6 5 20 6 4 1 6 7 110 43 3 145 6 136 4 0 17 8 6 5 9 2 115 46 1 157 6 146 8 5 15 0 9 1 11 8 120 48 9 170 3 157 7 10 12 2 12 0 14 6 125 51 7 183 6 169 1 15 9 4 15 0 17 7 130 54 4 197 6 181 0 20 6 7 18 4 21 0 135 57 2 212 4 193 5 25 3 9 22 1 24 6 140 60 0 227 9 206 6 30 1 1 26 1 28 5 145 62 8 244 3 220 3 35 1 7 30 4 32 6 150 65 6 261 4 234 6 40 4 4 35 0 37 0 15...

Page 86: ...ccur 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 i...

Page 87: ...ed 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 work 4 Install air monitoring...

Page 88: ...ank is filled Based on above information the following operating practices are recommended Leak Testing Equi pm entshoul dNEVER 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 underpositive air pressure Tank pressure shou...

Page 89: ...e 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 air is present DO NOT continue to evacuate a refrigeration system that has a major leak Thermal Decomposition HFC 134a vapors will decompose when exposed to high temperatures from flames or electric resistance heaters ...

Page 90: ... 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 operatin...

Page 91: ...ction out of the Mold The drive end of the 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 foood compartment into the Ice Mold The amount of water released is directly proportional to the length of time the Water Valve Switch is energ...

Page 92: ...g 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 adju...

Page 93: ...e front of theice 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 will not allow the ice maker to complete the revolution This switch can also be used to start the icemaker into a Harvest cycle Wiring A four prong plug connects the Ice Maker wiring to the cabinet wiring harness See Figure F3 ...

Page 94: ...er supply valve closed To manually cycle the Ice Maker push the ON OFF switch to the ON position and hold until the Ejector blades turn 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 addational testing is necessary you can turn the Ejector blades...

Page 95: ...s Subtracting 80 cc from 93 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 To Replace Front Cover See Figure F4 1 Remove ice from freezer 2 Ensure that Ice Maker is at room ...

Page 96: ...ly 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 7 Check Water Fill Cycle and adjust as required 8 Replace front Cover To Replace Motor 1 Remove Ice Maker from Freezer 2 Remove...

Page 97: ...hree screws holding Mounting Plate in place 4 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 5 Remove Fill Trough and bearing 6 Turn blades to 12 O clock position 7 Slide Ejector Blades back and up to remove 8 Replace in reverse order 9 Lubricate bearing ends of Ejector with Si...

Page 98: ...Loosen two Thermostat retaining clip mounting screws 5 Disconnect two thermostat wire leads and remove thermostat 6 Apply thermal mastic sealer to sensing surface of replacement thermostat to ensure a positive bond to mold 7 Replace thermostat in reverse order To Replace Thermal Cut Out TCO 1 Remove Ice Maker from Freezer 2 Remove front Cover 3 Remove three screws that attach Mounting Plate to Sup...

Page 99: ...12 Apply layer of thermal mastic sealer to Mold groove 13 Install replacement Mold Heater 14 Replace parts in reverse order Ensure that Thermostat gasket is in place Bond the Thermostat to Mold with thermal mastic sealer 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...

Page 100: ...eck 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 Re...

Page 101: ...that the Water Valve Switch is adjusted for proper water fill 78 to 83 cc s 5 Check thermal bond between Thermosat and Mold If necessary rebond with thermal mastic sealer 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 Has refrigerator been properly ...

Page 102: ...ating 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 Electric 1 NC C NC C NO NO Ice Maker connected to electricity Mold temperature above 15 F Motor not rotating Mold Heater off Control Arm in the down position ON OFF switch in the ON position Shut Off Switch...

Page 103: ... ON position Shut Off Switch closed C to NO Hold Switch closed C to NC Water Fill Switch open Thermostat closes Ice Maker Electric 3 NC C NC C NO NO 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...

Page 104: ...nging 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 Ice Maker Electric 4 NC C NC C NO NO 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 ...

Page 105: ...N 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 Ice Maker Electric 7 NC C NC C NO NO 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 ...

Page 106: ...tch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill Switch open Ice Maker Electric 9 NC C NC C NO NO 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 NC Hold Switch closed C to NO Water Fill Switch open Motor is rotating ...

Page 107: ...e ON position Shut Off Switch closed C to NC Hold Switch closed C to NO Water Fill Switch open Motor is rotating Ice Maker Electric 11 NC C NC C NO NO Ice Maker connected to electricity Mold temperature above15 F 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 Motor is ...

Page 108: ...witch in the ON position Shut Off Switch closed C to NO Hold Switch closed C to NO Water Fill Switch closed Motor is rotating Ice Maker Electric 13 NC C NC C NO NO Ice Maker connected to electricity Mold temperature above15 F 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...

Page 109: ...itch closed C to NC Water Fill Switch open Motor not rotating Operating Cycle Illustrations Mechanical Step 1 Water Ice Storage Bin Water Ice Storage Bin C o n t r o l A r m Ejector 1 Mold is filled with water 2 Thermostat is open 3 All components are de energized Freezer Cycle Step 2 Water Ice Storage Bin Water Ice Storage Bin C o n t r o l A r m Ejector 1 Thermostat closes 2 Mold heater Motor is...

Page 110: ...ns on preventing water fill Harvest Cycle Ice Storage Bin C o n t r o l A r m Ice Storage Bin Ejector Ice Step 6 1 End of 1st revolution 2 Hold Switch opens 3 Since Thermostat is still closed 2nd revolution of Ejector begins Harvest Cycle Ice Storage Bin Ice Storage Bin C o n t r o l A r m Ejector Ice Water Ice Storage Bin Water Ice Storage Bin C o n t r o l A r m Ejector 1 Holding Switch in norma...

Page 111: ...of Ejector Water Fill Switch closes and water fills mold Fill Cycle Ice Ice Ice C o n t r o l A r m Ejector Water Ice Storage Bin 1 Hold Switch goes to normally closed position 2 Water Fill Switch opens 3 Freeze Cycle begins End of Fill Cycle Ice Ice Ice C o n t r o l A r m Ejector Water Ice Storage Bin 1 Hold Switch closes 2 Motor energizes 3 Mold Heater remains energized 4 Shut Off Arm raises an...

Page 112: ...105 Section F Ice Maker ...

Page 113: ......

Page 114: ...er 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 1 Disconnect refrigerator from electrical supply 2 Remove Ice Cream Shelf and slide Ice Container forward and off Rail Assembly 3 Loosen ...

Page 115: ...screws on bottom of Rail Assembly holding it to mounting brackets Unplug Molex connector Lift up on Rail Assembly and pull forward freeing it from mounting brackets 5 Remove 4 screws holding back cover to rail assembly Remove foam block over solenoid coil 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 solen...

Page 116: ...over 6 Press in on two tabs on bottom of lamp socket base and push through mounting hole See Figure G4 7 Replace lamp socket in reverse order ICEAUGER CRUSHERASSEMBLY To remove Ice Auger 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 c...

Page 117: ...d water side by sides Seven Selection Dispenser See Figure 2 1 Extreme Freeze Press to drop freezer temp to 6 F for a period of 16 hours 2 Extra Ice Press to increase ice production for a period of 12 hours 3 Cube Press to get cubed ice 4 Crush Press to get crushed ice 5 Light Press to turn on light in dispenser 6 Filter RESET Press and Hold five seconds to reset light This light will tell you whe...

Page 118: ...zer temp to 6 F for a period of 16 hours 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 Statis Press and Hold five seconds to reset light This light will tell you when to replace the water filter 6 Lock Press to disable dispenser Child Lock Electrical Mechanical Dispenser SeeFigure5 1 Cube Press to get cubed ice 2 Crush Press to ...

Page 119: ...models the tabs are on the sides See Figure 9 Swing panel out to side being careful not to pull the ribbon connector for the control board Carefully unplug the ribbon connector from the power board on the dispenser in the door See Figure 10 This will give you access to the power board See Figure 11 Figure 8 Remove screws Icon Models All Other Models Figure 10 Unplug the ribbon from the power board...

Page 120: ...enoid The switch contacts should show open the off position and closed in the on position for the light The switch contacts for cube ice should show closed and should show open for crushed position See Figure 14 On models with electronic control to gain access to the control snap the light socket loose and remove the 6 small screws from the board See Figure 15 Pull board straight out of housing Di...

Page 121: ...nd lifting 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 Figure21 The door closer is mounted on the side of the housing See Figure 21 and connected to the door arm with a gear wheel to slow the closing of the door See F...

Page 122: ... at each end of the actuator and the two bladed spring in the middle See Figure 25 The actuators can be removed by removing the 4 screws and lifting the paddle ice chute out of the housing On models electrical mechanical switch the dispenser will come apart the same way as models with a control board The difference is the wiring to the actuator switches and the selector switch are connected direct...

Page 123: ... plug as the original heater See Figure 28 Fast Freeze Fast Ice When you select the Fast Freeze Acceler Freeze the control board sends a signal to the main power supply 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 send a signal to the main power supply for a 12 hour period to maintain a ...

Page 124: ... 32 The relays mounted on the board are numbered See Figure 33 K1 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 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...

Page 125: ...traight out Remove the control board from the front face plate and pull straight down on the lock tab holding the ribbon into the control board See Figure 37 Now you can unplug the ribbon from the control board The ribbon can be tested with a Multimeter using the Ohm setting and test for continuity on each pass of the ribbon When installing a ribbon into the power or the control board make sure th...

Page 126: ... the heater so it is on 50 of the time for a 12 hour period of time Should show O voltage until the Extra Ice button is pushed then should show line voltage To test the voltage from the power board located in the dispenser to the control board located in the front face plate use the low voltage section of the power board as shown in figure 40 To test 1 Check voltage between GND and V IN for input ...

Page 127: ...e between the two terminals shown in figure 3 under Auger for testing power from the control board to the relay that operates the auger motor Should read 0 voltage until the ice actuator is pushed in then you should read 5 VDC 10 NOTE Dispenser control board must be set for CUBE to operate the cube ice solenoid light relay Should read 0 voltage until the light switch button is pressed or an actuat...

Page 128: ... years The only difference is there are two small wires coming off the paddle with a plug on the end This plug will connect to pins on the power board See Figure 42 and 43 This will allow the servicer to replace the paddle with the lights attached Models with lighted paddles will use a different power board then models with the standard dispenser light off to the side The difference being the two ...

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Page 130: ...s of the dual coil valve The diodes are used to prevent current leakage from opening both coils on the dual coil valve everytime 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 into the ice maker and coming out the door at the same tim...

Page 131: ... psi Water Tanks Counter Depth refrigerators will have a roll tube tank Assembly as shown in Figure H4 The water line from the primary water valve single coil valve goes behind the trim located on the right side of the inside food compartment liner to the water filter From the water filter the line goes to the water tank then to the secondary water valve two coil valve The two coil valve dispenses...

Page 132: ...125 Section H Water System Figure H6 Rear Filter System Front Filter System Figure H5 ...

Page 133: ...ee figure H8 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 effect the coil on the secondary valve the secondary valve will open but if the primary valve does not open you will not supply water to the secondary valve TAN YELLOW TAN WITH YELLOW TRACER Figure H8 Diode Replacement Kit 5303918287 For Ice Water Model ...

Page 134: ... 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 Voltage Drop From Heater 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 11...

Page 135: ...y valve Place the line in a bucket Ice Maker Valve Run the ice maker through a fill and see if water will pass through the primary 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 valve If water is coming thr...

Page 136: ...rough the same plugs to the diode harness A 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 ...

Page 137: ...Voltage at Outlet Voltage at Coil 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 Voltage at 0utlet Voltage at Coil 120 VAC 50 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 Less than 10 VAC Open Dio...

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