GE Monogram ZDIS150WSS, Monogram ZDIS150WWW, Monogram ZDIS150WBB Technical Service Manual
GE Appliances & Lighting
Technical Service Guide
March 2010
Monogram
Under-the-Counter
Icemaker
ZDIS150WWW
31-9196
ZDIS150WSS
ZDIS150WBB
GE Appliances
General Electric Company
Louisville, Kentucky 40225
IMPORTANT SAFETY NOTICE
The information in this service guide is intended for use by
individuals possessing adequate backgrounds of air conditioning
and heat pump experience. Any attempt to repair an air conditioning
or heat pump system may result in personal injury and property
damage. The man u fac tur er or seller cannot be responsible for the
in ter pre ta tion of this in for ma tion, nor can it assume any liability in
connection with its use.
WARNING
To avoid personal injury, disconnect power before servicing air conditioning
or heat pu mp sy stem s. If e lectrical powe r is r equ ire d fo r dia gnosi s or tes t
purposes, disconnect the power immediately after performing the
necessary checks.
RECONNECT ALL GROUNDING DEVICES
If grounding wires, screws, straps, clips, nuts, or washers used to
complete a path to ground are removed for service, they must be
returned to their original position and properly fastened.
All rights reserved. This service guide may not be reproduced in whole or in part
in any form without written permission from the General Electric Company.
GE Appliances & Lighting
Technical Service Guide
Copyright © 2010
– 2 –
Table of Contents
Bin Light Bulb .....................................................................................................................................................................18
Bin Thermistor ....................................................................................................................................................................19
Care and Cleaning ......................................................................................................................................................... 13
Component Locator ........................................................................................................................................................16
Components ........................................................................................................................................................................18
Component Testing..........................................................................................................................................................32
Compressor .........................................................................................................................................................................27
Condenser ............................................................................................................................................................................29
Condenser Fan Motor .....................................................................................................................................................24
Control Board Diagnostics ............................................................................................................................................35
Control Features ................................................................................................................................................................12
Cutter Grid ............................................................................................................................................................................19
Door and Gasket ...............................................................................................................................................................18
Electronic Control Housing Components ..............................................................................................................21
Evaporator ...........................................................................................................................................................................29
Evaporator Thermistor ...................................................................................................................................................20
Features and Benefi ts ..................................................................................................................................................... 5
Hot Gas Solenoid...............................................................................................................................................................26
Hot Gas Valve .....................................................................................................................................................................27
Measured Fill Water Valve ............................................................................................................................................ 26
Nomenclature ....................................................................................................................................................................4
Reservoir Drain Pump .....................................................................................................................................................24
Schematics and Strip Circuits .....................................................................................................................................42
Sealed System ...................................................................................................................................................................27
Service Test Mode (Diagnostic Mode) ................................................................................................................... 40
Specifi cations .....................................................................................................................................................................5
Theory of Operation ........................................................................................................................................................6
Troubleshooting ................................................................................................................................................................37
Warranty .............................................................................................................................................................................. 44
Water Distributor ..............................................................................................................................................................20
Water Level Sensor ..........................................................................................................................................................23
Water Recirculation Pump ........................................................................................................................................... 22
– 3 –
Model Number
Nomenclature
Z D I S 150 W S S
Monogram
Ice Machine
Built-In
Stainless Capacity - 50 lbs
Nomenclature Tag
The nomenclature tag is located on the right
side of the ice bin. This tag contains important
information such as:
• Model/serial number
• Refrigerant charge
• Voltage rating
SS - Stainless Steel
BB - Black
WW - White
Model Year - 2009
Serial Number
The fi rst two characters of the serial number
identify the month and year of manufacture.
Example: AT123456S = January, 2010
A - JAN 2010 - T
D - FEB 2009 - S
F - MAR 2008 - R
G - APR 2007 - M
H - MAY 2006 - L
L - JUN 2005 - H
M - JUL 2004 - G
R - AUG 2003 - F
S - SEP 2002 - D
T - OCT 2001 - A
V - NOV 2000 - Z
Z - DEC 1999 - V
The letter des ig nat ing
the year re peats every
12 years.
Example:
T - 1986
T - 1998
T - 2010
Note: The Mini-Manual is located behind the
front cover panel. It is folded and tucked into
one of the loops of the condenser coil.
– 4 –
Specifi cations
AC Power Supply . . . . . . . . . . . . . . . . . . . 97 to 127 VAC (rated 115 VAC), 60 Hz
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Amps (max)
Minimum Circuit Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Amps
Ice Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 in. x 3/4 in. Square
Ice Thickness @ Normal Setting (Approximate) . . . . . . . . . . . . . . 0.32 in. (8.1 mm)
Ice Thickness @ Thin Setting (Approximate) . . . . . . . . . . . . . . . . . 0.28 in. (7.1 mm)
Ice Thickness @ Thick Setting (Approximate) . . . . . . . . . . . . . . . . .0.3915 In. (9.9 mm)
15 In. Storage Capacity (Approximate). . . . . . . . . . . . . . . . . . . . 25 lbs (11.3 kg)
Exterior Dimensions (W x D x H). . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 or 18 in. x 24 in. x 34 in.
(381 or 457.2 x 609.6 x 863.6 mm)
Exterior Finish . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless Steel or Painted Steel
Net Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 in. = 94 lbs (42.6 kg)
Cube Thickness Control . . . . . . . . . Water Level Sensor & Control Board Setting
Harvest Control . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermistor under Evaporator
Bin Ice Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . Thermistor on Side of Bin
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R134a
Ambient Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 to 100°F
Water Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 120 psig
Water Consumption (Dependent on Water Pressure) 6 to 10 gallons per 4 hours
Features and Benefi ts
Daily Ice Production at Ambient Temperatures
Ambient Temperature
70°F (21°C) 46 lbs (21 kg)
80°F (27°C) 47 lbs (21 kg)
90°F (32°C) 40 lbs (18 kg)
100°F (38°C) 40 lbs (18 kg)
110°F (43°C) 38 lbs (17 kg)
Water Temperature
60°F (15°C)
Hidden Electronic Controls allow for a fully •
integrated look.
Clean Sensor with LED Indicator•
Lighted Bin with Ice Scoop•
Reversible Door•
Daily Ice Production up to 50 lbs•
Water Level Sensor•
Electronic, LED Controls•
Drop-Down Door•
Clean Light•
Automatic Shut-Off•
– 5 –
Theory of Operation
Operating Systems
There are 3 operating systems in the icemaker:
Electrical System•
Refrigeration System•
Water System•
Electrical System
The icemaker’s electrical system provides power for
the refrigeration and water systems and controls
the operation of each component.
– 6 –
(Continued next page)
Refrigeration System
The refrigeration system is very similar to the
system used in other refrigeration appliances. The
refrigerant used in this unit is R134a.
There are 2 very important additions to the
refrigeration system in this Icemaker: the hot gas
valve and the condenser accumulator tube.
The 1. hot gas valve allows high pressure
refrigerant gas to bypass the condenser and
fl ow through the condenser accumulator tube.
Hot gas pushes liquid refrigerant through 2.
the condenser accumulator tube into
the evaporator, helping to evenly heat the
evaporator plate so that the ice slab releases
quickly and evenly.
Evaporator
Capillary Tube
Heat Exchanger
Hot Gas
Valve
Path of warm liquid refriger-
ant pushed by high-pres-
sure refrigerant gas
Accumulator
Condenser
Accumulating
Tube
Condenser
Suction
Tube
Drier
Compressor
– 7 –
High-Pressure
Refrigerant Gas
Warm Liquid
Refrigerant
Low-Pressure
Refrigerant Gas
(Continued next page)
Water System
The water system provides:
Fresh water for ice production•
Water recirculation as ice is produced•
Water removal after ice is produced•
The water system circulates water on the
evaporator to freeze into ice during the freeze cycle.
During the harvest cycle, it drains away minerals
and contaminates. During the clean cycle, cleaning
Water System Component Locations
Evaporator
solution is circulated to clean the system of minerals
and contaminates.
The hardness of the water supplied to the icemaker
will affect the quality of the ice that is produced. It
may also affect the operation of the water system.
A water softener, or poly-phosphate feeder, will not
cure all of the problems associated with hard water,
but they can be used to reduce scale buildup in the
icemaker.
Water Distributor
Water Return Tube
Water Valve Outlet Tube
Measured Fill
Water Inlet Valve
From Water Supply
Manual Drain
Drain Overfl ow
– 8 –
Water Level Sensor
Water Recirculation Pump
Reservoir Pan
Reservoir Drain Pan
Bin Drain
(Continued next page)
Operational Modes
There are 4 main operational modes for the
icemaker:
Ice-making cycle (Freeze Mode) 1.
Harvest2.
Clean3.
Service (Diagnostics)4.
Ice-Making Cycle (Freeze Mode)
There are 3 possible “Off” cycles for the icemaker.
They occur when:
The bin is full of ice and the ON LED is 1.
illuminated (Idle Mode).
The OFF control pad has been held for 3 sec. 2.
(The ON LED will go out.)
The power is interrupted by overfi ll. (Model ZPK1 3.
only with internal drain pump.)
Electrical System: Line voltage is supplied to
the electrical control switches and the primary
side of the step-down dual transformer. The dual
transformer reduces 120 VAC to 8.75 VAC for the
cutter grid and the bin light, and 12 VAC for the
drain and recirculating pumps.
The electronic control board directs 12 VAC to the
water recirculating and reservoir drain pumps, and
120 VAC to the hot gas solenoid, condenser fan
motor, and compressor.
During the later stages of the freeze mode, an ice
slab forms on the evaporator freezing plate. This
ice slab causes some of the refrigerant passing
through the evaporator to not evaporate into a
gas, but remain a liquid. This liquid refrigerant
settles in the accumulator. The refrigerant vapor is
sucked off through the suction tube at the top of the
accumulator.
This accumulated liquid refrigerant will eventually
be directed to the evaporator to quickly warm the
evaporator plate during the harvest mode.
Caution: It is very important that the accumulator
is not tilted out of a horizontal position. If moved, it
could cause compressor failure.
Water System: The water recirculation pump
moves the water from the reservoir pan up to the
distributor. The water fl ows out over the evaporator
freezing plate. Water that does not freeze on the
evaporator plate runs off the front edge. It falls back
into the reservoir, where it is recirculated back to the
water distributor.
As the ice slab forms, the minerals in the water are
on the surface of the ice. The water fl owing over
the top of the ice slab washes these minerals back
into the water reservoir pan. The water continues to
recirculate until the water level in the reservoir drops
below a level determined by the water level sensor.
At this point, the control terminates the freeze mode
and initiates the harvest mode.
The measured fi ll water inlet valve will always
have 120 VAC on the black and white wires and
14 VDC on the orange/white and black/red wires.
An evaporator thermistor supplies temperature
information to the electronic control to determine
when to terminate the harvest cycle. A water level
sensor initiates the next harvest.
Refrigeration System: The hot gas refrigerant,
under high pressure, is forced through the
condenser, where it changes into a liquid and
fl ows through the drier and capillary tube into the
evaporator. Under low pressure in the evaporator,
the liquid refrigerant absorbs heat from the
water fl owing over the evaporator and the liquid
refrigerant changes to gas. As a low-pressure gas,
the refrigerant fl ows back through the suction line of
the heat exchanger to the compressor.
During the freeze mode, some of the hot gas that is
in the condenser accumulating tube condenses to a
liquid and remains in the accumulating tube.
– 9 –
(Continued next page)
Harvest Mode
Electrical System: When the water level in the
reservoir drops below the water level sensor, it
signals the electronic control to terminate power to
the condenser fan, and then the water recirculating
pump. The reservoir drain pump is activated (on for
20 sec., off 20 sec., back on for 20 sec.), to fully drain
the reservoir. Power is then supplied to the hot gas
valve and a fi ll request is sent to the measured fi ll
water inlet valve. The fi ll valve fi lls to the requested
volume while the hot gas valve is energized for
the balance of the harvest mode. If the evaporator
thermistor is unplugged, the evaporator defaults to
a timed 4-minute harvest.
If the water level sensor is disconnected or open, the
control defaults to 25 minutes of freeze time. The
cleaning indicator LED feature will not function if the
water level sensor is disconnected.
Refrigeration System: The hot gas valve opens,
allowing high-pressure refrigerant gas to bypass
the condenser, and fl ow through the condenser
accumulating tube. The hot gas pushes the
liquid refrigerant that has accumulated in the
accumulator tube up into the evaporator. The hot
liquid refrigerant evenly heats the evaporator plate
so that the ice slab releases quickly and evenly.
Water System: The reservoir drain pump is
activated (on for 20 sec., off 20 sec., back on for 20
sec.) to fully drain the reservoir. When fully drained,
the electronic control board sends a signal to the
water valve. The signal tells the measured fi ll water
inlet valve how much water is to be fi lled, allowing
water to fl ow into the water reservoir pan. The water
fi ll volume is determined by the ice thickness setting.
Thin Ice uses 32oz (954cc), Normal Ice uses 37oz
(1106cc) and Thick Ice uses 42.5oz (1258cc).
Note: Two minute maximum fi ll. The cycling
between freeze and harvest continues until the ice
bin is full. The electronic control board operates the
various components and systems in the icemaker
for each of the freeze and harvest modes.
Clean Mode (CLEAN LED on Amber, then Red)
The CLEAN LED turns from green to amber, then to
red. The CLEAN LED will turn from green to amber
after 50 hung slabs* or 3500 freeze cycles. The
CLEAN LED will then turn to red after 70 hung slabs*
or 4000 freeze cycles.
With the CLEAN LED on red and steady, the unit
must be cleaned to turn it off. When the clean cycle
is complete (approximately 70 minutes), the CLEAN
LED will be green and the OFF LED will be red.
The ice slab, when released, slides off of the
evaporator plate onto the cutter grid.
As a result of the hot gas fl ow and the ice sliding off
the evaporator plate, the evaporator temperature
begins to rise. When the evaporator thermistor
reaches the set temperature (52°F), the unit switches
to the Freeze Mode.
Select and hold the OFF pad for 3 seconds to turn
the unit off. Then press the ON pad to turn the unit
on. Customer instructions for Clean Cycle are on the
inside of the door.
*Hung Slab: If the time between the start of a freeze cycle
and the start of the harvest cycle is less than fi ve minutes, the
control will count a hung slab.
– 10 –
(Continued next page)
Electrical System: The electronic control board
operates the various components and systems
during the clean mode. The clean mode may only
be selected while the icemaker is turned off (OFF
button held 3 sec.) at the user interface.
When the clean mode begins, the clean light fl ashes
1 sec. on then 1 sec. off. The circulation pump,
compressor, and hot gas valve are energized for
40 min.
The measured fi ll water inlet valve is energized
for 3 minutes, and then the recirculation pump is
energized for 3 minutes. This process is repeated 5
times for a total of 30 minutes.
The electrical control board turns all components
off. The CLEAN LED remains on with reservoir full.
Refrigeration System: The compressor and hot
gas valve operate to heat the evaporator. The
evaporator thermistor will cycle the compressor off
at 125°F and on at 95°F.
Water System: When the icemaker is in the CLEAN
mode, the water recirculating pump circulates
the cleaning solution that has been added to the
reservoir up to the water distributor, across the
evaporator, and back into the reservoir, where it is
recirculated.
Note: Do not continue with the diagnosis of the ice
maker if a fuse is blown, a circuit breaker is tripped,
or if there is less than a 120-Volt power supply at
the wall outlet. All units that have failed during the
fi rst few days of use should be checked for loose
connections or miswiring.
– 11 –
Control Features
User Controls
To start the normal ice making cycle, select 1. ON.
To stop icemaker operation, press and hold 2. OFF.
Note: The CLEAN setting is used whenever solutions
are circulated through the icemaker for cleaning.
How the Icemaker Works
When you fi rst start your icemaker, the water
reservoir will fi ll and the system will rinse itself
before starting to make ice. The rinsing process
takes about 5 min.
Under normal operating conditions, the icemaker
will cycle on and off as needed. The ice level sensor
located in the ice storage bin will monitor the ice
levels.
Notes:
When the desired thickness is reached, the ice 2.
sheet is released and slides onto a cutter grid.
The grid divides the sheet into individual cubes.
The water containing the rejected minerals is 3.
drained after each freezing cycle.
Fresh water enters the machine for the next ice-4.
making cycle.
Cubes fall into the storage bin. When the bin 5.
is full, the icemaker shuts off automatically
and restarts when more ice is needed. The ice
bin is not refrigerated and some melting will
occur. The amount of melting varies with room
temperature.
If the water supply to the icemaker is turned off, •
be sure to set the icemaker control to OFF. Drain
the water reservoir and leave the icemaker door
open to allow it to dry completely.
The icemaker is designed to make clear ice from •
the majority of water sources on a daily basis. If
your results are unsatisfactory, your water may
need to be fi ltered or treated.
Making Ice
Water is constantly circulated over a freezing 1.
plate. As the water freezes into ice, the minerals
in the water are rejected. This produces a clear
sheet of ice with a low mineral content.
Note: As the room and water temperatures vary,
so will the amount of ice produced and stored. This
means that higher operating temperatures result in
reduced ice production.
– 12 –
(Continued next page)
Care and Cleaning
Caring for the Icemaker
The CLEAN light signal will illuminate yellow when
the electronic control senses that the need for
cleaning is approaching. At this time you need to
purchase
nickel-safe ice machine cleaner
by
Nu-Calgon, available at most appliance repair shops
or through GE Parts and Accessories. Order part
number WX08X42870. In the U.S.A., call 1-800-626-
2002 or visit Monogram.com. In Canada call 1-800-
561-3344. The CLEAN light will eventually turn
red which means the icemaker must be cleaned,
otherwise ice production will decrease signifi cantly
or stop altogether.
IMPORTANT: For best results, use the entire contents
of the bottle to clean the unit. (See Icemaker System.)
The air-cooled condenser needs to be cleaned
regularly for effi cient ice production and energy
conservation.(See Cleaning the Condenser.)
Exterior surfaces
Door handles and trim―Clean with a cloth
dampened with soapy water. Dry with a soft cloth.
Keep the outside clean. Wipe with a clean cloth
lightly dampened with mild liquid dish detergent.
Dry with a clean, soft cloth. Do not wipe the
icemaker with a soiled dish cloth or wet towel. These
may leave a residue that can damage the fi nish.
Do not use scouring pads, powdered cleaners,
bleach or cleaners containing bleach because these
products can scratch and damage the fi nish.
Press and hold the 1. OFF button for 3 seconds.
Wait 5 to 10 minutes for the ice to fall into the 2.
storage bin. Remove all ice from the storage bin.
Unscrew the drain cap from the bottom of the 3.
water reservoir located inside the storage bin as
shown. Allow the water to drain completely.
Drain cap
Water reservoir
Replace the drain cap.4.
For best results, use the entire 16 oz. bottle of 5.
nickel-safe ice machine cleaner
. Follow all
safety precautions on the bottle. Pour one bottle
of solution into the water reservoir. Fill the bottle
twice with tap water and pour it into the water
reservoir.
Press and hold the CLEAN button for 3 sec. The 6.
CLEAN light will begin to blink, indicating that
the cleaning cycle is in process. The cleaning
time is approximately 70 min.
Stainless steel―Regularly clean and polish the
stainless steel door panels and handles (on some
models) with a commercially available stainless
steel cleaner such as Stainless Steel Magic™
to preserve and protect the fi ne fi nish. Stainless
Steel Magic is available through GE Parts and
Accessories, 800.626.2002, or monogram.com.
Order part number WX10X15. Do not use appliance
wax or polish on the stainless steel.
Icemaker System
Note: To remove stubborn buildup, pour a small
amount of cleaning solution on a non-scratching,
blue Scotch-Brite™ pad. Using only front-to-back
motions, clean the top of the plate, the sidewalls,
and the front edge of the evaporator. The frontto-back motion is important to avoid scratches
that could keep the ice slab from sliding off the
evaporator plate.
– 13 –
When the indicator light becomes solid and 7.
remains lit, the cleaning cycle is complete.
During the cleaning cycle, the system will both
clean and rinse itself.
After the cleaning cycle is complete, remove 8.
the drain cap from the water reservoir to see
if any cleaning solution, green in color, is left in
the water reservoir. If cleaning solution drains
from the water reservoir, you should run the
clean cycle again adding only tap water to
the reservoir. Be sure to replace the drain cap
before running the cycle again. If the cap is not
securely tightened, water can leak, causing thin
ice or no ice.
(Continued next page)
Note: Severe scale buildup may require repeated
cleaning with a fresh quantity of cleaning solution.
Press the 9. ON button for 3 sec. to resume ice
production.
Cleaning the Condenser
For best performance, brush or vacuum lint and dirt
from the condenser at least once a year. A dirty or
clogged condenser:
Uses more energy.•
Reverse-Osmosis System
IMPORTANT: The performance of the icemaker may
be affected when connected to a reverse-osmosis
system. An RO system may also reduce water
pressure and affect the fi ll cycle, which is dependent
on time and fl ow. The reduced water pressure may
cause the reservoir not to fi ll and fl ush properly
during the ice-making cycle. The pressure of the
water supply coming out of a reverse-osmosis
system going to the measured fi ll water inlet valve
of the icemaker needs to be between 30 and 120 psi.
Prevents proper airfl ow.•
Reduces ice-making capacity.•
Causes higher-than-recommended operating •
temperatures, which may lead to component
failure.
Unplug the icemaker or disconnect power.1.
Remove the 2 screws in the lower access panel 2.
and the 2 screws from the base grille area of the
front panel support. Pull forward to remove the
lower access panel.
Pull the bottom forward and then pull down to 3.
remove the lower access panel.
If a reverse-osmosis water fi ltration system is
connected to your cold water supply, the water
pressure to the reverse-osmosis system needs
to be a minimum of 40 psi. The reverse-osmosis
system must provide 1 gal. of water per hour to the
icemaker for proper icemaker operation.
Note: Do not use copper tubing when the icemaker
is connected to a reverse-osmosis water system.
Remove dirt and lint from the condenser 4.
fi ns and the unit compartment with a brush
attachment attached to a vacuum cleaner.
Replace the lower access panel using the 4 5.
screws.
Plug in the icemaker or reconnect power.6.
– 14 –
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