Jenn-Air Jenn-Air, Integrated Side by side refrigerators Service Manual

Service

Integrated Side-by-Side Refrigerators

Service Manual for Jenn-Air® models

This Base Manual covers Integrated Side-by-Side Refrigerators Refer to individual Technical Sheet for information on specific models.

This manual is to be used by qualified appliance technicians only. Maytag does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person.

16021730

July 2002

Important Information

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE

APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS.

Important Notices for Consumers and Servicers

WARNING

To avoid risk of serious injury or death, repairs should not be attempted by unauthorized personnel, dangerous conditions (such as exposure to electrical shock) may result.

CAUTION

Maytag will not be responsible for any injury or property damage from improper service procedures. If performing service on your own product, assume responsibility for any personal injury or property damage which may result.

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

MAYTAG APPLIANCES SALES COMPANY OR U.S. and Canada 1-800-Jenn-Air ATTN:Jenn-Air CAIR P.O. Box 2370 impaired, call 1-800-688-2080 Cleveland, TN 37320-2370

If outside the United States contact:

Recognize Safety Symbols, Words, and Labels

Center CALL U.S. customers using TTY for deaf, hearing

MAYTAG APPLIANCES SALES COMPANY ATTN: Jenn-Air CAIR® Center P.O. Box 2370 Cleveland, TN 37320-2370 Telephone: 1-800-Jenn-Air (1-800-536-6247)

DANGER

DANGERImmediate hazards which WILL result in severe personal injury or death.

WARNING

WARNINGHazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION

CAUTIONHazards or unsafe practices which COULD result in minor personal injury or product or property

damage.

16021730 Rev. 0 2

Table of Contents

Important Information .................................................... 2

Component Testing ....................................................... 4

Service Procedures ....................................................... 7

Service Equipment ........................................................ 7

Drier Replacement ........................................................ 7

Refrigerant Precautions ................................................. 7

Line Piercing Valves ...................................................... 7

Open Lines ................................................................... 8

Dehydrating Sealed Refrigeration System ..................... 8

Leak Testing .................................................................. 8

Testing Systems Containing a

Refrigerant Charge ................................................... 8

Testing Systems Containing

No Refrigerant Charge ............................................. 8

Restrictions ................................................................... 8

Symptoms .............................................................. 8

Testing for Restrictions ........................................... 9

Evacuation and Charging ............................................... 9

Evacuation .............................................................. 9

Charging ................................................................ 10

Refrigerant Charge ................................................. 10

HFC134a Service Information ....................................... 11

Health, Safety, and Handling .................................. 11

Comparison of CFC12 and HFC134a Properties ..... 11

Replacement Service Compressor ................................12

Brazing ........................................................................12

Refrigerant Flow ...........................................................13

Cabinet Air Flow ........................................................... 14

Ice and Water Flow Diagram ........................................ 15

Water Valves Diagram .................................................. 16

Troubleshooting Chart................................................17

System Diagnosis ........................................................ 20

Disassembly Procedures

Compressor Replacement ...................................... 23

Condenser Replacement ........................................ 24

Evaporator Replacement ........................................ 25

Heat Exchanger Replacement ............................... 27

Condenser Fan ...................................................... 28

Freezer Fan ...........................................................28

Fresh Food Fan .....................................................28

Defrost Heater ....................................................... 29

Drain Pan and Drain Tube Heater ........................... 30

Defrost Thermistor .................................................30

Auto Damper Stepper ............................................30

Ice & Water Fountain PC Board .............................30

Touch Fountain Board ............................................32

Fountain Bracket ................................................... 32

Ice Crusher Bin & Shelf.......................................... 33

Climate Zone Technolgy (CZT) ...............................35

Climate Zone Bulb Upper ....................................... 36

Climate Zone Bulb Lower ....................................... 36

Cimate Zone Test ...................................................37

Diagnostic Mode Procedures .................................38

Power Supply Diagnostics .....................................39

Diagnostic Control Mode ........................................ 40

Appendix A

Owners Manual ........ ........................................A-2

Appendix B

Installation Guide ................................................. B-2

3 16021730 Rev. 0

Component Testing

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test procedures require power to be connected. Discharge capacitor through a resistor before attempting to service. Ensure all ground wires are connected before certifying unit as repaired and/or operational.

Component Description Test Procedures

Variable Capacity Compressor

When compressor electrical circuit is energized the DC powered compressor is started at high speed or 4500 RPM down to 1600 RPM. For low speed from the compressor PCB board.

Resistance test

1. Disconnect power to unit.

2. Remove leads from compressor terminals.

3. Set ohmmeter to lowest scale.

4. Check for resistance between any two terminals. Resistance should be equal between any two terminals.

5. If either compressor winding reads open (infinite or very high resistance) or dead short (0 ohms), replace compressor.

Ground test

1. Disconnect power to refrigerator.

2. Remove compressor leads and use an ohmmeter set on highest scale.

3. Touch one lead to compressor body (clean point of contact) and other probe to each compressor terminal.

• If reading is obtained, compressor is grounded and must be replaced.

Operation test

If voltage and motor winding tests do not show cause for failure, perform the following test:

1. Activate the Diagnostic test mode (See Diagnostic test mode section)

2. Activate Test mode #16 (which is High Speed for compressor)

3. Check the A/C voltage between pins 1 and 2 of JP10 (Voltage should be

approximately 2.3VAC)

4. Verify that line voltage is available to Compressor PCB at CNO1 between

pins 2 and 5 If AC voltage is there.

5. Check voltage at CNO5 at pins 1 and 6 voltage should read approximately

230VAC

6. Check Voltage at CNO5 at pins 1 and 3 voltage should read approximately

230VAC

7. Check Voltage at CNO5 at pins 3 and 6 voltage should read approximately

230VAC

8. The readings at all three above readings should be the same if not bad

PCB board

9. If voltage is the same suspect a failed compressor.

16021730 Rev. 0

Component Testing

WARNING

Component Description Test Procedures

Condenser Condenser is a tube and fin construction

located in machine compartment.

Condenser is on high-pressure discharge side of compressor. Condenser function is to transfer heat absorbed by refrigerant to ambient.

Higher-pressure gas is routed to condenser where, as gas temperature is reduced, gas condenses into a highpressure liquid state. Heat transfer takes place because discharged gas is at a higher temperature than air that is passing over condenser. It is very important that adequate airflow over condenser is maintained.

Condenser is air cooled by condenser fan motor. If efficiency of heat transfer from condenser to surrounding air is impaired, condensing temperature becomes higher. High liquid temperature means liquid will not remove as much heat during boiling in evaporator as under normal conditions. This would be indicated by high than normal head pressures, long run time, and high wattage. Remove any lint or other accumulation that would restrict normal air movement through condenser.

Leaks in condenser can usually be detected by using an electronic leak detector or soap solution. Look for signs of compressor oil when checking for leaks. A certain amount of compressor oil is circulated with refrigerant.

Leaks in post condenser loop are rare because loop is a one-piece copper tube.

For minute leaks

1. Separate condenser from rest of refrigeration system and pressurize condenser up to a maximum of 235 PSI with a refrigerant and dry nitrogen combination.

2. Recheck for leaks.

WARNING

To avoid severe personal injury or death from sudden eruption of high pressures gases, observe the following:

Protect against a sudden eruption if high pressures are required for leak checking. Do not use high-pressure compressed gases in refrigeration systems without a reliable pressure regulator and pressure relief valve in the lines.

From condenser the refrigerant flows into a post condenser loop which helps control exterior condensation on flange, center mullion, and around freezer door. Refrigerant the flows through the drier to evaporator and into compressor through suction line.

Refrigerator light switch

Thermostat Thermostat is in a series circuit with

Single pole, single throw switch completes circuit for light when door is open.

terminal 2 of defrost timer, and defrost heater. Circuit is complete if evaporator fan motor operates when cold.

Controls the circuit from freezer thermostat through defrost terminator to defrost heater. Opens and breaks circuit when thermostat senses preset high temperature.

Check resistant across terminals.

Switch arm depressed

“NO” terminals Open

Switch arm up

“NO” terminals Closed

Test continuity across terminals.

With power off and evaporator coil below freezing, thermostat should show continuity when checked with ohmmeter. See “Heater, evaporator (defrost)” section for additional tests.

After defrost thermostat opens, thermostat remains open until end of defrost cycle and refrigerator starts cooling again. Defrost thermostat senses a preset low temperature and resets (closes).

16021730 Rev. 05

Component Testing

WARNING

Drier Drier is placed at post condenser loop

outlet and passes liquefied refrigerant to capillary.

Desiccant (20) 8 x 12 4AXH - 7 M>S> Grams

Drier must be changed every time the system is opened for testing or compressor replacement.

NOTE: Drier used in R12 sealed system is not interchangeable with

drier used in R134a sealed system. Always replace drier in R134a system.

Before opening refrigeration system, recover HFC134a refrigerant for safe disposal.

1. Cut drier out of system using the following procedure. Do not unbraze drier.

2. Applying heat to remove drier will drive moisture into the system.

3. Score capillary tube close to drier and break.

4. Reform inlet tube to drier allowing enough space for large tube cutter.

5. Cut circumference of drier 1 ¼" below condenser inlet tube joint to drier.

6. Remove drier.

7. Apply heat trap paste on post condenser tubes to protect grommets from high heat.

8. Unbraze remaining part of drier. Remove drier from system.

9. Discard drier in safe place. Do not leave drier with customer. If refrigerator is under warranty, old drier must accompany warranty claim.

WARNING

To avoid death or severe personal injury, cut drier at correct location. Cutting drier at incorrect location will allow desiccant beads to scatter. If spilled, completely clean area of beads.

Evaporator Inner volume of evaporator allows liquid

Evaporator defrost heater

refrigerant discharged from capillary to expand into refrigerant gas.

Expansion cools evaporator tube and fin temperature to approximately -20 transferring heat from freezer section to refrigerant.

Passing through suction line to compressor, the refrigerant picks up superheat (a relationship between pressure and temperature that assures complete vaporization of liquid refrigerant) as the result of capillary tube soldered to suction line.

Refrigerant gas is pulled through suction line by compressor, completing refrigeration cycle.

Activated when Main control board activates defrost mode or when forced in Diagnostic mode.

Test for leaks in evaporator with electronic leak detector or with soap solution. Compressor oil is circulated with refrigerant; check for oil when checking for leaks.

For minute leaks

1. Separate evaporator from rest of refrigeration system and pressurize

evaporator up to a maximum of 140 PSI with a refrigerant and dry nitrogen combination.

2. Recheck for leaks.

WARNING

To avoid severe personal injury or death from sudden erruption of high pressurres gases, observe the following:

• Protect against a sudden eruption if high pressures are required for leak checking.

•

Do not use high pressure compressed gases in refrigeration systems without a reliable pressure regulator and pressure relief valve in the lines.

Check resistance across heaters. If resistance heater is open and should be replaced. In diagnostic mode test # 11 Energize heater (the defrost system should draw about 3 amps).

16021730 Rev. 0

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting to service. Ensure all ground wires are connected before certifying unit as repaired and/or operational.

Service Equipment

Listed below is equipment needed for proper servicing of HFC134a systems. Verify equipment is confirmed by manufacturer as being compatible with HFC134a and ester oil system.

Equipment must be exclusively used for HFC134a. Exclusive use of equipment only applies to italic items.

 Evacuation pump

Check with vacuum pump supplier to verify equipment is compatible for HFC134a. Robinair, Model 15600

2 stage, 6 cubic feet per minute pump is

recommended.

 Four-way manifold gauge set, with low loss hoses

 Leak detector  Charging cylinder

 Line piercing saddle valve

(Schroeder valves). Seals must be HFC134a and ester oil compatible. Line piercing valves may be used for diagnosis but are not suitable for evacuation or charging, due to minute holes pierced in tubing. Do not leave mechanical access valves on system. Valves eventually will leak. Molecules of HFC134a are smaller than other refrigerants and will leak where other refrigerants would not.

 Swagging tools

 Flaring tools

 Tubing cutter

 Flux  Sil-Fos  Silver solder

 Oil for swagging and flaring

Use only part # R0157532

 Copper tubing

Use only part # R0174075 and # R0174076

 Dry nitrogen

99.5% minimum purity, with -40°F or lower dew point  Crimp tool  Tube bender  Micron vacuum gauge

 Process tube adaptor kit

 Heat trap paste

 ICI appliance grade HFC134a

Drier Replacement

Before opening refrigeration system, recover HFC134a refrigerant for safe disposal.

Every time sealed HFC134a system is repaired, drier filter must be replaced.

Cut drier out of system by completing the following steps. Do not unbraze drier filter. Applying heat to remove drier will drive moisture into system.

1. Score capillary tube close to drier and break.

2. Reform inlet tube to drier allowing enough space for large tube cutter.

3. Cut circumference of drier at 1-1/4", below condenser inlet tube joint to drier.

4. Remove drier.

5. Apply heat trap paste on post condenser tubes to protect grommets from high heat.

6. Unbraze remaining part of drier. Remove drier from system.

7. Discard drier in safe place. Do not leave drier with customer. If refrigerator is under warranty, old drier must accompany warranty claim.

Refrigerant Precautions

WARNING

To avoid risk of personal injury, do not allow refrigerant to contact eyes or skin.

CAUTION

To avoid risk of property damage, do not use refrigerant other than that shown on unit serial number identification plate.

NOTE: All precautionary measures recommended by

refrigerant manufacturers and suppliers apply and should be observed.

Line Piercing Valves

Line piercing valves can be used for diagnosis, but are not suitable for evacuating or charging due to holes pierced in tubing by valves.

NOTE: Do not leave line piercing valves on system.

Connection between valve and tubing is not hermetically sealed. Leaks will occur.

7 16021730 Rev. 0

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting to service. Ensure all ground wires are connected before certifying unit as repaired and/or operational.

Testing Systems Containing No Refrigerant Charge

1. Connect cylinder of nitrogen, through gauge

Open Lines

During any processing of refrigeration system, never leave lines open to atmosphere. Open lines allow water vapor to enter system, making proper evacuation more difficult.

Dehydrating Sealed Refrigeration System

Moisture in a refrigerator sealed system exposed to heat generated by the compressor and motor reacts chemically with refrigerant and oil in the system and forms corrosive hydrochloric and hydrofluoric acids. These acids contribute to breakdown of motor winding insulation and corrosion of compressor working parts, causing compressor failure.

In addition, sludge, a residue of the chemical reaction, coats all surfaces of sealed system, and will eventually restrict refrigerant flow through capillary tube.

To dehydrate sealed system, evacuate system (see paragraph Evacuation).

Leak Testing

DANGER

To avoid risk of serious injury or death from violent explosions, NEVER use oxygen or acetylene for pressure testing or clean out of refrigeration systems. Free oxygen will explode on contact with oil. Acetylene will explode spontaneously when put under pressure.

It is important to check sealed system for refrigerant leaks. Undetected leaks can lead to repeated service calls and eventually result in system contamination, restrictions, and premature compressor failure.

Refrigerant leaks are best detected with halide or electronic leak detectors.

Testing Systems Containing a Refrigerant Charge

1. Stop unit operation (turn refrigerator off).

2. Holding leak detector exploring tube as close to system tubing as possible, check all piping, joints, and fittings.

NOTE: Use soap suds on areas leak detector cannot

reach or reliably test.

manifold, to process tube of compressor and liquid line strainer.

2. Open valves on nitrogen cylinder and gauge manifold. Allow pressure to build within sealed system.

3. Check for leaks using soap suds.

If a leak is detected in a joint, do not to attempt to repair by applying additional brazing material. Joint must be disassembled, cleaned and rebrazed. Capture refrigerant charge (if system is charged), unbraze joint, clean allparts, then rebraze.

If leak is detected in tubing, replace tubing. If leak is detected in either coil, replace faulty coil.

Restrictions

Symptoms

Restrictions in sealed system most often occur at capillary tube or filter drier, but can exist anywhere on liquid side of system.

Restrictions reduce refrigerant flow rate and heat removal rate. Wattage drops because compressor is not circulating normal amount of refrigerants.

Common causes of total restrictions are moisture, poorly soldered joints, or solid contaminants. Moisture freezes at evaporator inlet end of capillary tube. Solid contaminants collect in filter drier.

If restriction is on low side, suction pressure will be in a vacuum and head pressure will be near normal.

If restriction is on high side, suction pressure will be in a vacuum and head pressure will be higher than normal during pump out cycle.

Refrigeration occurs on low pressure side of partial restriction. There will be a temperature difference at the point of restriction. Frost and/or condensation will be present in most case at the point of restriction. Also, system requires longer to equalize.

Slight or partial restriction can give the same symptoms as refrigerant shortage including lower than normal back pressure, head pressure, wattage, and warmer temperatures.

Total restriction on the discharge side of compressor, when restriction is between compressor and first half of condenser, results in higher than normal head pressure and wattage while low side is being pumped out.

16021730 Rev. 0 8

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting to service. Ensure all ground wires are connected before certifying unit as repaired and/or operational.

Testing for Restrictions

To determine if a restriction exists:

1. Attach gauge and manifold between suction and discharge sides of sealed system.

2. Turn unit on and allow pressure on each side to stabilize. Inspect condenser side of system. Tubing on condenser should be warm and temperature should be equal throughout (no sudden drops at any point along tubing).

 If temperature of condenser tubing is consistent

throughout, go to step 4.

 If temperature of condenser tubing drops suddenly at

any point, tubing is restricted at point of temperature drop (if restriction is severe, frost may form at point of restriction and extend down in direction of refrigerant flow in system). Go to step 5.

3. Visually check system for kinks in refrigeration line which is causing restriction. Correct kink and repeat step 2.

4. Turn unit off and time how long it takes high and low pressure gauges to equalize:

 If pressure equalization takes longer than 10

minutes, a restriction exists in the capillary tube or drier filter. Go to step 5.

 If pressure equalization takes less than 10 minutes,

system is not restricted. Check for other possible causes of malfunction.

5. Recover refrigerant in sealed system.

NOTE: Before opening any refrigeration system, capture

refrigerant in system for safe disposal.

6. Remove power from unit.

CAUTION

To avoid risk of personal injury or property damage, take necessary precautions against high temperatures required for brazing.

7. Remove and replace restricted device.

8. Evacuate sealed system.

9. Charge system to specification.

NOTE: Do not use captured or recycled refrigerant in

Maytag units. Captured or recycled refrigerant voids any Maytag and/or compressor manufacturer's warranty.

NOTE: Charge system with exact amount of refrigerant.

Refer to unit nameplate for correct refrigerant charge. Inaccurately charged system will cause future problems.

Evacuation and Charging

CAUTION

To avoid risk of fire, sealed refrigeration system must be air free. To avoid risk of air contamination, follow evacuation procedures exactly.

NOTE: Before opening any refrigeration system, EPA

regulations require refrigerant in system to be captured for safe disposal.

Proper evacuation of sealed refrigeration system is an important service procedure. Usable life and operational efficiency greatly depends upon how completely air, moisture and other non-condensables are evacuated from sealed system.

Air in sealed system causes high condensing temperature and pressure, resulting in increased power requirements and reduced performance.

Moisture in sealed system chemically reacts with refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids. These acids attack motor windings and parts, causing premature breakdown.

Before opening system, evaporator coil must be at ambient temperature to minimize moisture infiltration into system.

Evacuation

To evacuate sealed refrigeration system:

1. Connect vacuum pump, vacuum tight manifold set with high vacuum hoses, thermocouple vacuum gauge and charging cylinder as shown in illustration.

Evacuation should be done through I.D. opening of tubes not through line piercing valve.

2. Connect low side line to compressor process tube.

3. Connect high side line to drier/process tube.

4. Evacuate both simultaneously. With valve C and F closed, open all other valves and start vacuum pump.

9 16021730 Rev. 0

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting to service. Ensure all ground wires are connected before certifying unit as repaired and/or operational.

Charging NOTE: Do not use captured or recycled refrigerant in

Maytag units. Captured or recycled refrigerant voids any warranty.

NOTE: Charge system with exact amount of refrigerant.

Refer to unit serial plate for correct refrigerant charge. Inaccurately charged system will cause future problems.

To charge system:

1. Close valves A to vacuum pump and C to vacuum gauge and E to low side manifold gauge.

2. Set scale on dial-a-charge cylinder for corresponding HFC134a pressure reading.

3. Open valve F to charging cylinder and let exact amount of refrigerant flow from cylinder into system. Close valve.

Low side gauge pressure should rise shortly after opening charging cylinder valve as system pressure equalizes through capillary tube.

If pressure does not equalize, a restriction typically exists at capillary/drier braze joint.

4. If pressure equalizes, open valve E to low side manifold gauge and pinch off high side drier process tube.

5. Start compressor and draw remaining refrigerant from charging hoses and manifold into compressor through compressor process tube.

6. To check high side pinch-off drier process tube. Close valve D to high side gauge. If high side pressure rises, repeat high side pinch-off and open valve D. Repeat until high side pinch-off does not leak.

7. Pinch-off compressor process tube and remove charging hose. Braze stub closed while compressor is operating.

8. Disconnect power. Remove charging hose and braze high side drier process tube closed.

9. Recheck for refrigerant leaks.

Refrigerant Charge

Refrigerant charge in all capillary tube systems is critical and exact amount is required for proper performance. Factory charges are shown on serial plate. NOTE: Do not use refrigerant other than shown on serial

plate.

High Side Gauge

Valve

Charg ing Hose

Drier/Process Tube

Valve

Charging

Cylinder

Thermistor

Vacuum Gauge

Compressor

Low Side Gauge

Charging Hose

Compressor Process Tube

.6 cm Copper

Tubing

Valve

Vacuum Pump

Equipment Setup For Evacuation And Charging

5. After compound gauge (low side) drops to approximately 29 inches gauge, open valve C to vacuum thermocouple gauge and take micron reading.

NOTE: A high vacuum pump can only produce a good

vacuum if oil in pump is not contaminated.

6. Continue evacuating system until vacuum gauge registers 600 microns.

7. At 600 microns, close valve A to vacuum pump and allow micron reading in system to balance. Micron level will rise.

 If in 2 minutes, micron level stabilizes at 1000

microns or below, system is ready to be charged.

 If micron level rises above 1000 microns and

stabilizes, open valve A and continue evacuating.

 If micron reading rises rapidly and does not stabilize,

a leak still exists in system.

Close valve A to vacuum pump and valve C to vacuum gauge. Invert charging cylinder and open

charging cylinder valve F to add partial charge for leak checking. With leak detector, check manifold connections and system for leaks. After locating leak, capture refrigerant, repair leak, and begin at step 1.

16021730 Rev. 0 10

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting to service. Ensure all ground wires are connected before certifying unit as repaired and/or operational.

HFC134a Service Information

HFC134a is alternative refrigerant for CFC12. HFC134a has an ozone depletion potential (ODP) factor of 0.0 and a global warming potential (GWP) factor of 0.27. HFC134a is not flammable and has acceptable toxicity levels. HFC134a is not interchangeable with CFC12. There are significant differences between HFC134a and CFC12 which must be considered when handling and processing refrigeration system.

Health, Safety, and Handling

Health, safety and handling considerations for HFC134A are virtually no different than those for CFC12.

Properties/Characteristics CFC12 HFC134a

Ozone Depletion Potential (ODP) Global Warming Potential (GPW) Molecular weight 121 102 Boiling point at 1 atmospher e -22°F (-30°C) -15°F (-

Vapor pressure at 77°F (25°C) Liquid density at 77°F (25°C) 82 lb/ft Flammability No No High-side system operating Pressure at 65°F (18°C) Low-side system operating Pressure at 65°F (18°C)

1.0* 0.0*

3.2* 0.27*

80 psig 82 psig

HFC134a approximately 3 psig higher than CFC12 HFC134a approximately 2 psig lower than CFC12

126°C)

75 lb/ft

Health, Safety, and Handling

Allowable overall exposure limit Vapor exposure to skin No effect Same Liquid exposure to skin Can cause frostbite S ame Vapor exposure to eye Very slight eye irritant Same Liquid exposure to eye Can cause frostbite Sam e Above minimum exposure limit

Safety and handling Wear appropriate skin

Spill management Remove or extinguish

Fire explosion hazards May decompose if

Disposal procedures Recycle or reclaim. Same

1,000 ppm Same

Can cause Asphyxiation, Tachycardia, and Cardia Arrhythmias

and eye protection. Use with adequate ventilation.

ignition or combustion sources. Evacuate or ventilate area.

contact with flames and heating elements. Container may explode if heated due to resulting pressure rise. Combustion products are toxic.

CFC12 HFC134a

Same

Comparison of CFC12 and HFC134a Properties

To minimize contamination, exercise extreme care when servicing HFC134A sealed systems.

 No trace of other refrigerants is allowed in HFC134a

systems. Chlorinated molecules in other refrigerants such as CFC12, etc. will lead to capillary tube plugging.

 Ester oil is used in HFC134a systems. Do not use

mineral oil. HFC134a and mineral oils cannot be mixed. If mineral oils were used in HFC134a systems, lubricant would not return to compressor and would cause early compressor failure. If significant amount of oil has been lost from compressor, replace oil rather than adding oil.

 Ester oils used in HFC134a systems are so

hydroscopic that by the time an inadequate system performance is detected, oil will be saturated with moisture.

 CFC12 has much higher tolerance to system

processing materials, such as drawing compounds, rust inhibitors, and cleaning compounds, than HFC134a. Such materials are not soluble in HFC134a systems. If materials were to be washed from system surfaces by ester oils, they could accumulate and eventually plug capillary tube.

 Care must be taken to minimize moisture entering

HFC134a system. Do not leave compressor or system open to atmosphere for more than 10 minutes. Excessive moisture in HFC134a system will react with compressor oil and generate acid.

 Compressor must be replaced when performing low side

leak repair.

 Drier filter must always be replaced.

11 16021730 Rev. 0

Service Procedures

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting to service. Ensure all ground wires are connected before certifying unit as repaired and/or operational.

Important: Unbrazing drier filter from tubing will drive

moisture from desiccant and into system, causing acids to form. Do not unbraze filter drier from tubing. If CFC12 service drier was installed in HFC134A system, drier could overload due to excessive moisture.

 HFC134a compatible copper tubing, part #R0174075 (1/

4" O.D. X 18" length) and part #R0174076 (5/16" O.D. X 24" length) must be used when replacing tubing.

 Avoid system contamination by using Towerdraw E610

evaporating oil, part # R0157532, when flaring, swagging, or cutting refrigeration tubing.

Replacement Service Compressor

HFC134a service compressors will be charged with ester oil and pressurized with dry nitrogen. Before replacement compressor is installed, pull out 1 rubber plug. A pop from pressure release should be heard. If a pop sound is not heard, do not use compressor. Positive pressure in compressor is vital to keep moisture out of ester oil. Do not leave compressor open to atmosphere for more than 10 minutes.

Compressor Testing Procedures

WARNING

To avoid death or severe personal injury, never use oxygen, air or acetylene for pressure testing or clean out of refrigeration system. Use of oxygen, air, or acetylene may result in violent explosion. Oxygen may explode on contact with oil and acetylene will spontaneously explode when under pressure.

Refer to Technical Data Sheet Temperature Relationship Chart for operating watts, test points, and temperature relationship test for unit being tested.

 Temperature testing is accomplished by using 3 lead

thermocouple temperature tester in specific locations. Test point T-1 is outlet on evaporator coil and T-2 is inlet. Test point T-3 is suction tube temperature midway between where armaflex ends and suction port of compressor (approximately 12 inches from compressor).

 Thermocouple tips should be attached securely to

specified locations.

 Do not test during initial pull down. Allow one off cycle

or balanced temperature condition to occur before proceeding with testing.

 Refrigerator must operate minimum of 20 minutes after

thermocouples are installed.  Turn control to colder to obtain required on time.  Wattage reading must be recorded in conjunction with

temperature test to confirm proper operation.  Suction and head pressures are listed on Temperature

and Relationship Chart. Normally these are not

required for diagnosis but used for confirmation on

systems which have been opened.

Brazing

CAUTION

To avoid risk of personal injury or property damage, take necessary precautions against high temperatures required for brazing.

Satisfactory results require cleanliness, experience, and use of proper materials and equipment.

Connections to be brazed must be properly sized, free of rough edges, and clean.

Generally accepted brazing materials are:  Copper to copper joints: SIL-FOS (alloy of 15 percent

silver, 80 percent copper, and 5 percent phosphorous).

Use without flux. Recommended brazing temperature is

approximately 1400°F. Do not use for copper to steel

connection.

 Copper to steel joints: SILVER SOLDER (alloy of 30

percent silver, 38 percent copper, 32 percent zinc). Use

with fluoride based flux. Recommended brazing

temperature is approximately 1200°F.  Steel to steel joints: SILVER SOLDER (see copper

to steel joints).  Brass to copper joints: SILVER SOLDER (see copper

to steel joints).  Brass to steel joints: SILVER SOLDER (see copper

to steel joints).

16021730 Rev. 0 12

Refrigerant Flow

Side by Side

Refrigerant Flow Diagram

13 16021730 Rev. 0

Cabinet Air Flow

Side by Side

Cabinet Air Flow Diagram

16021730 Rev. 0 14

Ice and Water Dispenser Diagram

Ice Maker

5/16" Water line to Dispenser

1/4" Water Line

Secondary Water Valve

Water Coil

Primary Water Valve

Side by Side

Water Filter

Ice and Water Flow Diagram

15 16021730 Rev. 0

Water Valves Diagram

Secondary Valve

Bypass

Filter Head

Primary Valve

Bottom View

Back View

16021730 Rev. 0 16

Troubleshooting Chart

WARNING

Troubleshooting chart on following pages contains symptoms that may be seen in malfunctioning units. Each symptom is accompanied by one or more possible causes and by a possible remedy or test to determine if components are working properly.

Symptom Possible Causes Corrective Action

Unit does not run

Refrigerator sect i on too wa rm

No power to unit Check for power at outlet. Check

fuse box/circuit breaker for blown fuse or tripped breaker. Replace or reset.

Faulty power cord Check with test light at unit; if no

circuit and current is indicated at outlet, replace or repair.

Low voltage Check input voltage for proper

voltage. Take appropriate action to correct voltage supply problem.

Faulty compressor Check compressor motor windings

for opens/shorts. Perform compressor diagnostic test

Replace if necessary. Excessive door opening Consumer education Overloading of shelves Consumer education

Warm or hot foods placed in cabinet Consumer education Cold control set too warm Set control to colder setting. Poor door seal Level cabinet. Adjust hinges.

Replace gasket. Refrigerator airflow Check auto damper is opening by

removing grille. With door open,

damper should open. Replace if

faulty. Interior light remains on Check switch. Replace if necessary.

Faulty condenser fan or evaporator fan

Faulty compressor Replace compressor.

Check fan and wiring. Replace if

necessary.

17 16021730 Rev. 0

Troubleshooting Chart

WARNING

Symptom Possible Causes Corrective Action

Refrigerator section too cold

Freezer and refrigerator sections too warm

Unit runs continuously

Noisy operation

Refrigerator temperature control set too cold

Refrigerator air f l o w not pro per ly adjusted Temperature controls set too warm Reset temperature controls.

Poor door seal Level cabinet. Adjust hinges.

Dirty condenser or obstructed grille Check condenser and grille. Clean. Faulty control Test control. Replace if failed. Refrigerant shortage or restriction Check for leak or restriction. Repair,

Freezer temp control set too cold Adjust freezer temperature control. Freezer section too cold Faulty control Test control. Replace if failed. Temperature control set too cold Adjust temperature control.

Dirty condenser or obstructed grille Check condenser and grille. Clean. Poor door seal Level cabinet. Adjust hinges.

Interior light remains on Check switch. Replace if necessary. Faulty condenser fan or evaporator

fan Faulty control Test control. Replace if failed.

Refrigerant shortage or restriction Check for leak or restriction. Repair,

Refrigerant overcharge Check for overcharge. Evacuate and

Air in system Check for low side leak. Repair,

Loose flooring or floor not firm Repair floor or brace floor. Cabinet not level Level cabinet. Tubing in contact with cabinet, other

tubing, or other metal Drip pan vibrating Adjust drain pan. Fan hitting another part Ensure fan properly aligned and all

Worn fan motor bearings Check motor for loss of lubricant or

Compressor mounting grommets worn or missing. Mounting hardware loose or missing Free or loose parts causing or allowing noise duri ng op era ti on

Adjust refrigerator temperature control.

Check air flow.

Replace gasket.

evacuate and recharge s ystem.

Replace gasket.

Check fan and wiring. Replace if necessary.

evacuate and recharge s ystem.

recharge system.

evacuate and recharge s ystem.

Adjust tubing.

attaching hardware and brackets are tight and not worn. Tighten or replace.

worn bearings. Replace if necessary. Tighten hardware. Replace

grommets if necessary. Inspect unit for parts that may have

worked free or loose or missing screws. Repair as required.

16021730 Rev. 0 18

Troubleshooting Chart

WARNING

Symptom Possible Causes Corrective Action

Frost or ice on evaporator

Defrost thermostat faulty Check defrost thermostat. Replace if

failed.

Evaporator fan faulty Check fan motor. Replace if failed. Defrost heater remains open Check defrost heater continuity.

Replace if failed. Defrost control faulty Check control and replace if failed. Open wire or connector Check wiring and connections.

Repair as necessary. Refrigerant shortage or restriction Check for leak or restriction. Repair,

evacuate and recharge s ystem. Supply voltage out of specification Check input voltage. Correct any

supply problems. Faulty fan motor Check fan motor. Replace if failed.

Restricted air flow Check condenser and grille for dirt.

Clean. Refrigerant shortage or restriction Check for leak or restriction. Repair,

evacuate and recharge s ystem.

19 16021730 Rev. 0

System Diagnosis

SUCTION

PRESSURE

CONDITION

Refrigerant

Overcharge

Shortage of

Refrigerant

Partial

Restriction

Air in System Near Normal Increase Warmer Warmer Warmer Increase Low Ambient

Installations

(High

Ambients the

Reverse)

Additional

Heat Load

VARIATION

FROM

NORMAL

Increase Increase Warmer Warmer Colder Increase

Decrease

Decrease Decrease Colder Warmer Warmer Decrease

Increase Increase Warmer Warmer Warmer Increase

HEAD PRESSURE VARIATION

FROM

NORMAL

Decrease or

Increase

See Text

Decrease or

Increase

See Text

Note 2

T1 INLET

TEMPERATURE

VARIATION

FROM NORMAL

Colder Warmer Warmer Decrease

T2 OUTLET

TEMPERATURE

VARIATION

FROM NORMAL

T3 SUCTION

TEMPERATURE

VARIATION

FROM NORMAL

WATTAGE

VARIATION

FROM

NORMAL

Inefficient

Compressor

Increase

Normal or Decrease

Warmer or

Colder

Symptoms of an Overcharge

 Above normal freezer temperatures.  Longer than normal or continuous run.  Freezing in refrigerator.  Higher than normal suction and head pressure.  Higher than normal wattage.  Evaporator inlet and outlet temperatures warmer than

normal.

 Suction tube temperature below ambient. Always

check for separated heat exchanger when suction temperature is colder than ambient.

Various conditons could indicate an overcharge. For example, if the cooling coil is not defrosted at regular intervals, due to a failure of the defrost system, the refrigerant will "flood out" and cause the suction line to frost or sweat. The cause of this problem should be corrected rather than to purge refrigerant from the sytem. Running the freezer section colder than necessary (-2 to -1 F. is considered normal package temperatures) or continuous running of the compressor for a variety of reasons, or the freezer fan motor not running, may give the indication of an overcharge.

Warmer Warmer Decrease

Symptoms of Refrigeration Shortage

 Rise in food product temperature in both

compartments. (See Note 1 below.)  Long or continuous run time.  Look for obvious traces of oil that would occur due to a

leak or cracked refrigerant line.  Lower than normal wattage.  Compressor will be hot to touch because of the heat

generated by the motor windings from long continuous

running. It will not be as hot as it would be with a full

charge and long run times for some other reason such

as a dirty condenser.  Depending on the amount of the shortage, the

condenser will not be hot, but closer to room

temperature. The capillary tube will be warmer than

normal from a slight shortage.  If the leak is on the high side of the system, both

gauges will show lower than normal readings and will

show progressively lower readings as this charge

becomes less. The suction pressure guage will

probably indicate a vacuum.  If the leak is on the low side of the system the suction

pressure guage will be lower than normal - probably in

a vacuum - and the head pressure gauge will be

higher than normal. It will probably continue to

become higher because air drawn in through the leak

is compressed by the compressor and accumulates in

16021730 Rev. 0 20

System Diagnosis

the high side (condenser) of the system.

 Only partial frosting of evaporator instead of even

frosting of entire coil.

NOTE 1: Usually the first thing that is noticed by the

user is a rise in temperature foods. Although temperatures will rise in both the freezer section and the food compartment, the frozen meats and vegetables will not thaw immediately. The customer doesn't associate the problem with the freezer section and will first notice that milk and other food beverages are not cold enough.

Under some circumstances, such as in the case of forced air meatkeeper model with a slight shortage of refrigerant, freezing in the food compartment may be experienced due to the additional running time. With a refrigerant leak, however, it always gets worse and as the refrigerant charge decreases the temperature will continue to rise.

With a shortage of refrigerant the capillary line will not have a full column of liquid. As a result, there is a noticeable hissing sound in the evaporator. This should not be mistaken for the regular refrigerant boiling sounds that would be considered normal.

Symptoms of a Restriction

Always remember refrigeration (cooling) occurs on the low pressure side of a partial restriction (obviously a total restriction will completely stop the circulation of refrigerant and no cooling will take place).

Physically feel the refrigeration lines when a restriction is suspected. The most common place for a restriction is at the drier-filter or at the capillary tube inlet or outlet. If the restriction is not total there will be a temperature difference at the point of restriction, the area on the evaporator side will be cooler. In many cases frost and/ or condensation will be present. A longer time is required for the system to equalize.

Any kinked line will cause a restriction so the entire system should be visually checked.

A slight restriction will give the same indications as a refrigerant shortage with lower than normal back pressure, head pressure, and wattage, warmer product temperatures.

NOTE 2: If a total restriction is on the discharge side of

the compressor, higher than normal head pressures and wattages would result. This is true only while the low side is being pumped out and if the restriction was between the compressor and the first half of the condenser.

21 16021730 Rev. 0

To diagnose for a restriction versus a refrigerant shortage, discharge the system, replace the drier-filter, evacuate and recharge with the specified refrigerant charge. If the unit performs normally three possibilities exist: 1) refrigerant loss, 2) partially restricted drierfilter, and 3) moisture in system.

If the unit performs as it previously did you may have a restricted capillary line or condenser or kinked line. Find the point of restriction and correct it.

A restriction reduces the flow rate of the refrigerant and consequently reduces the rate of heat removal. Complete restriction may be caused by moisture, solid contaminants in the system, or a poorly soldered joint. Moisture freezes at the evaporator inlet end of the capillary tube or solid contaminants collect in the drierfilter. The wattage drops because the compressor is not circulating the usual amount of refrigerant.

As far as pressure readings are concerned, if the restriction, such as a kinked line or a joint soldered shut is anywhere on the low side, the suction pressure would probably be in a vacuum while the head pressure will be near normal. If the restriction is on the high side, the suction pressure, again, will probably be in a vacuum while the head pressure will be higher than normal during the pump out period described earlier. In either case, it will take longer than the normal ten minutes or so for the head pressure to equalize with the low side after the compressor stops.

Symptoms of Air in System

This can result from a low side leak or improper servicing. If a leak should occur on the low side, the temperature control would not be satisfied; thus, continuous running of the compressor would result. The compressor would eventually pump the low side into a vacuum drawing air and moisture into the system. Air and R134A do not mix so the air pressure would be added to the normal head pressure, resulting in higher than normal head pressures.

One way to determine if air is in the system is to read the head pressure gauge with the product off and evaporator and condenser at the same temperature and then take the temperature on the condenser outlet tube. This temperature should be within 3° or 4° F. of what the Pressure-Temperature Relation chart shows for the given idle head pressure. If the temperature of the condenser outlet is considerably lower than the idle head pressure of the gauge this would indicate there is air in the system.

Thorough leak checking is necessary. Correct the source of the leak. Do not attempt to purge off the air because this could result in the system being undercharged. It is best to discharge, replace drier, evacuate and recharge with the specified refrigerant charge.

System Diagnosis

Symptoms of Low or High Ambient Temperature Installation

Lower ambient air temperature reduces the condensing temperature and therefore reduces the temperature of the liquid entering the evaporator. The increase in refrigeration effect due to operation in a lower ambient results in a decrease in power consumption and run time. At lower ambients there is a reduction in cabinet heat leak which is partially responsibile for lower power consumption and run time.

An increase in refrigeration effect cannot be expected below a certain minimum ambient temperature. This temperature varies with the type and design of the product.

Generally speaking, ambient temperatures cannot be lower than 60° F. without affecting operating efficiency. Conversely, the higher the ambient temperature the higher the head pressure must be to raise the high side refrigerant temperature above that of the condensing medium. Therefore, head pressure will be higher as the ambient temperature raises. Refrigerators installed in ambient temperatures lower than 60° F. will not perform as well because the pressures within the system are generally reduced and unbalanced. This means that the lower head pressure forces less liquid refrigerant through the capillary line. The result is the symptoms of a refrigerant shortage. The lower the ambient temperature the more pronounced this condition becomes.

When a point where the ambient temperature is below the cut-in of the Temperature Control is reached, the compressor won't run.

The drain traps will freeze in ambient temperatures of 32° F.

Heat Load

A greater heat load can result from the addition of more than normal supply of foods, such as after doing the weekly shopping. Other items contributing to an additional heat load would be excessive door openings, poor door sealing, interior light remaining on, etc.

An increase in heat being absorbed by the refrigerant in the evaporator will affect the temperature and pressure of the gas returning to the compressor. Compartment temperatures, power consumption, discharge, and suction pressures are all affected by heat load. Pressures will be higher than normal under heavy heat load.

16021730 Rev. 0 22

COMPRESSOR REPLACEMENT

1. Turn the main power switch in the machine compartment to the off position

Evacuate the sealed system.

Cut Here

Slide Rail Mounting Screw

2. Remove the high side slide rail mounting screw.

3. Slide the high side foward into the service position.

4. Clean and cut the refrigerant lines as close as possible to the compressor stubs, leaving enough length to install the replacement compressor.

NOTE: A new drier must be installed each time any

component of the system is opened or replaced.

NOTE: The holding charge is your assurance that

the new compressor is dry and ready to install. If you receive a replacement compressor that shows no evidence of holding charge when you remove the plugs, return it.

Cut Here

5. Disconnect lead wires from compressor terminals.

6. Remove the bolts from the compressor mounts. Remove defective compressor from cabinet and install rubber grommets on replacement compressor.

7. Clean the compressor stubs with an abrasive cloth such as grit cloth No. 23. Do not open the compressor stubs.

8. Install the replacement compressor using the mounting bolts previously removed.

9. Connect the compressor leads.

10.Transfer the process tube from the old compressor. Connect the refrigerant tubing to the compressor stubs using silfos on copper to copper joints and silver solder and flux on steel to copper joints.

11. Locate and remove old drier. Install new drier. The new driver is installed in the following manner: a. Carefully bend the old drier and tubing away

from electrical parts.

b. Use steel wool or fine emery paper to clean

the capillary tube 3 inches from the original joint. Also, clean the input tubing to the drier of 3 inches from the original joint.

c. Use steel wool or fine emery paper to clean

both ends of the new drier. Use a knife or file to score the capillary tube 1 inch from the original joint. Use your finger to break the connection.

d. Make an offset 1/2" from the end of the cap

tube to prevent it from penetrating too far into the drier.

e. Cut the inlet tube of the replacement drier and

use pliers to snap off the scored end. Transfer the process line to the new drier.

f. Install the new drier using silfos yoder tube

and the drier to compressor.

23 16021730 Rev. 0

Wicks

Main Power Switch

Centigrade / Fahrenheit Switch

Figure 1

Defrost Water Drain Pan Filter Drier

12.Evacuate, recharge and leak test the system.

13.Test run the unit to check operation

14.Replace the machine compartment

cover.

CONDENSER REPLACEMENT

The following general information explains how to successfully replace the condenser for any model covered in this manual.

1. Remove the Machine compartment access door.

2. Turn the main power switch in the machine com-

partment to the off position. (See figure 1)

3. Remove the high side slide rail mounting screw. (See figure 2).

Figure 2

4. Slide the highside assembly forward into the service position. (See figure 3).

16021730 Rev. 0 24

+ 54 hidden pages

Jenn-Air Jenn-Air, Integrated Side by side refrigerators Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual