Kenmore 795.75219.402, 795.75214.402, 795.75212.402, 795.75209.402, 795.75204.402 Service Manual

...

REFRIGERATOR

SERVICE MANUAL

CAUTION

BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL.

MODELS:

795.75002.402

795.75004.402

795.75009.402

795.75012.402

795.75014.402

795.75019.402

795.75202.402

795.75204.402

795.75209.402

795.75212.402

795.75214.402

795.75219.402

CONTENTS

SAFETY PRECAUTIONS

1. SPECIFICATIONS

2. PARTS IDENTIFICATION

3. DISASSEMBLY

4. ADJUSTMENT

5. CIRCUIT DIAGRAM

6. TROUBLESHOOTING

7. OPERATION PRINCIPLE AND REPAIR METHOD OF ICEMAKER

8. DESCRIPTION OF FUNCTION & CIRCUIT OF MICOM

………………………………………………………………. 2

………………………………………………………………. 3

………………………………………………………………. 4

………………………………………………………………. 6

………………………………………………………………. 8

……………………………………………………………….10

……………………………………………………………….12

……………………………………………………………….18

……………………………………………………………….22

9. EXPLODED VIEW & REPLACEMENT PARTS LIST ……………………………………………………………….42

SAFETY PRECAUTIONS

Please read the following instructions before servicing your refrigerator.

1. Check the refrigerator for electrical faults.

2. To prevent electric shock, unplug before servicing.

3. Always check line voltage and amperage.

4. Use standard electrical components.

5. Don't touch metal products in the freezer with wet hands. This may cause frostbite or cause your skin to freeze and stick to the surfaces inside the freezer.

6. Prevent water from flowing onto electric elements in the mechanical parts.

7. Close the top door before opening the bottom door. Otherwise, you might hit your head when you stand up.

8. When tilting the refrigerator, remove any materials on the refrigerator, especially the glass shelves and stored foods.

9. When servicing the evaporator, wear cotton gloves. This is to prevent injuries from the sharp evaporator fins.

10. Disassembly, repair, and servicing the sealed refrigeration system should be performed only by qualified and certified personnel. Refrigerant should not be vented into the atmosphere; proper recovery equipment should be used.

- 2-

1. SPECIFICATIONS

1-1 DISCONNECT POWER CORD BEFORE

SERVICING IMPORTANT RECONNECT ALL GROUNDING DEVICES

All parts of this appliance capable of conducting electrical current are grounded. 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.

1-2 IMPORTANT NOTICE

This information is intended for use by individuals possessing adequate backgrounds of electrical, electronic and mechanical experience. Any attempt to repair a major appliance may result in personal injury and property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.

1-3 ELECTRICAL SPECIFICATIONS

Temperature Control (Position : MID)........................ 8-(-6)°F

Defrost Control..............................................................Automatic.

Defrost Thermostat......................................................... 50°F

Electrical Rating :115V. AC, 60 Hz...........................1-5 Amp.

Maximum Current Leakage.........................................0.5 mA

Maximum Ground Path Resistance...................... 0.14 Ohms

Energy Consumption..

520kWh/yr (meet DOE) 530kWh/yr (meet DOE)

795.75004.402 795.75204.402

795.75002.402 795.75202.402

795.75009.402 795.75209.402

795.75014.402 795.75214.402

795.75012.402 795.75212.402

795.75019.402 795.75219.402

1-4 NO LOAD PERFORMANCE

CONTROL POSITION: MID/MID

And Ambient of :.........................70°F..........................90°F

Fresh Food, °F..............33°F to 41°F.............33°F to 41°F

Frozen Food, °F............ (-4°F) to 4°F.............(-4°F) to 4°F

Percent RunningTime .......25%-35%.................45%-60%

1-7 REPLACEMENT PARTS

Relay.............................................................6749C-0008D

Overload .......................................................6750C-0004S

Defrost Thermostat...................................... 6615JB2005C

Defrost Heater.............................. 20cu. ft : 5300JB1100D

...............................22cu. ft : 5300JB1100J

Evaporator Fan Motor.................................. 4680JK1002B

Capacitor ....................................................OCZZJB2012J

Compressor (Hi-Side).................................. 2521CRA5715

Evaporator (Lo-Side)..................... 20cu. ft : 5421JJ1001A

.....................22cu. ft : 5421JJ1001B

Condenser ...............................................5403JJ1007A

Dryer .............................................................5851JJ2002B

Condenser Fan Motor ..................................4680JK1001B

Temperature Control.............................6871JB2047A

Main Control...........................................6871JB1215F

1-8 AIR FLOW / CIRCULATION D' AIR

EVAPORATOR FAN

DRYER

EVAPORATOR

HOT LOOP

CONDENSER FAN

PERFORMANCE DATA

(NORMAL OPERATING CONDITIONS)

AMB WATTS

70°F 90°F

110°F

98 (+10 / -10) 98 (+10 / -10) 103 (+5 / -5)

1-5 REFRIGERATION SYSTEM

Minimum Compressor Capacity Vacuum ...................21 in.

Minimum Equalized Pressure

@ 70°F .......................................................49 PSIG

@ 90°F ....................................................... 56 PSIG

Refrigerant - R - 134a .............................................

Compressor ......................................................

1-6 INSTALLATION

Clearance must be provided at top, sides and rear of the refrigerator for air circulation.

AT TOP ........................................................................

AT SIDES ...................................................................1/8 in

AT REAR ......................................................................1 in

SYSTEM PRESSURE (PSIG)

HIGH SIDE LOW SIDE

97 (+5 / -3) 130 (+3 / -3) 174 (+5 / -5)

(-5) to (-2)

(-4) to 1 (-2) to 3

4.2 Oz

BTU/hr

700

1 in

- 3-

COMPRESSOR

CONDENSER

21cu.ft............................................ 5.47 oz.

FRESH FOOD

COLD AIR

MIXED AIR

AIR RETURN TO EVAPORATOR

EVAPORATOR

Vegetable box

FREEZER

2. PARTS IDENTIFICATION

Freezer Drawer Model

Cool sense

Electronic

Temperature

Control system

Refrigerator Light

Refrigerator Shelves

Egg Box

Snack Pan

Super Fresh Crisper

with Tilt-out

Compartment

Keeps fruits and

vegetable fresh

and crisp

Adjust cube

Icemaker

Ice Bin

Durabase

Divider

Dairy Corner

Modular Door Bin

Refrigerator Door Rack

Freezer Light

Glide-Out Drawer Basket

- 4 -

Swing Out Freezer Door Model

Cool sense

Electronic

Temperature

Control system

Refrigerator Light

Refrigerator Shelves

Snack Pan

Super Fresh Crisper

with Tilt-out

Compartment

Keeps fruits and

vegetable fresh

and crisp

Dairy Corner

Modular Door Bin

Refrigerator Door Rack

Ice Maker

Ice Bin

Durabase

Base Grille

Freezer Light

Freezer Door Rack

Glide-Out Drawer Basket

- 5 -

3. DISASSEMBLY

3-1 DOOR

Refrigerator Door

1. Remove the hinge cover by pulling it upwards.

2. Loosen the hexagonal bolts attaching the upper hinge to the body and lift the freezer door.

HINGE COVER BOLT

HINGE

Figure 1

3. Pull out the door gasket to remove from the door foam assembly.

GASKET

Freezer Door

1. Loosen the hexagonal bolts attaching the lower hinge to the body to remove the refrigerator door only.

LOWER HINGE

BOLT

Figure 3

2. Pull out the door gasket to remove from the door foam assembly.

3-2 DOOR SWITCH

1. To remove the door switch, pry it out with a slotted-type driver, as shown in (Figure 4).

2. Disconnect the lead wire from the switch.

Figure 2

LEAD WIRE DOOR SWITCH

Figure 4

- 6 -

3-3 FAN AND FAN MOTOR

1. Remove the freezer shelf. (If your refrigerator has an icemaker, remove the icemaker first)

2. Remove the grille by pulling it out and by loosening a screw.

3. Remove the Fan Motor assembly by loosening 2 screws and disassemble the shroud.

4. Pull out the fan and separate the Fan Motor and Bracket.

BRACKET

MOTOR

FAN MOTOR

3-5-1 Refrigerator Compartment Lamp

1. Unplug the power cord from the outlet.

2. Remove refrigerator shelves.

3. Release the hooks on both ends of the lamp shield and pull the shield downward to remove it.

4. Turn the lamp counterclockwise.

5. Assemble in reverse order of disassembly. Replacement bulb must be the same specification as the original (Max. 60 W-2EA).

FAN

GRILLE

Figure 5

3-4 DEFROST CONTROL ASSEMBLY

Defrost Control assembly consists of Defrost Sensor and FUSE–M.

The Defrost Sensor works to defrost automatically. It is attached to the metal side of the Evaporator and senses its temperature. At 72°C, it turns the Defrost Heater off.

Fuse-M is a safety device for preventing over-heating of the Heater when defrosting.

1. Pull out the grille assembly. (Figure 6)

2. Separate the connector with the Defrost Control assembly and replace the Defrost Control assembly after cutting the Tie Wrap. (Figure 7)

GRILLE ASSEMBLY

DEFROST-CONTROL ASSEMBLY

Figure 9

3-5-2 Freezer Compartment Lamp

1. Unplug refrigerator or disconnect power.

2. Reach behind light shield to remove bulb.

3. Replace bulb with a 40-watt appliance bulb.

4. Plug in refrigerator or reconnect power.

3-6 CONTROL BOX-REFRIGERATOR

1. First, remove all shelves in the refrigerator, than remove the Refrigerator control Box by loosening 2 screws.

CONTROL BOX

COVER LAMP

2. Remove the Refrigerator Control Box by pulling it downward.

3. Disconnect the lead wire on the right position and separate the lamp sockets.

Figure 10

3-5 LAMP

Figure 6

Figure 7

Figure 8

3-7 MULTI DUCT

1. Remove an upper and lower Cap by using a flat screwdriver, and loosen 3 screws. (Figure 11)

2. Disconnect the lead wire on the bottom position.

Figure 11

- 7 -

4. ADJUSTMENT

4-1 COMPRESSOR 4-1-1 Role

The compressor intakes low temperature and low pressure gas from the evaporator of the redrigerator and compresses this gas to high-temperature and high-pressure gas. It then delivers the gas to the condenser.

4-1-2 Composition

The compressor includes overload protection. The PTC starter and OLP (overload protector) are attached to the outside of the compressor. Since the compressor is manufactured to tolerances of 1 micron and is hermetically sealed in a dust and moisture-free environment, use extreme caution when repairing it.

4-1-3 Note for Usage

(1) Be careful not to allow over-voltage and over-current. (2) If compressor is dropped or handled carelessly, poor operation and noise may result. (3) Use poper electric components appropriate to the Particular Compressor in your product. (4) Keep Compressor dry. If the Compressor gets wet (in the rain or a damp environment) and rust forms in the pin of the Hermetic Terminal, poor operation and contact may result. (5) When replacing the Compressor, be careful that dust, humidity, and soldering flux don’t contaminate the inside of the compressor. Dust, humidity, and solder flux contaminate the cylinder and may cause noise, improper operation or even cause it to lock up.

4-2 PTC.STARTER 4-2-1 Composition of PTC-Starter

(1) PTC (Positive Temperature Coefficient) is a no-contact semiconductor starting device which uses ceramic material consisting of BaTiO3. (2) The higher the temperature is, the higher the resistance value. These features are used as a starting device for the Motor.

4-2-2 Role of PTC-Starter

(1) The PTC is attached to the Sealed Compressor and is used for starting the Motor (2) The compressor is a single-phase induction motor. During the starting operation, the PTC allows current flow to both the start winding and main wiinding

4-2-3 PTC-Applied Circuit Diagram Starting Method for the Motor

OVERLOAD PROTECTOR

PTC

Resistance Starter Capacitor Running

PTC STARTER

COMPRESSOR MOTOR

SEALED TERMINAL

Figure 12

4-2-4 Motor Restarting and PTC Cooling

(1) It requires approximately 5 minutes for the pressure to equalize before the compressor can restart. (2) The PTC device generates heat during operation. Therefore, it must be allowed to cool before the compressor can restart.

4-2-5 Relation of PTC-Starter and OLP

(1) If the compressor attempts to restart before the PTC device is cooled, the PTC device will allow current to flow only to the main winding. (2) The OLP will open because of the over current condition. This same process will continue (3 to 5 times) when the compressor attempts to restart until the PTC device has cooled. The correct OLP must be properly attached to prevent damage to the compressor. Parts may appear physically identical but could have different electrical ratings. Replace parts by part number and model number. Using an incorrect part could result in damage to the product, fire, injury, or possibility death.

4-2-6 Note for Using the PTC-Starter (1) Be careful not to allow over-voltage and over-current. (2) Do not drop or handle carelessly. (3) Keep away from any liquid. If liquid such as oil or water enters the PTC, PTC materials may fail due to breakdown of their insulating capabilities. (4) If the exterior of the PTC is damaged, the resitance value may be altered. This can cause damage to the compressor and result inn a no-start or hard-to-start condition. (5) Always use the PTC designed for the compressor and make sure it is properly attached to the compressor. Parts may appear physically identical but could have different electrical ratings. Replace parts by part number and model number. Using an incorrect part could result in damage to the product, fire, injury, or possibly death.

- 8 -

4-3 OLP (OVERLOAD PROTECTOR) 4-3-1 Definition of OLP

(1) OLP (OVERLOAD PROTECTOR) is attached to the Compressor and protects the Motor by opening the circuit to the Motor if the temperature rises and activating the bimetal spring in the OLP. (2) When high current flows to the Compressor motor, the Bimetal works by heating the heater inside the OLP, and the OLP protects the Motor by cutting off the current flowing to the Compressor Motor.

4-3-2 Role of the OLP

(1) The OLP is attached to the Sealed Compressor used for the Refrigerator. It prevents the Motor Coil from being started in the Compressor. (2) For normal operation of the OLP, do not turn the Adjust Screw of the OLP in any way.

(OVERLOAD PROTECTOR cross section)

Part No. Name

Base, phenolic (UL 94 V-0 rated) Movable arm support, plated steel Stationary contact support, plated steel Heater support, plated steel Heater, resistance alloy Disc, thermostatic alloy Movable arm, spring temper copper alloy Contact, movable, silver on copper Contact, stationary, silver on copper Slug, plated steel Cover, polyester (UL 94 V -0 rated) Pin connector, plated copper alloy (To engage 2.33/2.66 mm dia. pin) Quick-connect terminal, brass, conforms to UL 310, MEMA DC-2, DIN 46344

Electrical

characteristics

part number

12345678

330 FBYY -S1 BOX98

Customer part number

Lot code/ date code

Physical

termination part number

4-4 TO REMOVE THE COVER PTC

(1) Remove the Cover Back M/C. (2) Remove the screw on Cover PTC

(3) Remove two Housings on upper part of Cover PTC.

Figure 13

(4) Take out the cover PTC from upper to lower position like 1 .

(5) Turn 45° in the direction of 2 and take it out. (6) Assembly in reverse order of disassembly.

- 9 -

5. CIRCUIT DIAGRAM

PWB(PCB) ASSEMBLY,DISPLAY-R

CON101

WH PR

CON1

POWER SUPPLY CORD

L N

GN/YL

(GN)

GN/YL

(GN)

SEATH

HEATER,

ICE SENSOR

WHWHWH 111

CON4

ICE MAKER PART

BK 2

CON2

CON3

CON5

PWB (PCB) ASSEMBLY, ICE MAKER

*P.T.C START OPTION, WATER VALVE PART, HEATER AND FUSE CONFIGURATION, CAPACITOR PART, ICE MAKER PART, ICE MAKER CONFIGURATION, PLUG TYPE AND COMP' EARTH PART ON CIRCUIT DIAGRAM ARE SUBJECT TO CHANGE IN DIFFERENT LOCALITIES AND MODEL TYPE.

ICE MAKER

MOTOR

BL 2

CON1

FUSE-M

POWER

BK 1

CON6

CON3

PWB(PCB) ASSEMBLY,MAIN

BLYL

(98

WATER VALVE PART

S/W

RD 1

BKBKPK

CAPACITOR PART

* P.T.C START OPTION

MC COMP'

4 3

P.T.C START

WH PR

EGU COMP'

4 2

CON4

BL BL

2 3

WH BO

5 6

CON5

2 3

PK PK

4 5

BNPK

SBBN

CON2

HIGH

OVER LOAD

PROTECTOR

EARTH PART

COMPRESSOR

GN/YL

(GN)

C-FAN

BL BL

A B C D

LOW

F-FAN

F-SENSOR

R-SENSOR

DEF-SENSOR

R-DOOR PERCEPTION S/W F-DOOR PERCEPTION S/W

STEEPING

MOTOR

DOOR

S/W-R

com

(72 C)

FUSE-M

THERMOSTAT

R-LAMPS

SEATH

HEATER,

BL BL BL

BO RD

DOOR S/W-F

com

F-LAMP

6 5

- 10 -

6. TROUBLESHOOTING

6-1 COMPRESSOR AND ELECTRIC COMPONENTS

Power Source.

Remove PTC-Starter from Compressor and measure voltage between Terminal C of Compressor and Terminals 5 or 6 of PTC.

No Voltage.

Applied voltage isn't in range of Rating Voltage ±10%.

(Reated Voltage ±10%)?

YES

OLP disconnected?

Advise customer that power supply needs to be checked by an electrician.

YES

Replace OLP.

Check connection condition.

Reconnect.

Check resistance of Motor Compressor.

Check resistance of PTC-Starter.

Check OLP.

Check starting state.

Check resistance between M-C, S-C and M-S in Motor Compressor.

Check resistance of two terminals in PTC-Starter.

Check resistance of two terminals in OLP.

Check the power supply under load. (Compressor attempting to re-start after being off for 5 minutes).

Open or short

Supply voltage rating with ±10%.

The range of resistance is between 1~50W (OK)

Replace Compressor.

4.5~9 W

Open

Not open

Open or short

YES

Replace PTC-Starter.

Replace OLP.

Did compressor start?

YES

Compressor is OK

Replace the compressor

4 5

- 11 -

6-2 PTC AND OLP

Normal operation of Compressor is impossible or poor.

Separate PTC-Starter from Compressor and measure resistance between No. 5 and 6 of PTC-Starter with a Tester. (Figure 14)

Separate OLP from Compressor and check resistance value between two terminals of OLP with a Tester. (Figure 15)

Observation value is 115V/60Hz : 6.8 ±30%

The resistance value is 0 (short) or u (open).

Shows continuity

Open

Replace PTCStarter.

Check another electric component.

Replace OLP.

Figure 14

Figure 15

- 12 -

6-3 OTHER ELECTRICAL COMPONENTS

Not cooling at all

Compressor doesn't run.

Poor cooling performance

Compressor runs poorly.

Check for open short or incorrect resistance readings in the following components

a. Starting devices b. OLP

c. Compressor coil d. Wiring harness

Check starting voltage.

Check voltage at starting devices.

Cause

Short, open, or broken. Poor contact

or shorted. Coil open or shorted.

Poor contact or shorted.

Low voltage.

Poor or broken or open contact.

Replace indicated component.

Advise customer that the Power supply needs to be checked by an electrician.

Replace indicated component.

Fan motor doesn't run.

Heavy frost buildup on EVAPORATOR.

Check current flowing in sub-coil of Compressor.

Check rating of OLP.

Check wiring circuit.

Check Fan Motor.

Check current flow in the following components: Sensor Fuse-M

Check current flow in the Defrost Heater.

Shorted.

Lack of capacity.

Wire is open or shorted.

Coil is shorted or open.

Open.

Replace indicated component.

Replace Defrost Heater.

- 13 -

6-4 SERVICE DIAGNOSIS CHART

COMPLAINT POINTS TO BE CHECKED REMEDY

No Cooling.

Cools poorly.

Foods in the Refrigerator are frozen.

Condensartion or ice forms inside the unit.

Condensartion forms in the Exterior Case.

There is abnormal noise.

• Is the power cord unplugged from the outlet?

• Check if the power switch is set to OFF.

• Check if the fuse of the power switch is shorted.

• Measure the voltage of the power outlet.

• Check if the unit is placed too close to the wall.

• Check if the unit is placed too close to the stove, gas cooker, or in direct sunlight.

• Is the ambient temperature too high or the room door closed?

• Check if food put in the refrigerator is hot.

• Did you open the door of the unit too often or check if the door is sealed properly?

• Check if the Control is set to Warm position.

• Is food placed in the cooling air outlet?

• Check if the control is set to colder position.

• Is the ambient temperature below 41°F(5°C)?

• Is liquid food sealed?

• Check if food put in the refrigerator is hot.

• Did you open the door of the unit too often or check if the door is sealed properly?

• Check if the ambient temperature and humidity of the surrounding air are high.

• Is there a gap in the door gasket?

• Is the unit positioned in a firm and even place?

• Are any unnecessary objects placed in the back side of the unit?

• Check if the Drip Tray is not firmly fixed.

• Check if the cover of the compressor enclosure in the lower front side is taken out.

• Plug into the outlet.

• Set the switch to ON.

• Replace the fuse.

• If the voltage is low, correct the wiring.

• Place the unit about 4 inches (10 cm) from the wall.

• Place the unit away from these heat sources.

• Lower the ambient temperature.

• Put in foods after they have cooled down.

• Don't open the door too often and close it firmly.

• Set the control to Recommended position.

• Place foods in the high-temperature section. (front part)

• Set the control to Recommended position.

• Set the control to Warm position.

• Seal liquid foods with wrap.

• Put in foods after they have cooled down.

• Don't open the door too often and close it firmly.

• Wipe moisture with a dry cloth. It will disappear in low temperature and humidity.

• Fill up the gap.

• Adjust the Leveling Screw, and position the refrigerator in a firm place.

• Remove the objects.

• Fix the Drip Tray firmly in the original position.

• Place the cover in its original position.

Door does not close well.

Ice and foods smell unpleasant.

Other possible problems:

Check if frost forms in the freezer.

Check the refrigeration system.

Check the Thermistor.

• Check if the door gasket is dirty with an item like juice.

• Is the refrigerator level?

• Is there too much food in the refrigerator?

• Check if the inside of the unit is dirty.

• Are foods with a strong odor unwrapped?

• The unit smells of plastic.

Not defrosting

The system is faulty.

The operation of the Thermistor is incorrect.

• Clean the door gasket.

• Position in the firm place and level the Leveling Screw.

• Make sure food stored in shelves does not prevent the door from closing.

• Clean the inside of the unit.

• Wrap foods that have a strong odor.

• New products smell of plastic, but this will go away after 1-2 weeks.

Check Components of the defrosting circuit.

Perform sealed system repair.

Replace the Thermistor.

- 14 -

6-5 REFRIGERATION CYCLE

Troubleshooting Chart

CAUSE

PARTIAL Freezer Low flowing sound of A little higher • Refrigerant level is low due LEAKAGE compartment and Refrigerant is heard and than ambient • to a leak.

LEAKAGE

COMPLETE Freezer Flowing sound of refrigerant Equal to ambient • No discharging of Refrigerant. LEAKAGE compartment and is not heard and frost isn't temperature. • Normal cooling is possible by

CLOGGED BY DUST

PARTIAL Freezer Flowing sound of refrigerant A little higher • Normal discharging of the CLOG compartment and is heard and frost forms than ambient • refrigerant.

WHOLE CLOG

MOISTURE Cooling operation Flowing sound of refrigerant Lower than • Cooling operation restarts CLOG stops periodically. is not heard and frost melts. ambient when heating the inlet of the

COMPRESSION

COMP- Freezer and Low flowing sound of A little higher • Low pressure at high side

DEFECTIVE

RESSION Refrigerator refrigerant is heard and ambient of compressor due to low

STATE OF

THE UNIT

Refrigerator don't frost forms in inlet only. temperature. • Normal cooling is possible by cool normally. • restoring the normal amount of

Refrigerator don't formed. • restoring the normal amount of cool normally. • refrigerant and repairing the leak.

Refrigerator don't in inlet only. temperature. • The capillary tube is faulty. cool normally.

Freezer compartment and Refrigerator don't cool.

don't cool. frost forms in inlet only. temperature. refrigerant level.

STATE OF THE

EVAPORATOR

Flowing sound of refrigerant Equal to ambient • Normal discharging of the is not heard and frost isn't temperature. Refrigerant. formed.

TEMPERATURE

OF THE

REMARKS

COMPRESSOR

• refrigerant and repairing the leak.

temperature. capillary tube.

NO COMP- No compressing Flowing sound of refrigerant Equal to ambient • No pressure in the high RESSION operation. is not heard and there is temperature. pressure part of the

no frost. compressor.

Leakage Detection

Observe the discharging point of the refrigerant, which may be in the oil discharging part of the compressor and in a hole in the evaporator.

Check if compressor runs.

Frost formed normally

Moisture Clog

YES

Normal amount

Faulty Compressor.

Check Compressor

Check if frost forms in Evaporator.

Inject refrigerant in compressor and check cooling operation.

Clogged by dust. Gas leakage.

No frost or frost forms in inlet only

Observe the discharged amount of Refrigerant.

Frost formed normally

Check if oil leaks.

None or too much

(Find the leak and repair it)

YES

- 15 -

General Control of Refrigerating Cycle

NO. ITEMS UNIT STANDARDS PURPOSES REMARKS

Pipe and

piping system opening time

Welding

parts

Refrige-

ration Cycle

sealed

Evacuation time

Vacuum degree

Vacuum

Vacuum piping

Min.

Nitrogen pressure

Confirm N2

leak

Min.

Torr

Pipe: within 1 hour. Comp: within 10 minutes. Drier: within 20 minutes.

Weld under Nitrogen atmosphere. (N

2 pressure:

0.1~0.2 kg/cm

)

Confirm the sound of pressure relief when removing the rubber cap. Sound: usable No sound: not usable

More than 40 minutes

Below 0.03 (ref)

High and low pressure sides are evacuated at the same time for models above 200 l.

Use R-134a manifold exclusively.

To protect moisture penetration.

To protect oxide scale formation.

To protect moisture penetration.

To remove moisture.

To protect mixing of mineral and ester oils.

The opening time should be reduced to a half of the standards during rain and rainy seasons (the penetration of water into the pipe is dangerous).

- Refer to repair note in each part.

- R-134a refrigerant is more susceptible to leaks than R-12 and requires more care during welding.

Do not apply force to pipes before and after welding to protect pipe from cracking.

- In case of evaporator parts, if it doesn't make sound when removing rubber cap, blow dry air or N

2 gas for more

than 1 min. and than use the parts.

Note: Only applicable to the model

equipped with reverse flow protect plate.

Vacuum efficiency can be improved by operating compressor during evacuation.

The rubber pipes for R-12 refrigerant will be melted when they are used for R-134a refrigerant (causes of leak.)

Refrigerant

weighing

Drier

replacement

Leak check

Pipe coupler

Outlet (Socket)

Plug

Use R-134a manifold exclusively.

R-134a manifold exclusively.

Use R-134a exclusively. Weighing allowance: ±5g Note: Winter: -5g

Summer: +5g

- Use R-134a exclusively for R-134a refrigerator.

Replace drier whenever repairing refrigerator cycle piping.

- Do not use soapy water for check. It may be sucked into the pipe by a vacuum.

To protect R-12 refrigerant mixing.

Do not mix with R-12 refrigerant.

To remove the moisture from pipe inside.

Defect in refrigerant leak area.

- Do not weigh the refrigerant at too hot or too cold an area. (77¡F [25¡C] is adequate.)

- Make Copper charging canister (Device filling refrigerant) Socket: 2SV Plug: 2PV R-134a Note: Do not burn O-ring (bushing)

during welding.

- Check for an oil leak at the refrigerant leak area. Use an electronic leak detector if an oil leak is not found.

- The electronic leak detector is very sensitive to halogen gas in the air. It also can detect R-141b in urethane. Practice many times before using this type of detector to avoid false readings.

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7. OPERATION PRINCIPLE AND REPAIR METHOD OF ICEMAKER

7-1 OPERATION PRINCIPLE

7-1-1 Operation Principle of Icemaker

Power On

Start Position

Icemaking

Mode

Harvest

Mode

Fill

Park Position

Test Mode

Adjusts Ejector to Start Position whit power on.

•

Waits until water becomes cold after starting the

Icemaking operation.

• Runs MOTOR to drop ice from the tray into the ICE BIN.

• Performs Icemaking Mode after supplying water by operating the SOLENOID in ICE VALVE.

• With the detect lever, checks if the ICE BIN is full.

• To operate LINE and SERVICE, press and hold the Fill Key for 3 seconds. The icemaking will run through 3 stages: Harvest Fill Icemaking.

1. Turning the Icemaker stop switch off (O) stops the icemaking function.

2. Setting the Icemaker switch to OFF and then turning it back on will reset the icemaker control.

Water amount control button

Power (On/Off) Switch

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7-2 ICEMAKER FUNCTIONS

7-2-1 Start Position

1. After POWER OFF or Power Outage, check the EJECTOR's position with MICOM initialization to restart.

2. How to check if it is in place:

- Check HIGH/LOW signals from HALL SENSOR in MICOM PIN.

3. Control Method to check if it is in place: (1) EJECTOR is in place,

- It is an initialized control, so the mode can be changed to icemaking control.

(2) EJECTOR isn't in place:

A. If EJECTOR is back in place within 2 minutes with the motor on, it is being initialized. If not, go to Step B. B. If EJECTOR is back in place within 18 minutes after the heater turns from ON to OFF, it is being initialized. If not, it is

not functioning. Repeat Step B with Heater and Motor off.

7-2-2 Icemaking Mode

1. Icemaking refers to the freezing of supplied water in the ice trays. Complete freezing is assured by measuring the temperature of the Tray with Icemaking SENSOR.

2. Icemaking starts after completion of the water fill operation.

3. The Icemaking function is completed when the sensor reaches -7°C, 60 to 240 minutes after starting.

4. If the temperature sensor is defective, the ice-making function will be completed in 4 hours.

NOTE :After icemaker power is ON, the icemaker heater will be on for test for 9 seconds.

7-2-3 Harvest Mode

1. Harvest (Ice removing) refers to the operation of dropping cubes into the ice bin from the tray when icemaking has Completed.

2. Harvest mode: (1) The heater is ON for 30 seconds, then the motor starts. (2) After performing Step 1 (the heater is turned OFF), the ejector will be back in place wthin 18 minutes. (Hall sensor

sign = OV). Ice removal is then complete. Then the icemaker cycles to the fill mode. The water supply fails to start, it is not functioning. Put the heater and motor in the off position. Restart every 2 hours. (Refer to figure1)

NOTE :If the motor malfunctions and starts before the detect lever rises, MICOM regards the Ice-Removing phase as completed. Water then starts flowing. To prevent this, MICOM doesn’t switch to water-supply mode, but restarts the iceremoving mode. If this happens 3 times, the motor is malfunctioning and you should stop the loads (heater, motor). Then restart the Ice-Removing mode every 2 hours. (See Step 2 above.)

Icemaking sensor temperature is 10ºC or more Maximum 18 minutes After detect LEVER rises

Heater

Motor

Hall IC

off

30 sec.

on off

2 ms

Ice removing completion point

10 sec.

5V 0V

Figure1. Harvest mode Process

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