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

TM

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		………………………………………………………………. 2
1.	SPECIFICATIONS	………………………………………………………………. 3
2.	PARTS IDENTIFICATION	………………………………………………………………. 4
3.	DISASSEMBLY	………………………………………………………………. 6
4. ADJUSTMENT		………………………………………………………………. 8
5. CIRCUIT DIAGRAM		……………………………………………………………….10
6. TROUBLESHOOTING		……………………………………………………………….12
7. OPERATION PRINCIPLE AND REPAIR METHOD OF ICEMAKER		……………………………………………………………….18
8. DESCRIPTION OF FUNCTION & CIRCUIT OF MICOM		……………………………………………………………….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.

1-7 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

1-3 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%

	PERFORMANCE DATA
(NORMAL OPERATING CONDITIONS)
AMB	WATTS	SYSTEM PRESSURE (PSIG)
		HIGH SIDE		LOW SIDE
70°F	98 (+10 / -10)	97 (+5 / -3)		(-5) to (-2)
90°F	98 (+10 / -10)	130 (+3 / -3)		(-4) to 1
110°F	103 (+5 / -5)	174 (+5 / -5)		(-2) to 3
1-5 REFRIGERATION SYSTEM
Minimum Compressor Capacity Vacuum ...................				21 in.
Minimum Equalized Pressure
@ 70°F .......................................................				49 PSIG
@ 90°F .......................................................				56 PSIG
Refrigerant - R - 134a .............................................				4.2 Oz
Compressor ......................................................				700 BTU/hr

1-6 INSTALLATION

Clearance must be provided at top, sides and rear of the

refrigerator for air circulation.	1 in
AT TOP ........................................................................
AT SIDES ...................................................................	1/8 in
AT REAR ......................................................................	1 in

1-8 AIR FLOW / CIRCULATION D' AIR

EVAPORATOR

EVAPORATOR FAN

HOT LOOP

DRYER

CONDENSER FAN

COMPRESSOR CONDENSER

21cu.ft............................................

5.47 oz.

FRESH FOOD

COLD AIR

MIXED AIR

AIR RETURN TO

EVAPORATOR

Vegetable box

EVAPORATOR

FREEZER

- 3-

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

Ice Maker

Ice Bin

Durabase

Base Grille

Dairy Corner

Modular

Door Bin

Refrigerator

Door Rack

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

Figure 2

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.

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		FAN MOTOR
	MOTOR

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 6

Figure 7

3-5 LAMP

Figure 8

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).

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

Figure 10

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

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

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
N	C
PTC	5	COMPRESSOR
2		MOTOR
	S	M	M
3	6	S
L1
PTC STARTER		SEALED
Resistance Starter Capacitor Running		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)

		Customer part
	12345678	number
		Lot code/
330 FBYY	-S1 BOX98	date code
Electrical		Physical
characteristics		termination
part number		part number

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

Figure 13

4-4 TO REMOVE THE COVER PTC

(1)Remove the Cover Back M/C.

(2)Remove the screw on Cover PTC

1

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

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

2

(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

8

7

6

5

4

3

2

1

9

BK BN RD BO BL GY YL WH PR

			CON3			BK BN RD BO BL GY YL WH PR													CON4	1	BL
						1	2	3	4	5	6	7	8		9					2	BL
																				3	WH
				PWB(PCB) ASSEMBLY,MAIN																4	WH
																				5	BO
																				6	BO
																			CON5	1	GY
																				2	GY
																				3	PK
																				4	PK
																				5	BL
																				6	BK
7	6	5	4	3	2	1					1	2	3	4	5	6	7	8	9	7	YL
																				8	RD
CON1 YL		BL		BL		BL				BK		PK			GY	BN			SB CON2
YL	BL		BL		BL					BK		PK		GY		BN		SB

POWER

SUPPLY

CORD

L

N

GN/YL

(GN)

BL

BL

YL

HIGH

BK

V

PART

PROTECTOR

BK

M-FUSE

(98C)

VALVEWATER

LOADOVER

FAN-

GN/YL

CAPACITOR PART

M

(GN)

SENSORICE

HEATER,

SEATH

MAKERICE

MOTOR

POWER

PK

M

S/W

Cr

C

2

BK

RD

C

COMPRESSOR

CON5

CON4

CON3

CON2 BK2

CON1

CON6

RD1

Cs

4

5

S

WH2

WH1

WH1

WH1

WH1

BL2

BK1

M

GN/YL

(GN)

PWB (PCB) ASSEMBLY, ICE MAKER

BL

3

6

BL EARTH PART

BL

P.T.C START

ICE MAKER PART

F-SENSOR

R-SENSOR

DEF-SENSOR

AR-DOOR

BPERCEPTION S/W

CF-DOOR

DPERCEPTION S/W

STEEPING

MOTOR

			DOOR		BO	RD
						DOOR
			S/W-R			S/W-F
			com		com	com		com
				nc	nc	nc		nc
			A	B	PR	C	D	BO
LOW	FUSE-M	(72C)	THERMOSTAT
FAN
M					PK
F-		RD			PR
			R-LAMPS
	HEATER,	SEATH				F-LAMP
BL		BL			BL	BL

*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.

* P.T.C START OPTION

MC COMP'		EGU COMP'
	2		3
4	5	4	6
3	6	2	5

- 10 -

6. TROUBLESHOOTING

6-1 COMPRESSOR AND ELECTRIC COMPONENTS

1

2

3

			Remove PTC-Starter		(Reated Voltage	YES
Power Source.			from Compressor and		±10%)?		2
			measure voltage
			between Terminal C of
			Compressor and
			Terminals 5 or 6 of PTC.

	YES		5
No Voltage.	OLP disconnected?	Replace OLP.
	NO	Check connection
		condition.

Reconnect.

	Applied voltage isn't		Advise customer that		5
	in range of Rating		power supply needs to be
	Voltage ±10%.		checked by an electrician.

Check resistance of Motor Compressor.

Check resistance of PTC-Starter.

	Check resistance			The range of resistance is between 1~50W(OK)					3
	between M-C, S-C and
			Open or short	Replace
	M-S in Motor				3		4		5
	Compressor.			Compressor.
				4.5~9 W					4
	Check resistance of
	two terminals in		Open			Replace
	PTC-Starter.								5
						PTC-Starter.

			Not open
4	Check OLP.	Check resistance of two	5
		terminals in OLP.	Open or short
			Replace OLP.

Check

5

starting state.

		Check the power supply		Supply	YES	Did		YES	Compressor
		under load.		voltage rating		compressor			is OK
		(Compressor attempting		with ±10%.		start?
		to re-start after being off							Replace the
		for 5 minutes).
								NO	compressor

1

NO

- 11 -

6-2 PTC AND OLP

Normal operation of

Compressor is

impossible or poor.

		Separate PTC-Starter		Observation value is
		from Compressor and		115V/60Hz : 6.8 ±30%
		measure resistance
		between No. 5 and 6
		of PTC-Starter with a
		Tester.
		(Figure 14)
				The resistance value
				is 0 (short) or
				u (open).

Replace PTC-

Starter.

Separate OLP from		Shows continuity	Check another
Compressor and check			electric component.
resistance value
between two terminals		Open
of OLP with a Tester.			Replace OLP.
(Figure 15)
6	5

Figure 14

Figure 15

- 12 -

6-3 OTHER ELECTRICAL COMPONENTS

Not cooling at all

Compressor doesn't run.

Check for open short or

Cause

incorrect resistance readings in the following components

a. Starting devices						Short, open, or broken.
b. OLP						Poor contact
						or shorted.
c. Compressor coil						Coil open or shorted.
d. Wiring harness						Poor contact		Replace
						or shorted.		indicated component.

Poor cooling performance
Compressor runs	Check starting	Low voltage.	Advise customer that
poorly.	voltage.		the Power supply
			needs to be checked
			by an electrician.

Check voltage at	Poor or broken or	Replace
starting devices.	open contact.	indicated component.

	Check current flowing		Shorted.
	in sub-coil of
	Compressor.

Check rating of OLP.

Lack of capacity.

	Fan motor	Check wiring circuit.	Wire is open or
	doesn't run.		shorted.
			Replace
			indicated component.
		Check Fan Motor.	Coil is shorted
			or open.

Heavy frost buildup on EVAPORATOR.

Check current flow in	Open.	Replace
the following		indicated component.
components:
Sensor
Fuse-M
Check current flow in	Open.	Replace
the Defrost Heater.		Defrost Heater.

- 13 -

6-4 SERVICE DIAGNOSIS CHART

COMPLAINT	POINTS TO BE CHECKED	REMEDY
No Cooling.	• Is the power cord unplugged from the outlet?	• Plug into the outlet.
	• Check if the power switch is set to OFF.	• Set the switch to ON.
	• Check if the fuse of the power switch is shorted.	• Replace the fuse.
	• Measure the voltage of the power outlet.	• If the voltage is low, correct the wiring.
Cools poorly.	• Check if the unit is placed too close to the wall.	• Place the unit about 4 inches (10 cm) from the wall.
	• Check if the unit is placed too close to the stove,	• Place the unit away from these heat sources.
	gas cooker, or in direct sunlight.
	• Is the ambient temperature too high or	• Lower the ambient temperature.
	the room door closed?
	• Check if food put in the refrigerator is hot.	• Put in foods after they have cooled down.
	• Did you open the door of the unit too often	• Don't open the door too often and close
	or check if the door is sealed properly?	it firmly.
	• Check if the Control is set to Warm position.	• Set the control to Recommended position.
Foods in the	• Is food placed in the cooling air outlet?	• Place foods in the high-temperature section.
Refrigerator		(front part)
are frozen.	• Check if the control is set to colder position.	• Set the control to Recommended position.
	• Is the ambient temperature below 41°F(5°C)?	• Set the control to Warm position.
Condensartion or ice	• Is liquid food sealed?	• Seal liquid foods with wrap.
forms inside	• Check if food put in the refrigerator is hot.	• Put in foods after they have cooled down.
the unit.	• Did you open the door of the unit too	• Don't open the door too often and close
	often or check if the door is sealed properly?	it firmly.
Condensartion forms	• Check if the ambient temperature and humidity	• Wipe moisture with a dry cloth. It will disappear
in the Exterior Case.	of the surrounding air are high.	in low temperature and humidity.
	• Is there a gap in the door gasket?	• Fill up the gap.
There is abnormal	• Is the unit positioned in a firm and even place?	• Adjust the Leveling Screw, and position the
noise.	• Are any unnecessary objects placed	refrigerator in a firm place.
		• Remove the objects.
	in the back side of the unit?
	• Check if the Drip Tray is not firmly fixed.	• Fix the Drip Tray firmly in the original position.
	• Check if the cover of the compressor enclosure	• Place the cover in its original position.
	in the lower front side is taken out.
Door does not	• Check if the door gasket is dirty with	• Clean the door gasket.
close well.	an item like juice.
	• Is the refrigerator level?	• Position in the firm place and level the
		Leveling Screw.
	• Is there too much food in the refrigerator?	• Make sure food stored in shelves does not prevent
		the door from closing.
Ice and foods	• Check if the inside of the unit is dirty.	• Clean the inside of the unit.
smell unpleasant.	• Are foods with a strong odor unwrapped?	• Wrap foods that have a strong odor.
	• The unit smells of plastic.	• New products smell of plastic, but this
		will go away after 1-2 weeks.

Other possible problems:

Check if frost forms in the freezer.

Check the refrigeration system.

Check the

Thermistor.

Not

defrosting

The system

is faulty.

The operation of the Thermistor is

incorrect.

Check Components of the defrosting circuit.

Perform sealed system repair.

Replace the

Thermistor.

- 14 -

6-5 REFRIGERATION CYCLE

Troubleshooting Chart

		CAUSE
		PARTIAL
		LEAKAGE
LEAKAGE		COMPLETE
		LEAKAGE
BYCLOGGED		PARTIAL
		CLOG
DUST		WHOLE
		CLOG
	MOISTURE
	CLOG
DEFECTIVE COMPRESSION		COMP-
		RESSION
		NO COMP-
		RESSION

	STATE OF	STATE OF THE	TEMPERATURE	REMARKS
			OF THE
	THE UNIT	EVAPORATOR
			COMPRESSOR
	Freezer	Low flowing sound of	A little higher	• Refrigerant level is low due
	compartment and	Refrigerant is heard and	than ambient	• to a leak.
	Refrigerator don't	frost forms in inlet only.	temperature.	• Normal cooling is possible by
	cool normally.			• restoring the normal amount of
				• refrigerant and repairing the leak.
	Freezer	Flowing sound of refrigerant	Equal to ambient	• No discharging of Refrigerant.
	compartment and	is not heard and frost isn't	temperature.	• Normal cooling is possible by
	Refrigerator don't	formed.		• restoring the normal amount of
	cool normally.			• refrigerant and repairing the leak.
	Freezer	Flowing sound of refrigerant	A little higher	• Normal discharging of the
	compartment and	is heard and frost forms	than ambient	• refrigerant.
	Refrigerator don't	in inlet only.	temperature.	• The capillary tube is faulty.
	cool normally.
	Freezer	Flowing sound of refrigerant	Equal to ambient	• Normal discharging of the
	compartment and	is not heard and frost isn't	temperature.	Refrigerant.
	Refrigerator don't cool.	formed.
	Cooling operation	Flowing sound of refrigerant	Lower than	• Cooling operation restarts
	stops periodically.	is not heard and frost melts.	ambient	when heating the inlet of the
			temperature.	capillary tube.
	Freezer and	Low flowing sound of	A little higher	• Low pressure at high side
	Refrigerator	refrigerant is heard and	ambient	of compressor due to low
	don't cool.	frost forms in inlet only.	temperature.	refrigerant level.
	No compressing	Flowing sound of refrigerant	Equal to ambient	• No pressure in the high
	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	YES	Check if frost		Check if oil
		forms in
runs.			No frost	leaks.
		Evaporator.
			or frost forms
			in inlet only
Frost formed normally			Observe the discharged
	Normal amount		amount of Refrigerant.
				None or too much
					YES
Moisture Clog	Faulty		Inject refrigerant in compressor
	Compressor.		and check cooling operation.
	Check Compressor	Clogged by dust.			Gas leakage.
			Frost formed normally		(Find the leak and repair it)

- 15 -

General Control of Refrigerating Cycle

NO.	ITEMS		UNIT	STANDARDS	PURPOSES	REMARKS
1	Pipe and		Min.	Pipe: within 1 hour.	To protect	The opening time should be reduced
	piping system			Comp: within 10 minutes.	moisture	to a half of the standards during rain
	opening time			Drier: within 20 minutes.	penetration.	and rainy seasons (the penetration of
						water into the pipe is dangerous).
2	Welding		Nitrogen	Weld under Nitrogen	To protect oxide	- Refer to repair note in each part.
			pressure	atmosphere.	scale formation.	- R-134a refrigerant is more
				(N2 pressure:		susceptible to leaks than R-12 and
				0.1~0.2 kg/cm2)		requires more care during welding.
						- Do not apply force to pipes before and
						after welding to protect pipe from cracking.
3	N2 sealed		Confirm	Confirm the sound of	To protect	- In case of evaporator parts, if it doesn't
	parts		N2 leak	pressure relief when	moisture	make sound when removing rubber
				removing the rubber cap.	penetration.	cap, blow dry air or N2 gas for more
				Sound: usable		than 1 min. and than use the parts.
				No sound: not usable
4	Refrige-	Evacuation	Min.	More than 40 minutes	To remove moisture.
	ration	time
	Cycle	Vacuum	Torr	Below 0.03 (ref)		Note: Only applicable to the model
		degree				equipped with reverse flow
						protect plate.
		Vacuum	EA	High and low pressure sides		Vacuum efficiency can be improved
				are evacuated at the same		by operating compressor during
				time for models above 200 l.		evacuation.
		Vacuum	EA	Use R-134a manifold	To protect mixing	The rubber pipes for R-12 refrigerant
		piping		exclusively.	of mineral and	will be melted when they are used for
					ester oils.	R-134a refrigerant (causes of leak.)
		Pipe	EA	Use R-134a manifold	To protect R-12
		coupler		exclusively.	refrigerant mixing.
		Outlet		R-134a manifold exclusively.	To protect R-12
		(Socket)			refrigerant mixing.
		Plug		R-134a manifold exclusively.	To protect R-12
					refrigerant mixing.
5	Refrigerant		EA	Use R-134a exclusively.	Do not mix with	- Do not weigh the refrigerant at too
	weighing			Weighing allowance: ±5g	R-12 refrigerant.	hot or too cold an area.
				Note: Winter: -5g		(77¡F [25¡C] is adequate.)
				Summer: +5g		- Make Copper charging canister
						(Device filling refrigerant)
						Socket: 2SV Plug: 2PV R-134a
						Note: Do not burn O-ring (bushing)
						during welding.
6	Drier			- Use R-134a exclusively for	To remove the
	replacement			R-134a refrigerator.	moisture from
				- Replace drier whenever repairing	pipe inside.
				refrigerator cycle piping.
7	Leak check			- Do not use soapy water for	Defect in	- Check for an oil leak at the refrigerant
				check. It may be sucked	refrigerant leak	leak area. Use an electronic leak
				into the pipe by a vacuum.	area.	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.

- 16 -

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:

HarvestFillIcemaking.

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

- 17 -

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

on

off

30 sec.

2 ms

Ice removing

Motor

on

off

completion point

10 sec.

5V

Hall IC

0V

Figure1. Harvest mode Process

- 18 -