KitchenAid 2003 M Technical Education
TECHNICAL EDUCATION
KAR-15
BUILT-IN SIDE-BY-SIDE
REFRIGERATOR WITH VARIABLE
CAPACITY COMPRESSOR
2003 M MODEL
JOB AID 4317344
FORWARD
This KitchenAid Job Aid, “2003 M Model Built-In Side-By-Side Refrigerator With Variable Capacity
Compressor” (Part No. 4317344), provides the technician with information on the installation,
operation, and service of the Built-In Side-By-Side Refrigerator. It is to be used as a training Job
Aid and Service Manual. For specific information on the model being serviced, refer to the “Use
and Care Guide,” or “Tech Sheet” provided with the refrigerator.
The Wiring Diagrams and Strip Circuits used in this Job Aid are typical and should be used for
training purposes only. Always use the Wiring Diagram supplied with the product when servicing
the unit.
GOALS AND OBJECTIVES
The goal of this Job Aid is to provide detailed information that will enable the service technician to
properly diagnose malfunctions and repair the Built-In Side-By-Side Refrigerator.
The objectives of this Job Aid are to:
• Understand and follow proper safety precautions.
• Successfully troubleshoot and diagnose malfunctions.
• Successfully perform necessary repairs.
• Successfully return the refrigerator to its proper operational status.
WHIRLPOOL CORPORATION assumes no responsibility for any repairs made
on our products by anyone other than Authorized Service Technicians.
Copyright © 2003, Whirlpool Corporation, Benton Harbor, MI 49022
- ii -
TABLE OF CONTENTS
Page
GENERAL............................................................................................................................... 1-1
Safety First......................................................................................................................... 1-1
Model & Serial Number Designations ................................................................................ 1-3
Model & Serial Number Label And Tech Sheet Locations................................................. 1-4
KitchenAid Built-In Refrigerator Warranty .......................................................................... 1-5
INSTALLATION INFORMATION ........................................................................................... 2-1
THEORY OF OPERATION ..................................................................................................... 3-1
COMPONENT ACCESS ......................................................................................................... 4-1
Component Locations ........................................................................................................ 4-1
Removing A Door Switch And The Power Switch ............................................................. 4-2
Removing The Inverter Assembly...................................................................................... 4-4
Removing The Condenser Fan Motor ............................................................................... 4-6
Removing The Ice Maker Inlet Heated Fill Tube ............................................................... 4-8
Removing The Main Control Board Assembly ................................................................... 4-9
Removing The Electronic Meat Pan Power Supply Board .............................................. 4-10
Removing The Compressor And Filter/Drier.................................................................... 4-12
Removing The Bimetal, The Evaporator Fan Motor,
The Defrost Heater, And The Evaporator ..................................................................... 4-14
Removing The Touch And Display Boards & The Motorized Air Door ............................ 4-18
Removing The Meat Pan Air Baffle & Thermistor, The Air Supply
Thermistor, And The Meat Pan Electronic Touch Control Assembly.......................... 4-20
Removing A Thermistor ................................................................................................... 4-23
Removing The Ice Maker, The Emitter, And The Receiver ............................................. 4-24
Removing The Auger Motor............................................................................................. 4-26
Removing The Water Reservoir And Water Valve .......................................................... 4-28
Removing A Light Socket ................................................................................................ 4-30
Removing The Water & Ice Dispenser ............................................................................ 4-31
Removing A Door ............................................................................................................ 4-34
COMPONENT TESTING ........................................................................................................ 5-1
Thermistor.......................................................................................................................... 5-1
Evaporator Fan Motor ........................................................................................................ 5-2
Condenser Fan Motor ........................................................................................................ 5-2
Compressor & Inverter....................................................................................................... 5-3
Motorized Air Door ............................................................................................................. 5-4
Defrost Heater & Bimetal ................................................................................................... 5-4
Main Control Board ............................................................................................................ 5-5
Power Switch ..................................................................................................................... 5-6
Door Switch ....................................................................................................................... 5-6
Air Supply Thermistor ........................................................................................................ 5-7
Water Valve Solenoid ........................................................................................................ 5-7
Checking The Auger Motor ................................................................................................ 5-8
Ice Maker Inlet Heated Fill Tube ...................................................................................... 5-10
Meat Pan Air Baffle Motor And Thermistor ...................................................................... 5-10
- iii -
Page
DIAGNOSTICS & TROUBLESHOOTING .............................................................................. 6-1
Diagnostics ........................................................................................................................ 6-1
Pre-Diagnostics Checks ................................................................................................. 6-1
Diagnostics Mode ........................................................................................................... 6-1
Service Diagnostics Mode Chart .................................................................................... 6-2
Water Filter Input (WFI) Test .......................................................................................... 6-2
Electronic Temperature-Controlled Meat Pan Diagnostics ............................................. 6-3
Troubleshooting Chart ....................................................................................................... 6-4
WIRING DIAGRAMS & STRIP CIRCUITS ............................................................................. 7-1
SXS Non Dispenser Wiring Diagram ................................................................................. 7-1
SXS Dispenser Wiring Diagram......................................................................................... 7-2
Bottom Mount Wiring Diagram........................................................................................... 7-3
Main Control Board Block Diagram ................................................................................... 7-4
Electronic Temperature-Controlled Meat Pan Diagram ..................................................... 7-5
SXS Tubing Joint Diagram ................................................................................................ 7-6
Bottom Mount Tubing Joint Diagram ................................................................................. 7-7
Strip Circuits ...................................................................................................................... 7-8
TECH TIPS ............................................................................................................................. 8-1
Servicing The Ice Bin Auger Assembly.............................................................................. 8-1
- iv -
GENERAL
SAFETY FIRST
Your safety and the safety of others is very important.
We have provided many important safety messages in this Job Aid and on the appliance. Always
read and obey all safety messages.
This is the safety alert symbol.
This symbol alerts you to hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word
“DANGER” or “WARNING.” These words mean:
You can be killed or seriously injured if you don’t
immediately follow instructions.
You can be killed or seriously injured if you don’t
follow instructions.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance
of injury, and tell you what can happen if the instructions are not followed.
ELECTRICAL POWER SUPPLY &
GROUNDING REQUIREMENTS
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.
Electrical Shock Hazard
Plug into a grounded 3-prong outlet.
Do not remove ground prong.
Do not use an adapter.
Do not use an extension cord.
Failure to follow these instructions can
result in death, fire, or electrical shock.
1-1
Electrical Shock Hazard
ELECTROSTATIC DISCHARGE
(ESD) SENSITIVE ELECTRONICS
ESD problems are present everywhere. ESD
may damage or weaken the electronic control
assembly. The new control assembly may appear to work well after repair is finished, but
failure may occur at a later date due to ESD
stress.
Connect green ground wire to ground
screw.
Failure to do so can result in death or
electrical shock.
ANTI-TIP
REQUIREMENTS
Tip Over Hazard
Refrigerator is top heavy and tips easily
when not completely installed.
Keep doors taped closed until refrigerator is completely installed.
• Use an antistatic wrist strap. Connect the
wrist strap to a green ground connection
point or unpainted metal in the appliance; or
touch your finger repeatedly to a green ground
connection point or unpainted metal in the
appliance.
• Before removing the part from its package,
touch the antistatic bag to a green ground
connection point or unpainted metal in the
appliance.
• Avoid touching electronic parts or terminal
contacts. Handle the electronic control assembly by the edges only.
• When repackaging the failed electronic control assembly in an antistatic bag, observe
the above instructions.
Use two or more people to move and
install refrigerator.
Failure do so can result in death or
serious injury.
1-2
MODEL & SERIAL NUMBER DESIGNATIONS
MODEL NUMBER
MODEL NUMBER K SS S 4 2 Q M X 0 0
PRODUCT GROUP
K = KitchenAid Brand
PRODUCT IDENTIFICATION
BR = Bottom Mount Right Hand Hinge
BL = Bottom Mount Left Hand Hinge
SS = Side-By-Side Built-In
MERCHANDISING SCHEME/SERIES
C = Wrap Around Stainless Steel
P = Factory Installed Panel Kit
S = Framed Trim Kit (Panels Not Included)
V = VBL Pro Line Series
CAPACITY/ SIZE
36 = 36″ Width
42 = 42″ Width
48 = 48″ Width
FEATURES
D = Ice & Water Dispensing
F = Factory Installed Ice Maker w/Filter
M = Factory Installed Ice Maker wo/Filter
Q = Ice/Crushed Ice & Water Dispensing w/Filter
YEAR OF INTRODUCTION
M = 2003
COLOR CODE
S = Stainless
M = Meteorite
X = No Color Used
ENERGY POWER CONSUMPTION CHANGE
0 = Original, 1 = 1st Change, 2 = 2nd Change, Etc.
ENGINEERING CHANGE (NUMERIC)
0 = Original, 1 = 1st Change, 2 = 2nd Change, Etc.
SERIAL NUMBER
SERIAL NUMBER Q P 30 10003
MANUFACTURING SITE
Q = LaVergne, TN
YEAR OF PRODUCTION
P = 2003
WEEK OF PRODUCTION
30th WEEK
PRODUCT SEQUENCE NUMBER
1-3
MODEL & SERIAL NUMBER LABEL
AND TECH SHEET LOCATIONS
The Model/Serial Number Label and Tech Sheet locations are shown below.
Model & Serial Number Location
(Refrigerator Compartment)
Tech Sheet Location
(On Unit Compartment Cover)
1-4
KITCHENAID® BUILT-IN REFRIGERATOR WARRANTY
TWO-YEAR FULL WARRANTY
For two years from the date of purchase, when this refrigerator (excluding the water filter cartridges) is operated
and maintained according to instructions attached to or furnished with the product, KitchenAid will pay for factory
specified replacement parts and repair labor costs to correct defects in materials or workmanship. Service must
be provided by a KitchenAid designated service company.
Water filter cartridge: 30 day limited warranty on water filter. For 30 days from the date of purchase, when this
filter is operated and maintained according to instructions attached to or furnished with the product, KitchenAid
will pay for replacement parts to correct defects in materials and workmanship.
THIRD THROUGH SIXTH YEAR FULL WARRANTY ON
SEALED REFRIGERATION SYSTEM PARTS AS LISTED
In the third through sixth years from the date of purchase, when this refrigerator is operated and maintained according to instructions attached to or furnished with the product, KitchenAid will pay for factory specified replacement parts and repair labor costs to correct defects in materials or workmanship in the sealed refrigeration system. These parts are: compressor, evaporator, condenser, dryer, and connecting tubing. Service must be performed by a KitchenAid designated service company.
SEVENTH THROUGH TWELFTH YEAR LIMITED
WARRANTY ON SEALED REFRIGERATION SYSTEM
In the seventh through twelfth years from date of purchase, when this refrigerator is operated and maintained
according to instructions attached to or furnished with the product, KitchenAid will pay for factory specified replacement parts to correct defects in materials or workmanship in the sealed refrigeration system. These parts
are: compressor, evaporator, condenser, dryer, and connecting tubing.
LIFETIME LIMITED WARRANTY ON DOOR BINS
For the life of the product, when this refrigerator is operated and maintained according to instructions attached to
or furnished with the product, KitchenAid will replace all Door Bins due to defective materials or workmanship.
KitchenAid will not pay for:
1. Service calls to correct the installation of your refrigerator, to instruct you how to use your refrigerator, to replace house fuses or correct house wiring or plumbing, to replace light bulbs, or to replace water filters other
than as noted above.
2. Repairs when your refrigerator is used in other than normal, single-family household use.
3. Pickup and delivery. Your refrigerator is designed to be repaired in the home.
4. Damage resulting from accident, alteration, misuse, abuse, fire, flood, improper installation, acts of God, or
use of products not approved by KitchenAid, or KitchenAid Canada.
5. Any food or medicine loss due to product failure.
6. Repairs to parts or systems resulting from unauthorized modifications made to the appliance.
7. Removal and replacement of trim or decorative panels that interfere with servicing the product.
8. Labor or parts installed by any non-designated service company during the full warranty period, unless approved by KitchenAid before service is performed.
9. In Canada, travel or transportation expenses for customers who reside in remote areas.
10. Any labor costs during the limited warranty periods.
KITCHENAID AND KITCHENAID CANADA SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages, so this
exclusion or limitation may not apply to you. This warranty gives you specific legal rights, and you may also have
other rights which vary from state-to-state, or province-to-province.
Outside the 50 United States and Canada, a different warranty may apply. Contact your authorized KitchenAid
dealer to determine if another warranty applies.
If you need service, first see the “Troubleshooting” section of the Use and Care Guide. After checking “Troubleshooting,” additional help can be found by checking the “Assistance or Service” section, or by calling the
KitchenAid Customer Interaction Center, 1-800-422-1230 (toll-free), from anywhere in the U.S.A. In Canada,
contact your designated KitchenAid Canada service company, or call 1-800-807-6777.
1-5
— NOTES —
1-6
INSTALLATION INFORMATION
831/
8
"
(211 cm)
A
(see chart following)
Width of Refrigerator
36" (91 cm)
42
"
(106 cm)
48
"
(122 cm)
36-1/4
"
(92 cm)
42-1/4
"
(107 cm)
48-1/4
"
(123 cm)
Model Width A (as shown above)
PRODUCT DIMENSIONS
Side View
1
2
831/8"
(211 cm)*
3
251/8"
(64 cm)
231/2"
(60 cm)
24"
(61 cm)
Power Cord
Front View
NOTE: (*) Dimensions shown are for leg levelers extended 1/8″ (3 mm) below the rollers. For
levelers fully extended 1-1/4″ (32 mm) below
the rollers, add 1-1/8″ (29 mm) to this dimension.
Top View
Model Width A
36" (91 cm)
42
"
(106 cm)
"
(122 cm)
48
1
/2" (9 cm)*
3
1. 25-1/8" (64 cm) dimension is to front of top grille
2. Power cord (24") (61 cm)
3. 5 ft. (1.5 m) water line tubing taped to back
A
25-1/8"
(64 cm)
35
"
(89 cm)
41
"
(104 cm)
"
(119 cm)
47
NOTE: The width dimensions shown represent
the distance from outside trim to outside trim.
2-1
Opening Dimensions
(
)
Model
Width A (as shown above)
36 in. (91.4 cm)
42 in. (106.7 cm)
48 in. (121.9 cm)
35-1/2 in. (90.2 cm)
41-1/2 in. (105.4 cm)
47-1/2 in. (120.7 cm)
The solid soffit must be within 1″ (2.5 cm)
maximum above the refrigerator. If the solid
soffit is higher than 1″ (2.5 cm) or one is not
available, then the refrigerator must be braced
to prevent tipping during use.
If the anti-tip boards are needed, they must be
attached to the rear wall studs 80″ to 90″ (203
- 229 cm) above the floor (see “Install Anti-Tip
Boards” for more information).
NOTE: A clearance of 1/2″ (1.3 cm) must be
maintained above the top grille in order for the
top grille to be removed.
1
/
2"
(1.3 cm)
A grounded 3 prong electrical outlet should be
placed within 4″ (10.2 cm) of the right side
cabinets or end panel.
The water shutoff should be located in the base
cabinet on either side of the refrigerator or
some other easily accessible area. If the water
shutoff valve is not in the cabinets, the plumbing for the water line can come through the floor
or the back wall (see “Water Supply Requirements” for more information).
80" - 90"
(203-229 cm)
4"
(10.2 cm)
831/4" (211.5 cm) min.
3
84
/4" (215 cm) max.
to bottom of solid soffit
Width
(see chart following)
3" (7.6 cm)
231/2"
(60 cm) min.
(28 cm)
A
11"
77"
(196 cm)
6"
(15.2 cm)
6"
(15.2 cm)
6"
15.2 cm
2-2
WATER SUPPLY REQUIREMENTS
r
ANTI-TIP BOARDS
All installations must meet local plumbing code
requirements.
The water shutoff should be located in the base
cabinet on either side of the refrigerator or
some other easily accessible area. The righthand side is recommended. The access hole
through the right-hand side cabinet must be
within 1/2″ (12.7 mm) of the rear wall.
6"
(15.2 cm)
3" (7.6 cm)
11"
231/2"
(60 cm) m in.
(28 cm)
6"
(15.2 cm)
6"
(15.2 cm)
If the water shutoff valve is not in the cabinets,
the plumbing for the water line can come through
the floor or the back wall. A 1/2″ (12.7 mm) hole
for plumbing should be drilled 6″ (15.2 cm) to
12″ (30.4 cm) from the right-hand side cabinet
or panel. On the floor, the hole should be no
more than 11″ (28 cm) away from the back wall.
On the wall, the hole should be no more than 3″
(7.6 cm) up from the floor.
IMPORTANT:
• The solid soffit must be within 1″ (2.5 cm)
maximum above the refrigerator. If the solid
soffit is higher than 1″ (2.5 cm), or one is not
available, prevent the refrigerator from tipping during use, as shown.
• It is recommended that the boards be installed before the refrigerator is installed.
• Boards must be long enough to fully cover
the width of the compressor cover.
• Locate the boards so the bottom surface of
the boards are 84″ (213 cm) from the floor.
• During installation, raise the refrigerator up
so there is 1/4″ (6.4 mm) maximum between
the top of the refrigerator and the bottom of
the anti-tip boards. Do not crush the condenser cover when raising the rear leveling
legs.
21
3
2" (5 cm)
If this recommended water line location is
used, no additional plumbing must be purchased. If additional tubing is needed, use
copper tubing and check for leaks. Install the
copper tubing only in areas where the household temperatures will remain above freezing.
Do not use a piercing-type or 3/16″ (4.76 mm)
saddle valve, which reduces water flow and
clogs more easily. NOTE: Any refrigerator
dealer has a kit available with a 1/4″ (6.35 mm)
saddle-type shutoff valve, a union, and copper
tubing. Before purchasing, make sure a saddletype valve complies with your local plumbing
codes.
Cold Water Supply
Connect the ice maker to a cold water line with
water pressure between 15 and 100 psi (103 690 kPa).
4
1. Center board 1/4" (6 mm) max. above refrigerato
2. Two 2" x 4" x 32" (5 cm x 10 cm x 81 cm) boards
3. Attach to studs with 6-#8 x 3" (7.6 cm) screws
4. Compressor cover
To Install The Anti-Tip Boards:
1. Mark the stud locations on the rear wall
80″ to 90″ (203 - 229 cm) above the floor.
2. Securely attach one or two 2″ x 4″ x 32″
(5 cm x 10 cm x 81 cm) wood boards to the
wall studs behind the refrigerator. Use six
#8 x 3″ (7.6 cm) or longer wood screws.
The wood screws must be screwed into
the studs at least 1-1/2″ (3.8 cm). The
boards must overlap the compressor cover.
2-3
LOWERING THE LEVELING LEGS
All four leveling legs must contact the floor to
support and stabilize the full weight of the
refrigerator. Rollers are for moving the refrigerator, and not for permanent support.
Use a socket wrench to turn the leg levelers on
both sides of the refrigerator to the right (clockwise) until the refrigerator weight is supported
by the legs. The rollers should be off the floor.
To avoid cabinet damage, do not apply more
than 50 in/lbs (58 cm/kg) of torque to the
leveling legs.
1. Rear leveling legs
2. Front leveling legs
1 2
LEVELING THE REFRIGERATOR
NOTE: Door panels must be installed before
leveling.
1. Open the doors and place a level on top of
the refrigerator frame. Check to see if the
refrigerator is level from left to right.
1
2. Use the leveling bolts to adjust the leveling
legs until the refrigerator is level from left
to right.
1
2
1. Rear leveling bolt
2. Front leveling bolt
1
2
3. Place a level on the shelves and check to
see if the refrigerator is level from front to
back.
4. Use the leveling bolts to adjust the leveling
legs until the refrigerator is level from front
to back.
5. Make sure that all four leveling legs contact the floor and support the full weight of
the refrigerator.
6. Make a final check to see that the refrigerator is level.
ADJUSTING THE DOORS
Door Alignment
Use the following steps to adjust the door
alignment to the left, right, in, or out.
1. Inspect the spacing of the gap between
the freezer and refrigerator doors. Make
sure that the spacing between the doors is
the same distance at the top and bottom.
2
1. Level to check left to right leveling
2. Level to check front to back leveling
1
1. Uneven door gap
2
2. If the door gap is uneven, loosen the four
T27 flat-head mounting screws on top of
both hinges. Loosen the screws to the
point that the hinge is movable, but there
is friction when trying to move the hinge.
NOTE: Do not loosen the two 1/4″ hexhead mounting screws.
2-4
1
2
1. T27 flat-head mounting screws
2. 1/4 in. hex-head mounting screws
3. Adjust the hinges so that the door gap is
the same distance at the top and bottom.
The bottom distance should be used as a
template for the top.
4. Tighten the screws on both hinges.
Door Height Adjustment
Overlay Models
Remove the two door stop screws: one
from the bottom side using a 3/8″ openend wrench, and one from the top side
using an Allen wrench.
12
1. Door stop screw from bottom
2. Door stop screw from top
Use the following steps to adjust the door
height up or down after the doors have been
leveled.
1. Open the freezer or refrigerator door and
locate the hinge assembly at the bottom of
the door, and remove the stop screw.
Classic & Architect® Models
Remove the door stop screw from the
bottom side of the hinge.
123
1. Locking plate
2. Door stop screw
3. Bushing
2. Remove the locking plate, as shown.
3. Turn the bushing located underneath the
bottom of the hinge using the open-end
wrench. Turning the bushing to the left
(counterclockwise) will raise the door.
Turning the bushing right (clockwise) will
lower the door.
4. After adjusting, check the doors to make
sure they are even at the top and bottom.
If the doors are not even, continue to turn
the bushing to adjust the door height.
5. Replace the locking plate.
6. Turn the bushing slightly to align the hinge
and locking plate screw holes.
7. Replace the door stop screw or screws
and tighten.
8. Make final recheck to make sure the doors
are aligned and even.
2-5
Door Swing Adjustment
1. Open the refrigerator and freezer doors
and make sure that they open freely. If a
door opens too wide, remove the door
stop screw(s) from the bottom hinge.
2. Hold the door open to a position that is less
than 90°.
3. Replace the door stop screw(s) in the
bottom hinge and tighten.
12 3
1. 130
°
2. 110
°
3. 90
°
2-6
THEORY OF OPERATION
Warmer
Power
On/Off
Colder
THE ELECTRONIC TEMPERATURE CONTROL PANEL
FREEZER REFRIGERATOR
°C
SELECT
OVERVIEW
The KitchenAid Built-In Refrigerator Constant
Flow Temperature Management System uses
two thermistors to monitor temperature changes
inside the refrigerator and freezer compartments. The electronic control manages the
operation of the variable capacity compressor
(VCC), a variable speed evaporator fan motor,
and a variable position air door. The air door
allows independent temperature control of the
refrigerator and freezer compartments.
The electronic control seeks the most efficient
means possible to maintain temperatures as it
controls the operation and speed of the compressor and the evaporator fan motor. Higher
fan speed is used before increasing the compressor speed to minimize power consumption. A nearly constant run time is sought at the
lowest possible fan and compressor speed.
Freezer temperatures can be set from 6°F to
–5°F (–14°C to –21°C). Refrigerator temperatures can be set from 46°F to 34°F, (8°C to
1°C).
The Adaptive Defrost Control (ADC) portion of
the electronic control utilizes “pulsed defrost”
technology to perform the defrost function (see
page 3-4).
Warmer
WATER FILTER
RESET
PERCENT LEFT
Colder
The electronic control monitors the water valve
for total elapsed time and gallons of water
used. The number displayed on the Water
Filter Indicator (WFI) is the percentage of filter
usage remaining.
The numeric display can be set for Fahrenheit
or Celsius and displays the actual temperatures. The display range for the refrigerator is
from 27° to 70°F (–2.8°C to 21°C). The normal
freezer display range is from –5°F to 70°F
(–21°C to 21°C). Temperatures above or below these limits will be displayed at the corresponding temperature limit. During Max Cool,
the freezer display will read –5°F (–21°C), and
the refrigerator will read 34°F (1°C).
The display will show the temperature setting
any time the actual temperature is within ±6°F
of the customer setting. This will prevent concern over temperature fluctuations when the
doors are opened. Press the temperature adjustment key to view the current temperature
setting, or to change the setting. When the
temperature adjustment key is used to change
the temperature setting, the display will brighten
for 5 seconds.
Available features include:
• Water Filter Indicator
• Max Cool
• Over-Temperature Alarm
• Holiday Mode
3-1
TEMPERATURE CONTROL
The electronic control checks the resistance of
the thermistors, and compares it to both the
customer temperature settings and the last
thermistor reading taken. This information is
used to determine when to begin a cooling
operation, and if a change is necessary in the
damper setting, or the evaporator fan or compressor speed.
When a warm refrigerator is first put into a
cooling mode, the air door partially opens, and
the compressor and evaporator fan motors
start to run at maximum rpm. The air door will
gradually move to its fully open position.
As the actual temperature in the refrigerator
nears the selected temperature setting, the
electronic control compares the temperatures
in both compartments. The compartment that
has the greatest need for cooling, will control
the speed of the evaporator fan motor.
Freezer Temperature Control —
Temperature Increasing
When the freezer calls for cooling, the compressor begins to run at minimum rpm, (see the
chart on page 3-3), and the evaporator fan
begins to run at 2000 rpm. The compressor
and evaporator speeds are continuously updated. Speed changes are made based on:
• The difference between the actual temperature and the selected temperature settings.
• The rate of temperature change.
If the temperature increases 4°F above the
selected temperature setting, the evaporator
fan speed begins to gradually increase. The
evaporator fan motor reaches the maximum
speed of 3000 rpm at 5°F above the selected
temperature setting, and the compressor speed
begins to gradually increase. A maximum compressor speed of 4500 rpm will be reached at
9°F above the selected temperature setting.
Freezer Temperature Control —
Temperature Decreasing
When the freezer temperature begins to decrease, the process will reverse. The compressor speed decreases, followed by the evaporator fan speed.
Refrigerator Temperature Control —
Temperature Increasing
When the refrigerator calls for cooling while
the freezer is satisfied, the air door begins to
open, and the evaporator fan starts to run at
minimum speed. If the temperature continues
to rise, the air door will continue to open. If the
temperature continues to rise after the air door
is fully open, the evaporator fan speed will
gradually increase to a maximum of 3000 rpm.
If the temperature continues to rise, the compressor starts to run, or if it has already been
running, begins to increase in speed.
Refrigerator Temperature Control —
Temperature Decreasing
As the refrigerator temperature approaches the
selected setting, the control compares the temperatures in both compartments to determine
which compartment will control the fan speed.
If the freezer is further from the selected temperature setting, it controls the fan speed, and
the air door begins to close, thus reducing the
airflow to the refrigerator.
If the freezer is satisfied, the air door remains
open, and the fan speed begins to decrease.
When the selected temperature setting is
reached, the air door closes.
3-2
COMPRESSOR
COMPRESSOR PROTECTION
The main control board supplies a 5 vdc, peakto-peak square wave, at 54 to 150 Hz, to the
inverter board. A standard VOM will read approximately 2.5 vdc. The inverter board supplies the variable capacity compressor with
three-phase 230 vac. Varying the frequency
to the inverter board, and not the voltage,
changes the speed of the compressor. The
compressor can run at speeds of 1620 to 4500
rpm.
NOTE: It is not necessary, nor is it recommended, to test the output of the inverter board.
While the compressor is running, its speed is
continuously updated. Speed is determined
after analyzing two factors:
• The difference between the actual tempera-
ture and the selected temperature settings.
• The rate of temperature change.
Minimum compressor speed is based on the
freezer’s selected temperature setting, as
shown in the following chart.
To protect the compressor and maintain efficiency, minimum compressor off time is programmed into the main control board. When
the compressor turns off, a minimum of 7 minutes must elapse before allowing a restart.
At the end of the 7 minute period, the condenser fan motor starts, and the main control
board sends the compressor speed signal to
the inverter. The compressor will not start for
an additional minute, due to the inverter delay.
The inverter board utilizes a current limiting
device and thermal protection that eliminates
the need for a compressor-mounted thermal
protector. The inverter will not allow a compressor restart for 8 minutes after the compressor
turns off. This inverter delay will not occur after a power interruption, because inverter
memory is lost (see “Power Interruption” on
page 3-4).
EVAPORATOR FAN MOTOR
The evaporator fan motor is a 12 vdc, variable
speed motor. The motor has four wires:
Freezer Temperature Compressor
Setting (°F)
Minimum Speed
6 to –2 1620 rpm
–3 1800 rpm
– 4 2000 rpm
–5 2200 rpm
The compressor generally cycles on and off
according to the cut-in and cut-out temperatures of the freezer, however, the refrigerator
can turn on the compressor if the evaporator
fan is at maximum speed and the refrigerator
temperatures are not dropping.
• A blue wire provides feedback to monitor the
speed of the motor.
• A red wire provides a constant 12 vdc.
• A yellow wire provides a variable voltage of
between 5 vdc and 17 vdc to control the
motor speed from 2000 to 3000 rpm.
• A white wire provides a common return.
EVAPORATOR FAN &
AIR DOOR DELAY
After defrost, an evaporator fan delay prevents
unnecessary movement of warm, moist air
through the refrigerator by chilling the evaporator prior to starting the fan. Immediately after defrost drip time, the compressor starts at
4500 rpm, but the evaporator fan is delayed
for 8 minutes. Also, the air door remains closed
during the 8 minute delay.
3-3
AIR DOOR
The air door is driven by a reversible DC
stepper motor. The motor operates on a 12
vdc, peak-to-peak square wave. Voltage is
delivered to the air door in a series of short
pulses. It is not possible to obtain a reliable
voltage reading with a VOM.
Separate windings are used to move the air
door open or closed. The door can be in any
one of 1800 positions from 0 to 90 degrees.
The air door is used to fine-tune the airflow to
the refrigerator.
The refrigerator temperature determines the
opening of the air door. When the refrigerator
requires cooling, if the evaporator fan motor is
already running for the freezer, the air door
partially opens, and then adjusts, if necessary.
While the refrigerator is cooling, the door will
be adjusting continuously to maintain or recover refrigerator temperature.
ADAPTIVE DEFROST
The adaptive defrost control allows the unit to
enter a defrost mode only when it is needed.
When powered up for the first time, the control
initiates a defrost cycle after 8 hours of compressor run time. By monitoring the duration of
defrost heating time and compressor run time,
the control will continuously adapt the time
between defrosts to optimize efficiency. Time
between defrost periods will vary between 8
and 100+ hours.
Defrost will occur immediately when the compressor has run at 4000 rpm or greater for 1
hour, and 8 hours have elapsed since the last
defrost.
PULSED DEFROST
For the first 2 minutes of defrost, the heater is
on continuously. It will then cycle off for 1
minute, and back on for 2 minutes. The heater
will continue to cycle at this ratio until the
bimetal opens, or until 33 minutes has elapsed.
At this point, heat is discontinued, and a
4-minute “drip time” begins. This allows the
water to drain before the unit returns to a
cooling mode. Maximum defrost time, (pulsed
heat on/off time + drip time) is 37 minutes.
When entering a defrost cycle, if the bimetal is
open, the time to defrost is reset to 8 hours, and
the control will time through the entire 37 minute
defrost period. During diagnostics this will allow a technician time to look for heater operation, and if necessary, bypass the bimetal.
POWER INTERRUPTION
After a power interruption, the following events
will occur:
• The unit returns to the same operating mode
and settings in use prior to the power interruption. If the unit was off, it remains off.
• Initially, the compressor, evaporator fan, and
condenser fan motors will be off.
• The air door will close, and then adjust to the
proper opening. The evaporator fan starts
when the air door opens.
• The adaptive defrost control resets the compressor run time counter to 0, and if the
freezer is above 20°F, the time to defrost is
set to 8 hours.
• If the freezer temperature is below 12°F
(–11.1°C), the compressor starts after a delay of 7 minutes. If the freezer temperature is
above 12°F, the compressor starts immediately.
FAILURE DEFAULTS
In the event of a thermistor, or keypad failure,
the control uses one of the following default
modes, which will continue until the failure is
corrected.
Refrigerator Thermistor
If the control senses an open or a shorted
thermistor, the air door and the evaporator fan
motor will begin to operate on a timed on and
off cycle, based on current selected temperature settings. The evaporator fan motor will run
when the air door is open.
At mid-settings of 37°F / 0°F, the air door will
open for 16 minutes, and close for 30 minutes.
Setting the freezer colder, or the refrigerator
warmer, will reduce the door-open time. Setting the freezer warmer, or the refrigerator
colder, will increase the door-open time.
3-4
Freezer Thermistor
MAX COOL MODE
If the control senses an open or a shorted thermistor, the compressor and the evaporator fan
motor will begin to operate on a timed on and
off cycle. The cycle time is based on current
selected temperature settings.
At mid-settings of 37°F / 3°C, the compressor
and the evaporator fan motors will run for 35
minutes, and be off for 25 minutes. Setting the
freezer colder will increase the run time. Setting the freezer warmer will decrease the run
time.
The compressor will run at minimum speed.
The evaporator fan will also run at minimum
speed, unless the refrigerator compartment
requests a higher speed.
Keypad
If the control detects that the keypad is not
working, it reverts to the default temperature
settings of 37°F (3°C) in the refrigerator, and
0°F (–18°C) in the freezer.
Max Cool changes the refrigerator temperature setting to 34°F (1 °C) and the freezer to
–5°F (–21°C) for 24 hours. During Max Cool,
the freezer and refrigerator temperature displays show the new temperature settings, not
the actual temperatures.
In most cases the motors run 100% for more
than 1 hour. The control returns to the previous
user setting after 24 hours, or any time the
temperature settings are changed.
AUTOMATIC MAX ICE
Automatic Max Ice operates any time the ice
maker water valve is energized. The duration
of Automatic Max Ice is 1-1/2 hours. During
Automatic Max Ice the following occurs:
• The freezer display shows the user tempera-
ture settings and not the actual temperature.
• The freezer temperature setting changes to
–5°F (–21°C).
• The evaporator fan runs at 3000 rpm.
Evaporator Fan Motor
If the evaporator fan motor malfunctions, the
compressor will run at 4500 rpm for an indefinite period, except during the defrost periods.
The “Call Service Alarm” will sound until the
failure has been corrected.
ELECTRONIC CONTROL
THERMAL SHUTOFF
The electronic control utilizes an on-board thermistor to shut the compressor off if the temperature rises above 160°F (71°C). When the
temperature drops to 130°F (55°C), the compressor returns to normal operation. This cycle
continues indefinitely until the cause of the high
temperature has been corrected.
If this cycle is repeated four times within 24
hours, the “Call Service” indicator lights, and
the alarm sounds.
• The compressor runs the entire 1-1/2 hour
mode. Speed is determined by the difference between actual freezer temperature
and –5°F (–21°C).
HOLIDAY MODE
The Holiday Mode may be used for the following occasions:
• On vacation.
• Religious observance (Sabbath Mode).
When the Holiday Mode is selected, the corresponding green LED flashes for 2 seconds,
and then remains on, to indicate that the feature is activated.
3-5
In the Holiday Mode the following occurs:
• Temperature selections remain at the current setting, but are not displayed.
• The Water Filter Indicator is not displayed,
but monitoring continues.
• The alarms are disabled.
• The ice maker is disabled.
• The interior lights are disabled.
MASTER ALARM RESET
Pressing the Over-Temperature Reset will turn
off the audio alarm, but does not affect the indicator light the first time the Over-Temperature Reset is pressed. The indicator light will
turn off once the Over-Temperature Reset is
pressed a second time. The audio alarm will
not sound again for the current condition that
caused the alarm until a new condition occurs.
• The temperature displays and all of the LEDs
will be off, except for the Holiday Mode LED.
The Holiday Mode LED will illuminate regardless of the door position.
• Keypad operation is disabled, with the exception of the Holiday Mode key, or the
Power On/Off key.
The Holiday Mode will be cancelled if one of the
following occurs:
• Pressing the Power On/Off, or Holiday Mode
keypads.
• Failure of both thermistors.
• No feedback from the evaporator fan motor.
• Temperatures that are 15°F above user settings in either compartment.
When the Holiday Mode is cancelled, the Holiday Mode LED turns off, and the control reverts to the settings in use prior to activation.
All inactive devices are restored, and the Water Filter Indicator is updated.
The Adaptive Defrost Control function is not
effected by use of the Holiday Mode.
OVER-TEMPERATURE ALARM
The Over-Temperature Alarm sounds, and the
indicator light flashes when either the refrigerator temperature exceeds 48°F (9°C), or the
freezer temperature exceeds 15°F (–9°C) for
over 1-1/2 hours. The appropriate temperature
display flashes to show the user which compartment is effected. The alarm stops if the
temperature(s) returns to normal, but the red
Over-Temperature indicator and temperature
display will continue to flash (refer to “Master
Alarm Reset” to reset the Over-Temperature
Alarm).
A Master Alarm Reset can be performed by
turning the power to the refrigerator off and on
again. The indicator light will turn on again after the Over-Temperature Reset is pressed, if
the condition that caused the alarm is still
present.
CALL SERVICE ALARM
Call Service is a visual and audio signal that
alerts the user that the refrigerator needs service. The Call Service Alarm will sound when:
• Both thermistors have failed.
• The evaporator fan motor loses its feedback
signal.
• An over-temperature condition occurs for 3
hours or more.
Reset using Master Alarm Reset.
DOOR OPEN ALARM
If either door is left open for more than 10 minutes, the interior lights will be disabled, the
Door Open icon will flash, and the alarm will
sound. If the door is closed during the alarm
operation, the alarm will reset, but the icon will
continue to flash until the temperature in the
refrigerator drops below 45°F (7°C) and the
freezer is below 15°F (–9°C)(refer to “Master
Alarm Reset” to reset the Door Open Alarm).
SALES DEMONSTRATION MODE
This mode provides a sequential display of the
temperature displays and feature LEDs. To
enter the Demonstration Mode, press and hold
the Max Cool and Power On/Off keys for 2
seconds. If the refrigerator or freezer door is open
for 10 minutes, the interior lights will turn off.
3-6
AIR CIRCULATION
In order to ensure the proper refrigerator and
freezer compartment temperatures, air must
be able to flow between the two sections.
Air enters the bottom of the freezer compartment and moves up through the evaporator.
Some of the cooled air from the evaporator is
directed back into the freezer, and the rest
goes into the refrigerator through the motorized air door. The refrigerator air then returns to
the freezer through the bottom air return (see
the illustration below).
It is important not to block any of the vents with
food items. If the vents are blocked, airflow will
be restricted, and the temperature management system will not function properly.
IMPORTANT: Because air circulates between
both sections, any odors formed in one section will transfer to the other. Keep both sections clean, and wrap or cover foods tightly to
prevent odors from occurring.
3-7
SEALED SYSTEM SCHEMATIC
Discharge
Freezer
Side
Compressor
Mullion
Refrigerator
Suction Line
Condenser
Drier
Heat Exchanger
Evaporator
Side
Condensate Loop
3-8
COMPONENT ACCESS
This section instructs you on how to service each component inside the refrigerator/freezer. The
components and their locations are shown below.
COMPONENT LOCATIONS
Compressor
Inverter Assembly
Freezer Door
Switch
Ice Maker
Filter/Drier
Ice Maker Inlet Heated Fill Tube
Condenser Fan Motor
Meat Pan Power Supply
Power Switch
Touch Control Assembly
Main Control
Board Assembly
Motorized
Air Door
Freezer Light
(1 of 2)
Freezer Thermistor
Auger Motor
Evaporator Fan
Motor Bimetal
Defrost Heater
Evaporator
Refrigerator
Thermistor
Refrigerator Light
Meat Pan Air Baffle
& Thermistor & Air
Supply Thermistor
Meat Pan Electronic
Touch Control Assy.
Water Reservoir
Water Valve
4-1
REMOVING A DOOR SWITCH AND THE POWER SWITCH
5. To remove a door switch:
a) With the door closed, remove the hex-
head screw from the door linkage at the
top of the door. NOTE: The door spring
will remain under slight tension when
the door is closed.
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.
1. Unplug refrigerator or disconnect power.
2. Lift the main decorative panel to unhook it
and remove the panel.
3. Lift and remove the louvered decorative
panel.
Main Decorative Panel Louvered Decorative Panel
Door Linkage Screw
b) Use a pair of pliers and lift the end of
the linkage off the square post.
4. Remove the eight screws from the unit
compartment front cover, and pull the cover
forward out of the way.
Screw (1 of 8) Unit Compartment Front Cover
Freezer Door Switch
(Refrigerator Door Switch
Shown In Right Column)
Power Switch
Square Post
c) Remove the two hex-head screws from
the door switch cover and remove the
cover.
2 Cover Screws
4-2
d) Disconnect the wire connectors from
1
2
3
4
5
6
Power Cord (Ribbed)
Power Cord (Smooth)
White Wire
Black Wire
N/CN/C
the door switch terminals.
2 Wire
Connectors
e) Press against the locking tab on the
switch body and push the switch out of
the bracket.
b) Disconnect the wire connectors from
the switch terminals. NOTE: Be sure
to reconnect the wires to the same terminal locations, as shown below.
c) Press against the four locking tabs on
the body of the power switch, and push
the switch out of the bracket.
4 Wire Connectors
Push Switch Out Of Bracket
6. To remove the power switch:
a) Remove the two hex-head screws from
the switch bracket and turn the bracket
over so you can access the wires.
Bracket Screws
Switch Locking Tabs
(2 of 4)
REASSEMBLY NOTE: When you reinstall the
power switch in the bracket, be sure to position
the switch with the On and Off markings as
shown below. The switch wiring is also shown
below. The terminal numbers are shown on the
switch body.
Power Switch
4-3
REMOVING THE INVERTER ASSEMBLY
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.
1. Unplug refrigerator or disconnect power.
Ground Screw
Inverter Mounting Screws
2. Remove the main and louvered decorative panels (see page 4-2).
3. Remove the eight screws from the unit
compartment front cover, and pull the cover
forward out of the way (see page 4-2).
4. Disconnect the two inverter assembly wire
connectors from the harness.
Inverter Assembly
2 Wire Connectors
5. Remove the two hex-head screws from
the inverter assembly (see the photo at the
top of the right column).
7. Using a large screwdriver, pry down on the
compressor terminal cover, and remove it
from the compressor.
8. Pull the inverter connector off the compressor pins.
9. Pull the green ground connector off the
compressor terminal.
Pry Down &
Unsnap Cover
Compressor
Ground Connector
6. Pull the inverter assembly forward and
remove it from the rear bracket, then position the assembly out of the way.
Inverter Connector
4-4
10. Remove the hex-head screw from the
inverter’s green ground wire, (see the photo
at the top of the right column on page 4-4),
and remove the inverter assembly.
Electrical Shock Hazard
Connect green ground wire to ground
screw.
Failure to do so can result in death or
electrical shock.
11. Install the new inverter assembly and connect the green ground wire to the chassis
with its hex-head screw.
4-5
Loading...