Maytag MFI2266AES, MFI2067AE Series, MFI2266AE Series, MFI2568AE Series, AFI2237AE Series Service Manual

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Service

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

Ice and Water

This Base Manual covers general information

Refer to individual Technical Sheet

for information on specific models

This manual includes, but is

not limited to the following:

Amana AFI2237AE*

AFI2538AE* AFD25BCZX* AFD25WBZX*

Bottom Mount Refrigerators

Maytag MFI2067AE*

MFI2266AE* MFI2568AE*

16026312

February 2006

Important Information

Important Notices for Servicers and Consumers

Maytag will not be responsible for personal injury or property damage from improper service procedures. Pride and workmanship go into every product to provide our customers with quality products. It is possible, however , that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service information. IT IS THE TECHNICIANS RESPONSIBILITY TO

REVIEW ALL APPROPRIATE SERVICE INFORMA TION BEFORE BEGINNING REPAIRS.

To avoid risk of severe personal injury or death, disconnect power before working/servicing on appliance to avoid electrical shock.

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

Customer Service Support Center

CAIR Center

Web Site Telephone Number

WWW.AMANA.COM ............................................... 1-800-843-0304

WWW.JENNAIR.COM ............................................ 1-800-536-6247

WWW.MAYTAG.COM............................................. 1-800-688-9900

CAIR Center in Canada.......................................... 1-800-688-2002

Amana Canada Product .......................................... 1-866-587-2002

WARNING

Recognize Safety Symbols, Words, and Labels

DANGER

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

WARNING

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

CAUTION

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

damage.

Table of Contents

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

Product Design ............................................................. 4

Component T esting ....................................................... 5

Service Procedures ......................................................10

Service Equipment .......................................................10

Drier Replacement .......................................................10

Refrigerant Precautions ................................................11

Line Piercing V alves .....................................................11

Open Lines ..................................................................11

Compressor Operational T est .......................................11

Dehydrating Sealed Refrigeration System ....................12

Leak T esting.................................................................12

T esting Systems Cont aining a

Refrigerant Charge .................................................12

T esting Systems Containing

No Refrigerant Charge............................................12

Restrictions..................................................................13

Symptoms.............................................................13

T esting for Restrictions ..........................................13

Evacuation and Charging..............................................14

Evacuation .............................................................14

Charging ................................................................15

Refrigerant Charge .................................................15

HFC134a Service Information .......................................16

Health, Safety , and Handling..................................16

Comparison of CFC12 and HFC134a Properties.....16

Replacement Service Compressor................................17

Compressor T esting Procedures ............................17

Brazing ........................................................................17

Refrigerant Flow 20, 22, 25 cu. ft.................................1 8

Cabinet Air Flow 20, 22, 25 cu. ft ................................1 9

20, 22, 25 cu. ft Machine Compartment

Air Flow Diagram .........................................................20

Water Dispenser Flow..................................................21

Water Flow Schematic.................................................22

Typical External Sweat Pattern...................................23

Troubleshooting Chart................................................24

System Diagnosis........................................................27

Disassembly Procedures Door Removal

Fresh Food Doors ..................................................30

Freezer Drawer ......................................................30

Refrigerator Compartment

Upper Light Bulb Cover ..........................................30

Light Bulb Assembly..............................................30

Light Bulb Sockets ................................................30

Light Switches .......................................................30

Fresh Food Thermistor...........................................31

Water Tank ............................................................31

Water Dispenser Facade .......................................31

Low Voltage Board.................................................31

Chute Extension / Yoke Assembly.........................31

Ice Box Compartment

Ice Bin Assembly...................................................31

Icemaker Assembly ...............................................31

Ice Box Fan ...........................................................31

Auger Motor...........................................................31

Solenoid ................................................................32

Damper.................................................................. 32

Ice Box Thermistor................................................. 32

Freezer Compartment

Freezer Thermistor.................................................32

Light Socket ..........................................................32

Light Switch...........................................................32

Freezer Back Panel ...............................................33

Evaporator Fan and Evaporator Motor ...................33

Defrost T erminator (thermostat)..............................33

Defrost Heater .......................................................33

Evaporator Removal ...............................................33

Drawer Assembly...................................................34

Drawer Rails ..........................................................34

Rack and Pinion Gear............................................34

Bottom of Cabinet

Front roller assembly .............................................34

Rear roller assembly............................................34

Machine Compartment

Condenser Fan and Fan motor...............................34

Compressor ...........................................................34

Overload/Relay/Capacitor.......................................35

Condensate Drain Pan ...........................................35

Condensate Drain Tube..........................................35

Condenser Removal ...............................................35

Cabinet Back

High Volt age Board ................................................35

Control Board (Fully Electronic)

Programming Mode ...............................................36

Defrost Operation...................................................36

Forced Defrost Mode .............................................36

Service T est Mode .................................................37

Show Room Mode .................................................40

Appendix A

Owner’s Manual........ ........................................A-1

Product Design

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

Refrigeration System

Compressor forces high temperature vapor into fan cooled tube and wire condenser where vapor is cooled and condensed into high pressure liquid by circulation of air across condenser coil. (See Refrigerant Flow Diagram, page 18)

High pressure liquid passes into post-condenser loop which helps to prevent condensation around freezer compartment opening and through molecular sieve drier and into capillary tube. Small inside diameter of capillary offers resistance, decreasing pressure and temperature of liquid discharged into evaporator. Capillary diameter and length is carefully sized for each system.

Capillary enters evaporator at top front. Combined liquid and saturated gas flows through front to bottom of coil and into suction line. Aluminium tube evaporator coil is located in freezer compartment where circulating evaporator fan moves air through coil and into fresh food compartment.

Large surface of evaporator allows heat to be absorbed from both fresh food and freezer compartments by airflow over evaporator coil causing some of the liquid to evaporate. Temperature of evaporator tubing near end of running cycle may vary from -13°F to -25°F.

Saturated gas is drawn off through suction line where superheated gas enters compressor. To raise temperature of gas, suction line is placed in heat exchange with capillary.

WARNING

Defrost System Fully Electronic Defrost System

The Control Board adapts the compressor run time between defrosts to achieve optimum defrost intervals by monitoring the length of time the defrost heater is on.

After initial power up, defrost interval is 4 hours compressor run time. Defrost occurs immediately after the 4 hours.

Note: Once unit is ready to defrost there is a 4 minute

wait time prior to the beginning of the defrost cycle.

Temperature Controls

Freezer compartment temperature is regulated by air sensing thermistor at top front of freezer compartment which actuates compressor. Control should be set to maintain freezer temperature between 0°F to -2°F.

Fresh food compartment temperature is regulated by an air damper control governing amount of refrigerated air entering fresh food compartment from freezer. Fresh food compartment temperature should be between 38°F and 40°F.

Evaporator and Ice Box Fans are multiple speed low voltage fans that change speeds depending on conditions changing in refrigerator.

Component Testing

WARNING

Component Description Test Procedures

Compressor

When compressor electrical circuit is energized, the start winding current causes relay to heat. After an amount of starting time, the start winding circuit turns off. The relay will switch off the start winding circuit even though compressor has not started (for example, when attempting to restart after momentary power interruption).

With “open” relay, compressor will not start because there is little or no current to start windings. Overload protection will open due to high locked rotor run winding current.

With “shorted” relay or capacitor, compressor will start and overload protector will quickly open due to high current of combined run and start windings.

With open or weak capacitor, compressor will start and run as normal but will consume more energy.

Resistance test

1. Disconnect power to unit.

2. Discharge capacitor by shorting across terminals with a resistor for 1 minute. NOTE: (Some compressors do not have a run capacitor.)

3. Remove leads from compressor terminals.

4. Set ohmmeter to lowest scale.

5. Check for resistance between Terminals “S” and “C”, start winding Terminals “R” and “C”, run winding

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

Ground test

1. Disconnect power to refrigerator.

2. Discharge capacitor, if present, by shorting terminals through a resistor.

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

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

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

Operation test

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

1. Disconnect power to refrigerator.

2. Discharge capacitor by shorting capacitor terminals through a resistor.

3. Remove leads from compressor terminals.

4. Wire a test cord to power switch.

5. Place time delayed fuse with UL rating equal to amp rating of motor in test cord socket. (Refer to Technical Data Sheet)

6. Remove overload and relay.

7. Connect start, common and run leads of test cord on appropriate terminals of compressor.

8. Attach capacitor leads of test cord together. If capacitor is used, attach capacitor lead to a known good capacitor of same capacity.

To AC supply

Switch

Compressor

Fuses

CRS

Capacitor

Test configuration

9. Plug test cord into multimeter to determine start and run wattage and to check for low voltage, which can also be a source of trouble indications.

10. With power to multimeter, press start cord switch and release.

• If compressor motor starts and draws normal wattage, compressor is okay and trouble is in capacitor, relay/overload, freezer temperature control, or elsewhere in system.

• If compressor does not start when direct wired, recover refrigerant at high side. After refrigerant is recovered, repeat compressor direct wire test. If compressor runs after recovery but would not run when direct wired before recover, a restriction in sealed system is indicated.

• If compressor does not run when wired direct after recovery, replace faulty compressor.

Component Testing

WARNING

Component Description Test Procedures

Capacitor

Condenser Condenser is a tube and wire

Run capacitor connects to relay terminal 3 and L side of line.

Some compressors do not require a run capacitor; refer to the Technical Data Sheet for the unit being serviced.

construction located in machine compartment.

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

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

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

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

To avoid electrical shock which can cause severe personal injury or death, discharge capacitor through a resistor before handling.

1. Disconnect power to refrigerator.

2. Remove capacitor cover and disconnect capacitor wires.

3. Discharge capacitor by shorting across terminals with a resistor for 1 minute.

4. Check resistance across capacitor terminals with ohmmeter set on “X1K” scale.

• Good—needle swings to 0 ohms and slowly moves back to infinity.

• Open—needle does not move. Replace capacitor.

• Shorted—needle moves to zero and stays. Replace capacitor.

• High resistance leak—needle jumps toward 0 and then moves back to

constant high resistance (not infinity).

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

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

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

2. Recheck for leaks.

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

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

WARNIN G

6 16026312

Component Testing

WARNING

Component Description Test Procedures

Overload / Relay

Control board See “Control Board” section for Evaporator fan

motor

When voltage is connected and relay is cool, current passes through relay to start winding.

After a short time, current heats the resistor in relay and resistance will rise blocking current flow through relay.

Start winding remains in the circuit through run capacitor.

Solid state relay plugs directly on compressor start and run terminals. Relay terminals 2 and 3 are connected within relay. Run capacitor is connected to relay terminal 3. L2 side of 120 VAC power is connected to relay terminal 2.

troubleshooting information. Evaporator fan moves air across evaporator coil and throughout refrigerator cabinet.

1. Disconnect power to the refrigerator.

2. Remove relay cover and disconnect leads.

3. Check resistance across terminals 2 and 3 with an ohmmeter: Normal = 3 to 12 ohms Shorted = 0 ohms Open = infinite ohms

1. Use Control board testing to check operation of motor.

2. If fan motor does not operate, check for voltage at motor leads.

3. Replace motor if power is present.

4. Replace Control board if no power.

Ice Box fan motor

Right Refrigerator & Freezer light switch

Ice maker water valve

Evaporator heater (defrost)

Left Refrigerator Light Switch

Ice Box fan moves air across Ice Maker and throughout refrigerator cabinet.

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

Controls water flow to the ice maker. Controlled by ice maker. See “Control Board” section for further

testing information.

Activated when defrost thermostat control board completes circuit through heater.

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

1. Use Control board testing to check operation of motor.

2. If fan motor does not operate check for voltage at motor leads.

3. Replace motor if power is present.

4. Replace Control board if no power.

Check resistant across terminals. Switch arm depressed “C“ and ”NC” terminals Open

Switch arm up “C“ and ”NC” terminals Closed

Check resistance across coil windings.

Check resistance across heater. To check defrost system :

1. Use Control Board testing to check operation of defrost heater.

2. If heater does not operate, check defrost thermostat to see if closed.

3. If no power to heater, replace control board. Check resistant across terminals. Switch arm depressed “C” and “NC” terminals Open “C” and ”NO” terminals Closed Switch arm up “C” and “NC” terminals Closed “C” and “NO” terminals Open

Component Testing

WARNING

Component Description Test Procedures

Drier

Evaporator Inner volume of evaporator allows liquid

Thermostat (defrost)

Drier is placed at post condenser loop outlet and passes liquified refrigerant to capillary.

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

refrigerant discharged from capillary to expand into refrigerant gas.

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

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

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

Thermostat is in a series circuit with terminal main control board and defrost heater.

Controls the circuit from main control board through defrost thermostat to defrost heater. Opens and breaks circuit when thermostat senses preset high temperature.

Drier must be changed every time the system is opened for testing or compressor replacement. NOTE: Drier used in R12 sealed system is not interchangeable with

drier used in R134a sealed system. Always replace drier in R134a system with Amana part number B2150504.

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

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

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

3. Score capillary tube close to drier and break.

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

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

6. Remove drier.

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

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

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

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

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

For minute leaks

1. Separate evaporator from rest of refrigeration system and pressurize

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

2. Recheck for leaks.

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

Test continuity across terminals. With power off and evaporator coil below freezing, thermostat should show “0”

ohms when checked with ohmmeter. See “Heater, evaporator (defrost)” section for additional tests. If evaporator coil is warm, should show 56k ohms with an ohm meter.

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

WARNING

WARNIN G

8 16026312

Component Testing

WARNING

Component Description Test Procedures

Thermistor

ECM condenser motor

Electric damper control

Auger Motor Auger motor is controlled by Dispenser

Ice Box Solenoid Ice Box Solenoid is controlled by

Door Chute Motor Door chute motor is controlled by

DispenserCavity Heater

Mullion Heater Mullion Heater is controlled by Control

Temperature sensing device Check resistance across leads.

Condenser fan moves cooling air across condenser coil and compressor body.

Condenser fan motor is in parallel circuit with compressor.

Damper control balances the air delivery between refrigerator and freezer compartments providing temperature control for refrigerator. Electrical voltage activates damper control and door closes restricting flow of air from freezer/ ice box compartment to refrigerator compartment.

switch. Depressing dispenser switch activates Auger Motor, Ice Box Solenoid and Door Chute Motor.

Dispenser switch. Depressing dispenser switch activates Auger Motor, Ice Box Solenoid and Door Chute Motor.

Dispenser switch. Depressing dispenser switch activates Auger Motor, Ice Box Solenoid and Door Chute Motor. Cavity Heater is controlled by Control Board.

Board.

Nominal Temperature Resistance 77°F 9,820 - 10182 ohms 36°F 29,198 – 29,788 ohms 0°F 84,561 – 88,011 ohms

1. Use control board testing to check operation of motor.

2. If motor does not operate check for voltage at motor.

3. If no voltage at motor replace control board.

1. Use control board testing to check operation of damper.

2. If damper does not operate check for voltage at damper.

3. If no voltage at damper replace control board.

1. Use control board testing to check operation of motor.

2. If motor does not operate check for voltage at motor.

3. If no voltage at motor replace control board.

1. Use control board testing to check operation of solenoid.

2. If motor does not operate check for voltage at motor.

3. If no voltage at solenoid replace control board.

1. Use control board testing to check operation of motor.

2. If motor does not operate check for voltage at motor.

3. If no voltage at motor replace control board.

1. Use control board testing to check operation of heater.

2. If heater does not operate check for voltage at heater.

3. If no voltage at heater replace Control Board.

1. Use control board testing to check operation of heater.

2. If heater does not operate check for voltage at heater.

3. If no voltage at heater replace Control Board.

Service Procedures

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

Service Equipment

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

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

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

2 stage, 6 cubic feet per minute pump is

recommended.

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

• Leak detector

• Charging cylinder

• Line piercing saddle valve

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

• Swaging tools

• Flaring tools

• T ubing cutter

• Flux

• Sil-Fos

• Silver solder

• Oil for swaging and flaring

Use only part # R0157532

• Copper tubing

Use only part # R0174075 and # R0174076

• Dry nitrogen

99.5% minimum purity, with -40°F or lower dew point

• Crimp tool

• Tube bender

• Micron vacuum gauge

• Process tube adaptor kit

• Heat trap paste

• ICI appliance grade HFC134a

WARNING

Drier Replacement

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

Every time sealed HFC134a system is repaired, drier filter must be replaced with, part # B2150504.

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

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

1. Score capillary tube close to drier and break.

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

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

4. Remove drier.

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

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

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

WARNING

Service Procedures

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

Refrigerant Precautions

WARNING

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

CAUTION

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

NOTE: All precautionary measures recommended by

refrigerant manufacturers and suppliers apply and should be observed.

Line Piercing Valves

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

NOTE: Do not leave line piercing valves on system.

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

Open Lines

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

Compressor Operational Test

(short term testing only) If compressor voltage, capacitor, overload, and motor

winding tests are successful (do not indicate a fault), perform the following test:

1.Disconnect power to unit.

2.Discharge capacitor by shorting capacitor terminals through a resistor.

NOTE: Not all units have run capacitor.

3.Remove leads from compressor terminals.

4.Attach test cord to compressor windings.

• Common lead on test cord attaches to C terminal

on compressor.

• Start lead on test cord attaches to S terminal on

compressor.

• Run lead on test cord attaches to R terminal on

compressor.

WARNING

Attaching Capacitor for Compressor Test

5. Connect a known good capacitor into circuit as shown above. For proper capacitor size and rating, see technical data sheet for unit under test.

NOTE: Ensure test cord cables and fuses meet

specifications for unit under test (see Technical Sheet for unit under test).

6. Replace compressor protector cover securely .

7. Plug test cord into outlet, then press and release start cord switch.

To avoid risk of damage to compressor windings, immediately disconnect (unplug) test cord from power source if compressor does not start. Damage to compressor windings occurs if windings remain energized when compressor is not running.

If compressor runs when direct wired, it is working properly. Malfunction is elsewhere in system.

If compressor does not start when direct wired, recover system at high side. After the system is recovered, repeat compressor direct wire test.

If compressor runs after system is recovered (but would not operate when wired direct before recovery) a restriction in sealed system is indicated.

If motor does not run when wired direct after recovery, replace faulty compressor.

To AC supply

Switch

Compressor

Fuses

CRS

Capacitor

CAUTION

Service Procedures

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

Dehydrating Sealed Refrigeration System

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

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

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

Leak Testing

DANGER

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

WARNING

Testing Systems Containing No Refrigerant Charge

1. Connect cylinder of nitrogen, through gauge manifold, to process tube of compressor and liquid line strainer.

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

3. Check for leaks using soap suds.

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

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

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

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

Testing Systems Containing a Refrigerant Charge

1. Stop unit operation (turn refrigerator of f).

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

NOTE: Use soap suds on areas leak detector cannot

reach or reliably test.

Service Procedures

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

Restrictions

Symptoms

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

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

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

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

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

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

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

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

Testing for Restrictions

To determine if a restriction exists:

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

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

• If temperature of condenser tubing is consistent

throughout, go to step 4.

• If temperature of condenser tubing drops suddenly

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

WARNING

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

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

• If pressure equalization takes longer than 10

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

• If pressure equalization takes less than 10 minutes,

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

5. Recover refrigerant in sealed system.

NOTE: Before opening any refrigeration system,

capture refrigerant in system for safe disposal.

6. Remove power from unit.

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

7. Remove and replace restricted device.

8. Evacuate sealed system.

9. Charge system to specification.

NOTE: Do not use captured or recycled refrigerant in

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

NOTE: Charge system with exact amount of refrigerant.

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

CAUTION

Service Procedures

WARNING

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

Evacuation and Charging

CAUTION

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

NOTE: Before opening any refrigeration system, EPA

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

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

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

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

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

Evacuation

To evacuate sealed refrigeration system:

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

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

2. Connect low side line to compressor process tube.

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

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

Thermistor

Vacuum Gauge

Compressor

Low Side Gauge

Chargi ng Hose

Compressor Process Tube

.6 cm Copper

Tubing

Valve

Vacuum Pump

Equipment Setup For Evacuation And Charging

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

NOTE: A high vacuum pump can only produce a good

vacuum if oil in pump is not contaminated.

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

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

• If in 2 minutes, micron level stabilizes at 1000

microns or below, system is ready to be charged.

• If micron level rises above 1000 microns and

stabilizes, open valve “A” and continue evacuating.

• If micron reading rises rapidly and does not

stabilize, a leak still exists in system. Close valve “A” to vacuum pump and valve “C” to

vacuum gauge. Invert charging cylinder and open charging cylinder valve “F” to add partial charge for leak checking. With leak detector, check manifold connections and system for leaks. Af ter locating leak, capture refrigerant, repair leak, and begin at step 1.

High S ide Gauge

Valve

Charging Hose

Drier/Process Tube

Charging

Cylinder

Valve

Service Procedures

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

Charging NOTE: Do not use captured or recycled refrigerant in

units. Captured or recycled refrigerant voids any warranty.

NOTE: Charge system with exact amount of refrigerant.

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

To charge system:

1. Close valves “A” to vacuum pump and “C” to vacuum gauge and “E” to low side manifold gauge.

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

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

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

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

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

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

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

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

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

9. Recheck for refrigerant leaks.

WARNING

Refrigerant Charge

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

serial plate.

Service Procedures

WARNING

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

HFC134a Service Information

CAUTION

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

Health, Safety, and Handling

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

Health, Safety, and Handling

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

Safety and handling Wear appropriate skin

Spill management Remove or extinguish

Fire explosion hazards May decompose if

Disposal procedures Recycle or reclaim. Same

1,000 ppm Same

Can cause Asphyxiation, Tachycardia, and Cardia Arrhythmias

and eye protection. Use with adequate ventilation.

ignition or combustion sources. Evacuate or ventilate area.

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

CFC12 HFC134a

Same

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

• No trace of other refrigerants is allowed in HFC134a systems. Chlorinated molecules in other refrigerants such as CFC12, etc. will lead to capillary tube plugging.

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

• Ester oils used in HFC134a systems are so hydroscopic that by the time an inadequate system performance is detected, oil will be saturated with moisture.

• CFC12 has much higher tolerance to system processing materials, such as drawing compounds, rust inhibitors, and cleaning compounds, than HFC134a. Such materials are not soluble in HFC134a systems. If materials were to be washed from system surfaces by ester oils, they could accumulate and eventually plug capillary tube.

• Care must be taken to minimize moisture entering HFC134a system. Do not leave compressor or system open to atmosphere for more than 10 minutes. Excessive moisture in HFC134a system will react with compressor oil and generate acid.

• Compressor must be replaced when performing low side leak repair.

• Drier filter must always be replaced with service drier filter, part #B2150504.

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

• HFC134a compatible copper tubing, part #R0174075 (1/4" O.D. X 18" length) and part #R0174076 (5/16" O.D. X 24" length) must be used when replacing tubing.

• Avoid system contamination by using Towerdraw E610 evaporating oil, part # R0157532, when flaring, swaging, or cutting refrigeration tubing.

Service Procedures

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

Replacement Service Compressor

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

Compressor Testing Procedures

WARNING

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

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

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

• Thermocouple tips should be attached securely to specified locations.

• Do not test during initial pull down. Allow one off cycle or balanced temperature condition to occur before proceeding with testing.

• Refrigerator must operate minimum of 20 minutes after thermocouples are installed.

• Turn control to colder to obtain required on time.

• Wattage reading must be recorded in conjunction with temperature test to confirm proper operation.

• Suction and head pressures are listed on “Temperature and Relationship Chart”. Normally these are not required for diagnosis but used for confirmation on systems which have been opened.

WARNING

Brazing

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

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

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

Generally accepted brazing materials are:

• Copper to copper joints: SIL-FOS (alloy of 15 percent silver, 80 percent copper, and 5 percent phosphorous). Use without flux. Recommended brazing temperature is approximately 1400°F. Do not

use for copper to steel connection.

• Copper to steel joints: SIL VER SOLDER (alloy of 30 percent silver, 38 percent copper, 32 percent zinc). Use with fluoride based flux. Recommended brazing temperature is approximately 1200°F.

• Steel to steel joints: SILVER SOLDER (see copper to steel joints).

• Brass to copper joints: SIL VER SOLDER (see copper to steel joints).

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

CAUTION

Refrigerant Flow

CAPILLARY

TUBE

Not e : Capillary Tub e and Suction Tube are located under Fresh

SUCTION

Food floor.

TUBE

CONDENSER

EVAPORATO R

COMPRESSOR

DISCHARGE

TUBE

POST CONDENSE TUBE

DRYER

PROCESS

TUBE

20, 22, 25 cu. ft. Bottom Mount

Refrigerant Flow Diagram

Cabinet Air Flow

20, 22, 25 cu. ft. Bottom Mount

Cabinet Air Flow Diagram

Machine Compartment Air Flow

COMPRESSOR

DRIP PAN

CONDENSER

20, 22, 25 cu. ft. Model Bottom Mount

Machine Compartment Air Flow Diagram

CONDENSER FAN ASSEMBLY

Water Dispenser

Water Inlet to Dispenser

Water Inlet to Ice Maker

Water Filter

Water Solenoid

Water Solenoid to Ice Maker &

to Ice Maker & Dispenser

Dispenser

Water T ank to Ice Maker & Dispenser

Water Line

20, 22, 25 cu. ft. Model Bottom Mount

Water Flow Diagram

Water Flow Schematic

1/4 “ O.D. PLASTIC TUBING

1/4 “

20, 22, 25 cu. ft. Model Bottom Mount

Water Flow Schematic

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