whirlpool R-92 Service Manual
CONSUMER SERVICES TECHNICAL
EDUCATION GROUP PRESENTS
R-92
WHIRLPOOL & KITCHENAID
IN-DOOR ICE SYSTEM
JOB AID
Part No. 4322658A
FORWARD
This Job Aid, “Whirlpool & KitchenAid In-Door Ice System,” (Part No. 4322658A), provides the
technician with information on the operation and service of the Whirlpool & KitchenAid In-Door
Ice System. 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/Freezer.
The Wiring Diagrams 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 In-Door Ice System.
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 In-Door Ice System to proper operational status.
WHIRLPOOL CORPORATION assumes no responsibility for any repairs made
on our products by anyone other than Authorized Service Technicians.
Copyright © 2002, Whirlpool Corporation, Benton Harbor, MI 49022
- ii -
TABLE OF CONENTS
Page
GENERAL............................................................................................................................... 1-1
Safety First......................................................................................................................... 1-1
PRODUCT INTRODUCTION .................................................................................................. 2-1
Overview ............................................................................................................................ 2-1
THEORY OF OPERATION ..................................................................................................... 3-1
COMPONENT ACCESS ......................................................................................................... 4-1
Component Locations ........................................................................................................ 4-1
Removing The Ice Maker & The Water Fill Tube............................................................... 4-2
Removing The Emitter & Receiver Modules ...................................................................... 4-5
Removing & Reinstalling The Motor .................................................................................. 4-6
Accessing The Selector Switch Pack & Dispenser Switches ............................................ 4-9
DIAGNOSTICS & TROUBLESHOOTING .............................................................................. 5-1
Diagnostics ........................................................................................................................ 5-1
Optics Diagnostics Mode ............................................................................................... 5-1
Optics Diagnostics For Original Design Boards ............................................................. 5-2
Optics Diagnostics For 2002 Design Boards ................................................................. 5-4
Component Diagnostics Mode ....................................................................................... 5-5
Optics Diagnostics Mode Charts .................................................................................... 5-6
Component Diagnostics Mode Chart ............................................................................. 5-7
Troubleshooting Chart A—Original Optics Design ............................................................ 5-8
Troubleshooting Chart B—2002 Optics Design ................................................................. 5-9
Troubleshooting Chart C—Component Diagnostics Mode .............................................. 5-10
Troubleshooting The Motor.............................................................................................. 5-11
WIRING DIAGRAMS & STRIP CIRCUITS ............................................................................. 6-1
Whirlpool Wiring Diagram .................................................................................................. 6-1
KitchenAid Wiring Diagram ................................................................................................ 6-2
Strip Circuits ...................................................................................................................... 6-3
CONFIRMATION OF LEARNING EXERCISES ..................................................................... 7-1
- iii -
— NOTES —
- 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
DANGER
WARNING
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.
immediately follow instructions.
You can be killed or seriously injured if you don’t
follow instructions.
ELECTRICAL POWER SUPPLY &
GROUNDING REQUIREMENTS
WARNING
Electrical Shock Hazard
Disconnect power before servicing.
Replace all panels before operating.
Failure to do so can result in death or
electrical shock.
WARNING
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
WARNING
Electrical Shock Hazard
Connect green ground wire to ground
screw.
Failure to do so can result in death or
electrical shock.
IMPORTANT
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.
• Use an antistatic wrist strap. Connect the
wrist strap to the green ground connection point, or to an unpainted metal surface in the appliance.
- OR -
• Touch your finger repeatedly to a green
ground connection point, or to an unpainted metal surface in the appliance.
• Before removing the part from its package, touch the antistatic bag to a green
ground connection point, or to an unpainted metal surface 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 previous instructions.
1-2
PRODUCT INTRODUCTION
OVERVIEW
The primary objective of the In-Door Ice System is to increase the usable space in the
freezer compartment of the current freestanding side-by-side refrigerator/freezer. The solution is to relocate the ice maker, the ice container, and drive mechanism, and replace this
eye-level volume with a cantilever shelving system. The following description is intended to
relate the changes that have been made from
the current side-by-side ice & water dispenser
configuration. The description is divided into
three categories: Ice Making, Ice Storage, &
Ice Dispensing.
ICE MAKING
The ice maker module and mold have not been
changed from the current models. However,
the location, mounting method, air delivery,
water delivery, ice stripper, and ice level shutoff
have all been redesigned.
Location & Mounting
Air Delivery
Air is delivered to the ice maker mold through
a duct. This duct hooks onto the rear air duct
at the back of the liner, and is secured to the
top of the liner with two screws. The duct directs approximately 50% of the freezer air forward to the ice maker mold. The mounting
bracket, mentioned in the previous section,
also serves as an air director, and directs the
air that is delivered by the duct, under the mold,
and allows it to escape just under the ice stripper.
The ice maker has been relocated to the top
front of the freezer liner, and has been rotated
90˚. Due to code requirements, the ice maker
heater area is now protected by a plastic (PVC)
mounting bracket. The bracket is attached to
the ice maker with three mounting screws, and
is held in place by grooved tracks on either
side of the freezer liner.
Grooved
Track
Screw
(1 of 3)
Mounting
Bracket
Grooved
Track
Air Duct
2-1
Water Delivery
Water is delivered to the ice maker mold by
means of a “tube-within-a-tube” design. A conduit system consisting of three separate pieces
(liner fitting, conduit, back panel fitting) is
foamed into place in the cabinet.
This conduit provides a pathway from the
freezer liner to the back panel. The majority of
this system is routed above the refrigerator liner
to prevent the water tubing from freezing. The
tubing that delivers the water is routed through
the conduit, and is secured by snapping into
place at the freezer liner fitting.
Water Nozzle
The water tube is made of polypropylene with
an overmolded santoprene nozzle. Due to the
rigid nature of the polypropylene, this tube is
mated to a more flexible polyethylene tube with
a John Guest fitting high on the back panel.
This change of material is necessary to prevent kinking when the tubing is attached to the
water valve.
Water
Tube
John
Guest
Fitting
Back Panel Fitting
2-2
Ice Stripper
Ice Level Shutoff
The ice stripper has been modified in order to
direct ice into the new ice container. The main
differences from the current stripper are: an
increased ramp, and a directing wall at the fill
cup end.
Ejector Blades
Ice Stripper & Ramp
The mechanical shutoff arm on the older ice
makers has been replaced with an electronic
ice level control system. This system is located
on either side of the freezer liner and utilizes
infrared light technology to sense the level of
ice in the door-mounted ice container. A manual
shutoff option is still available on the right side
of the freezer liner. This feature consists of a
plastic slide that covers the receiver sensor and
blocks the infrared beam.
5-Cavity Ice Maker For
22 Cu. Ft. Models
Infrared Emitter
Manual
Shutoff
Status LED
Infrared
Receiver
2-3
ICE STORAGE
ICE DISPENSING
The ice container has been redesigned and
relocated to the freezer door. It is secured in
place on the door liner with a sliding springloaded latch, mounted to a plate with two pins.
The mounting plate is foamed-in-place on the
door. The ice container is easily removed and
replaced on the door regardless of the auger
orientation.
The ice container is removed by pressing a
release button on the right side and lifting.
Removal instructions are printed on the container.
Other changes to the ice container consist of
a vertical rod ice auger, and a clear polycarbonate upper section. The vertical orientation
of the bin helps prevent “stale ice” areas, because the ice is a “first in—first out” system
which helps keep the ice fresher. Also, the ice
container can be completely emptied.
Major changes have been made to the power
train. The motor has been redesigned and relocated to the freezer door. The cube/crush
selector solenoid and its related linkage have
been eliminated, and a drive shaft/springloaded coupling have been added.
Motor
The motor is now located on the freezer door
in a foamed-in-place enclosure under the “dispenser bubble” area of the inner door panel.
The motor is mounted to a plastic mounting
bracket, which, in turn, is mounted to the enclosure with four mounting screws.
The motor operates on 115 volts DC (115 volts
AC is delivered to the motor, where it is converted within the motor assembly to DC). This
gives the motor a higher RPM than the earlier
dispenser motors, and results in a faster ice
delivery rate in both the cubed and crushed
modes.
Ice
Auger
Pins Plate
Crushed ice is delivered by turning the motor
in a clockwise direction, and cubed ice is delivered when the motor turns in a counterclockwise direction.
Ice
Container
Release
Button
Motor
Auger Coupling
2-4
Drive Shaft / Coupling
The drive shaft / coupling connects the motor
to the ice container auger. The coupling at the
top of the motor drive shaft is spring-loaded to
allow replacing the ice container without having to orient its coupling with the motor drive
shaft coupling. If the two couplings do not en-
Spring-Loaded Pin
Spring
gage when the container is placed on the door,
the motor drive shaft coupling will be depressed. The next time ice is dispensed, the
motor drive shaft coupling will spring up, and
engage the ice container coupling.
The original designed units use a pin that rests
on a spring, located inside the drive shaft. The
newly designed units have only the spring,
which rests in a shallower opening at the top
of the drive shaft, and eliminates the need for
the pin.
On newly designed models, the hex drive shaft
coupling has a skirt around it to prevent any
pieces of a damaged coupling from falling down
the chute.
Hex Drive Shaft
Top of Original Design
Hex Drive Shaft
Original Hex Drive
Shaft Coupling
Top of Newly Designed
Hex Drive Shaft
Newly Designed
Hex Drive Shaft
Coupling Skirt
Motor
2-5
— NOTES —
2-6
THEORY OF OPERATION
The new ice making system consists of the following: an ice maker with an integrated control module, an electronic ice level sensor, an
external water valve, and a freezer door compartment-mounted ice storage bin.
The ice maker control module is a stamped
circuit that provides power and control for the
ice making loads, which consist of the motor,
heater, and water valve.
The ice harvesting process begins when the
ice maker thermostat closes and signals that
the harvest temperature has been reached.
The closed thermostat applies power to the ice
maker motor and to the heater. As the heater
melts the outer layer of the ice, the motor rotates a rake, which sweeps the ice cubes out
of the mold, and into the storage bin.
Due to the placement of the storage bin on the
freezer door instead of on the cabinet, the
sensing of the ice level is quite different from
the earlier mechanical (bail arm) contact
method. The mechanical arm has been replaced by an electronic control that performs
this function, and two additional functions. It
controls power to the ice maker, and performs
system diagnostics, which includes optics diagnostics and component diagnostics.
The electronic control consists of two separate printed circuit boards mounted on opposite sides of the freezer liner just inside the
door. The board mounted on the freezer door
hinge-side of the cabinet is referred to as the
“emitter board,” and the board mounted on the
mullion side is referred to as the “receiver
board.”
When the ice maker thermostat closes and signals that ice is ready to be harvested, the emitter board sends out an infrared (IR) pulse. If
the path of the pulse is unobstructed to the
receiver board, the phototransistor on the receiver board will “sense” the pulse. The control will then energize a relay, which applies
power to the ice maker, and a harvest begins.
The ice maker loads, the motor, heater, and
water valve, are still controlled by the stamped
circuit module, which is part of the ice maker.
The electronic control will check periodically
to see if the ice maker is at the home position,
(when the ejector stops at the 2 o’clock position). If the ejector is at the home position, the
relay will deenergize, and remove power from
the ice maker until the next harvest.
To improve functionality and reliability, some
important differences exist between the new
In-Door Ice system, and the earlier mechanical-type ice making systems.
The first is that a harvest can only begin if the
freezer door is closed, and previous harvest
conditions are also met (ejector at home). If
the bin is full, and ice is removed, which lowers the ice level, it may take up to 5 minutes
before a harvest starts.
To prevent an early harvest from occurring after the last harvest is completed, a minimum
of 50 minutes must pass before another harvest will be initiated. Closing the receiver’s
shutoff slide covers the sensor and prevents
the ice maker from harvesting ice.
The In-Door Ice control contains two diagnostic routines. One is an optics test, and the other
is a component test. There are two optics tests:
one for the original style optics, and the other
for the 2002 design optics:
1.a) Original Optics—An optics circuit test is
run when the freezer door switch is actuated three times, and the freezer door
is closed to allow a path for the optics
beam to reach the receiver.
b) 2002 Design Optics—An optics circuit
test is run any time the freezer door is
opened.
2. Component Test—A component test is
run on power-up when the freezer door
is closed.
Both routines provide visual feedback as to the
result of the diagnostic. All other system enhancements are transparent during the ice
making system operation.
3-1
— NOTES —
3-2
COMPONENT ACCESS
COMPONENT LOCATIONS
Ice Maker Door
Infrared Emitter
Freezer Door
Ice Bin
Ice Container
Auger Coupling
Motor Drive
Coupling
Hex Drive Shaft
Water Fill
Nozzle
Ice Maker
Infrared
Receiver
Motor
4-1
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