Technical Service Guide

Technical Service Guide
GE Appliances & Lighting
Technical Service Guide
November 2014
Top Freezer Refrigerator
HPS15BTHR
HPS18BTH
HPE15BTH
GIE18HGH
GTS15CTHR
GIE18HSH
GTE15CTHR
GIE18GCH
GPE16DTH
GIE18GSH
GIE16DGH
GTE18LGH
GTE16DTH
GTE18LSH
GTS16DTH
GTE18LMH
GTS16GTH
GTE18GSH
GTE16GTH
GTE18GMH
GTE16GSH
GTE18GTH
GTS16GSH
GTE18CTH
GIE16GSH
GTS18GSH
GTS18GTH
GE Appliances & Lighting
General Electric Company
Louisville, Kentucky 40225
31-9237
IMPORTANT SAFETY NOTICE
The information in this service guide is intended for use by
individuals possessing adequate backgrounds of electrical,
electronic, and mechanical experience. Any attempt to repair a
major appliance may result in personal injury and property
damage. The manufacturer or seller cannot be responsible for the
interpretation of this information, nor can it assume any liability in
connection with its use.
WARNING
To avoid personal injury, disconnect power before servicing
this product . If electrical power is required for diagnosis or test
purposes, disconnect the power immediately after performing the
necessary checks.
RECONNECT ALL GROUNDING DEVICES
If grounding wires, screws, straps, clips, nuts, or washers used to
complete a path to ground are removed for service, they must be
returned to their original position and properly fastened.
GE Appliances & Lighting
Technical Service Guide
Copyright © 2014
All rights reserved. This service guide may not be reproduced in whole or in part
in any form without written permission from the General Electric Company.
–2–
Table of Contents
Safety Requirements..................................................................................................................................................... 5
Introduction....................................................................................................................................................................... 6
Key Features and Updates......................................................................................................................................... 6
Nomenclature................................................................................................................................................................... 7
Product Specifications.................................................................................................................................................. 8
Use & Care Manuals and Mini Manuals................................................................................................................ 12
Refrigeration and Airflow Diagram.........................................................................................................................12
Installation Instructions............................................................................................................................................... 13
Product Specifications.................................................................................................................................................. 15
Structure............................................................................................................................................................................. 16
Control Panel..................................................................................................................................................................... 19
Fresh Food Compartment Air Ducts and Drain Tube..................................................................................... 20
Control Panel..................................................................................................................................................................... 21
Cold Control....................................................................................................................................................................... 22
Electro-Mechanical Defrost Control.......................................................................................................................24
Defrost Controls............................................................................................................................................................... 25
Defrost Control Operations........................................................................................................................................ 26
Adaptive Defrost.............................................................................................................................................................. 27
Electronic Defrost Control (EDC)...............................................................................................................................28
EDC Process Flow Chart............................................................................................................................................... 29
EDC Cooling....................................................................................................................................................................... 30
EDC Defrost........................................................................................................................................................................ 31
EDC Dwell........................................................................................................................................................................... 32
Freezer Components..................................................................................................................................................... 33
Ice Maker Troubleshooting Chart............................................................................................................................35
Freezer Components..................................................................................................................................................... 36
Evaporator Fan Motor................................................................................................................................................... 37
Freezer Components..................................................................................................................................................... 38
Freezer Section Defrost System...............................................................................................................................39
Defrost Circuit................................................................................................................................................................... 42
–3–
(Continued next page)
Machine Compartment................................................................................................................................................ 43
Machine Compartment Components................................................................................................................... 44
Sealed System.................................................................................................................................................................. 49
Sealed System - Evaporator...................................................................................................................................... 50
Sealed System - Evaporator...................................................................................................................................... 51
DPO Evaporator / LokRing Installation................................................................................................................. 52
Sealed System - Heat Exchanger............................................................................................................................55
Sealed System - Compressor.................................................................................................................................... 56
Sealed System - Condenser....................................................................................................................................... 57
Sealed System - Dryer.................................................................................................................................................. 58
Sealed System Brazed Joints.................................................................................................................................... 59
Top Mount Electronic Defrost....................................................................................................................................60
Top Mount Electronic Defrost....................................................................................................................................61
Top Mount Mechanical Timer.................................................................................................................................... 62
Top Mount Mechanical Timer.................................................................................................................................... 63
Warranty............................................................................................................................................................................. 64
–4–
Safety Requirements
GE Factory Service Employees are required to use safety glasses with side shields, safety gloves and
steel toe shoes for all repairs.
Electrically Rated Glove and
Dyneema® Cut Resistant
Glove Keeper
Steel Toed Work Boot
Cut Resistant Sleeve(s)
Dyneema®Cut Resistant
Glove
Plano Type Safety Glasses
Prescription Safety Glasses
Safety Glasses must be ANSI
Z87.1-2003 compliant
Brazing Glasses
Prior to disassembly of the top freezer refrigerator to access
components, GE Factory Service technicians are REQUIRED to follow
the Lockout / Tagout (LOTO) 6 Step Process:
Step 1
Plan and Prepare
Step 2
Shut down the appliance
Step 3
Isolate the appliance
Step 4
Apply LOTO device and lock
Step 5
Control (discharge) stored energy
Step 6
“Try It” verify that the appliance is
locked out
–5–
Introduction
General Electric introduces its new line of energy efficient 15’, 16’, and 18’ cu. Ft. 28” wide top freezers. The
new top freezers were designed to meet the 2014 energy regulatory requirements. Along with meeting the
new energy requirements, it has new appearance features such as , new designer door handles, GE badge
and round doors that create an attractive external appearance. The interior has a Redesigned control
housing, Z-style fresh food shelves (on some models), 8% larger vegetable pans and a 2 position freezer
shelf. A newly designs air tower improves run time and air flow. The new ice maker location and redesigned
ice bucket helps to reduce ice spillage.
Key Features and Updates
•
GE’s simplest door reversal ever
•
Newly designed condenser (moved from bottom of fridge to rear behind access cover)
•
Front serviceable Cold Control, Defrost Control and Freezer components
•
Omega groove door liners for ease of replacing and adjusting door gaskets
•
Durable high gloss ABS liners helps prevent cracking
•
Galvanized doors for improved corrosion resistance
•
Heavy duty door hinge and handle system
•
Improved low friction pan slides prevent binding and squeaks
•
8% larger vegetable pans take advantage of dead air space on sides and below pans
•
Freezer shelf with 2 positions adding flexibility to freezer space
•
New high density ice maker system makes more ice faster and takes up less space with the new
efficiently designed ice bucket
•
New smooth handles replace textured handles for easier cleaning
•
Quick space shelf (on select models)
•
Clear modular door bins (on select models)
–6–
Nomenclature
Serial Number
The nomenclature breaks down and explains what the letters and numbers mean in the model number. The
first two characters of the serial number identify the month and year of manufacture. The letter designating
the year repeats every 12 years
Example: LA123456S = June, 2013
A – JAN
D – FEB
F – MAR
G – APR
H – MAY
L – JUN
M – JUL
R – AUG
S – SEP
T – OCT
V – NOV
Z – DEC
2024 - Z
2023 - V
2022 - T
2021 - S
2020 - R
2019 - M
2018 - L
2017 - H
2016 - G
2015 - F
2014 - D
2013 - A
The Model Serial ID Tag is located inside
the fresh food compartment in the left
hand corner.
The Mini Manual is taped to the
machine compartment cover.
–7–
Product Specifications
Specification for 15, 16 Cu Ft Mechanical Timer
Refrigerator
REFRIGERATION SYSTEM
DISCONNECT POWER CORD BEFORE SERVICING
Refrigerant Charge
4.6 ounces / 0.13 kg
(R134a)
Compressor @ 120 VAC 690 BTU/hr. / 202W
~60 Hz
Minimum Vacuum @ 2 19 inches / 48 cm
minutes
Minimum Equalized Pressure
@70°F / 21°C
37.8 PSIG / 362 kPa
(abs)
@90°F / 32°C
50.7 PSIG / 451 kPa (abs
IMPORTANT - RECONNECT ALL GROUNDING
DEVICES
All parts of this appliance capable of conducting
electrical current are grounded. If grounding wires,
screws, straps, clips, nuts or washers used to
complete a path to ground are removed for service,
they must be returned to their original position and
properly fastened.
IMPORTANT SAFETY NOTICE
This information is intended for use by individuals
possessing adequate backgrounds of electrical,
electronic and mechanical experience. Any attempt
to repair a major appliance may result in personal
injury and property damage. The manufacturer or
seller cannot be responsible for the interpretation of
this information, nor can it assume any.
INSTALLATION
Clearance must be provided for air circulation
TOP
SIDES
REAR
1 inch / 25 mm
3/4 inch / 19 mm
2 inch / 51 mm
REPLACEMENTPARTS
Temperature Control
Defrost Control
Defrost Thermostat
Defrost Heater
Condenser Fan Motor
Evaporator Fan Motor
Relay/Overload
Drier
Fuse Harness
ELECTRICAL SPECIFICATIONS
Cold Control (Position 5)
Defrost Control @ 120 VAC
~60 Hz
Defrost Thermostat
Electrical Rating:
Maximum Current Leakage
Maximum Ground Path
Resistance
28.0°F
15 hrs. / 33 min
64-23°F
120 VAC AC 60Hz
0.75 mA
0.14 Ohms
Pub. No. 31-51875-4
NO LOAD PERFORMANCE
Control Position 5/C and Ambient
Temperature of
Fresh Food, °F / °C
Frozen Food, °F / °C
Run Time %
70°F
33-39
(-4) -2
23-33
90°F
33-41
(-4) -4
37-49
–8–
WR09X21006
WR09X10049
WR50X10071
WR09X21107
WR60X20871
WR60X10346
WR08X10132
WR86X0096
WR55X21096
REFRIGERATION SYSTEM
Specification for 15, 16 Cu Ft Energy Star
Refrigerator
DISCONNECT POWER CORD BEFORE SERVICING
IMPORTANT - RECONNECT ALL GROUNDING
DEVICES
DISCONNECT POWER CORD BEFORE SERVICING
IMPORTANT - RECONNECT ALL GROUNDING DEVICES
All parts of this appliance capable of conducting
electrical current are grounded. If grounding wires,
screws, straps, clips, nuts or washers used to
complete a path to ground are removed for service,
they must be returned to their original position and
properly fastened.
IMPORTANT SAFETY NOTICE
This information is intended for use by individuals
possessing adequate backgrounds of electrical,
electronic and mechanical experience. Any attempt
to repair a major appliance may result in personal
injury and property damage. The manufacturer or
seller cannot be responsible for the interpretation of
this information, nor can it assume any.
Refrigerant Charge
4.5 oz
(R134a)
Compressor @ 120 VAC 615 BTU/hr. /180W
~60Hz
Minimum Vacuum @ 2 19 inches / 48 cm
minutes
Minimum Equalized Pressure
@70°F / 21°C
37.8 PSIG / 362 kPa
@90°F / 32°C
50.7 PSIG / 451 kPa
INSTALLATION
Clearance must be provided for air circulation
TOP
SIDES
REAR
REPLACEMENT PARTS
Temperature Control
Electronic Defrost
Control Board (EDC)
Defrost Thermostat
Defrost Heater
Condenser Fan Motor
Evaporator Fan Motor
Relay/Overload
Drier
Fuse Harness
ELECTRICAL SPECIFICATIONS
Cold Control (Position 5)
Defrost Control @ 120
VAC ~60Hz
Defrost Thermostat
Electrical Rating:
Maximum Current
Leakage
Maximum Ground Path
Resistance
28.0°F
Adaptive Defrost
64-23°F
120 VAC AC 60Hz
0.75 mA
0.14 Ohms
Pub. No. 31-51874-5
NO LOAD PERFORMANCE
Control Position 5/C and Ambient
Temperature of
70°F
Fresh Food, °F / °C
33-39
Frozen Food, °F / °C
(-4) -2
Run Time %
23-33
1 inch / 25 mm
3/4 inch / 19 mm
2 inch / 51 mm
90°F
33-41
(-4) -4)
37-49
–9–
WR09X21006
WR55X21128
WR50X10071
WR09X21107
WR60X20871
WR60X10346
WR07X10133
WR86X0096
WR55X21096
Specification for 18 Cu Ft Mechanical Timer
Refrigerator
DISCONNECT POWER CORD BEFORE SERVICING
IMPORTANT - RECONNECT ALL GROUNDING
DEVICES
All parts of this appliance capable of conducting
electrical current are grounded. If grounding wires,
screws, straps, clips, nuts or washers used to
complete a path to ground are removed for service,
they must be returned to their original position and
properly fastened.
REFRIGERATION SYSTEM
Refrigerant Charge
Refer to Rating Plate
(R134a)
Compressor Capacity 600 BTU/hr / 175.8W
(@ 10°F Evap and
105°F Cond)
Minimum Vacuum @ 2 19 inches / 48 cm
minutes
Minimum Equalized Pressure
@70°F / 21°C
26 PSIG / 179 kPa
@90°F / 32°C
35 PSIG / 241 kPa
IMPORTANT SAFETY NOTICE
This information is intended for use by individuals
possessing adequate backgrounds of electrical,
electronic and mechanical experience. Any attempt
to repair a major appliance may result in personal
injury and property damage. The manufacturer or
seller cannot be responsible for the interpretation of
this information, nor can it assume any.
INSTALLATION
Clearance must be provided for air circulation
TOP
SIDES
REAR
1 inch / 25 mm
3/4 inch / 19 mm
2 inch / 50 mm
ELECTRICAL SPECIFICATIONS
Temperature Control (Colder) 23.9-11.1°F /
(-4.5) - (-11.6)°C
Defrost Control
15 hrs/ 33 min
Defrost Thermostat
64-23°F / 17.8 (-5.0)°C
Electrical Rating: 110V to
6.5 Amp
127V AC 60Hz 100V AC 50 Hz
Maximum Current Leakage 0.75 mA
Maximum Ground Path
0.14 Ohms
Resistance
REPLACEMENT PARTS
Temperature Control
Relay
Defrost Control
Defrost Thermostat
Defrost Heater
Condenser Fan Motor
Evaporator Fan Motor
Drier
Harness Jumper Fuse
WR09X21005
WR08X22874
WR09X10049
WR50X22304
WR09X21107
WR17X21162
WR60X10346
WR86X0096
WR55X21096
Pub. No. 31-51904
NO LOAD PERFORMANCE
Control Position,
70°F /
90°F /
Colder Temperature
21°C
32°C
of
Fresh Food, °F / °C
34-40
35-39 /
/1.1-4.4 1.7-3.9
Frozen Food, °F / °C
-3 / -19.4 -3 / -19.4
Running Time %
20-30
41-53
– 10 –
Specification for 18 Cu Ft Energy Star Refrigerator
DISCONNECT POWER CORD BEFORE SERVICING
IMPORTANT - RECONNECT ALL GROUNDING
DEVICES
All parts of this appliance capable of conducting
electrical current are grounded. If grounding wires,
screws, straps, clips, nuts or washers used to
complete a path to ground are removed for service,
they must be returned to their original position and
properly fastened.
IMPORTANT SAFETY NOTICE
This information is intended for use by individuals
possessing adequate backgrounds of electrical,
electronic and mechanical experience. Any attempt
to repair a major appliance may result in personal
injury and property damage. The manufacturer or
seller cannot be responsible for the interpretation of
this information, nor can it assume any.
ELECTRICAL SPECIFICATIONS
Temperature Control (Colder) 34.6-13.4°F /
(-10.3) - (1.4)°C
Defrost Control @ 115V ~60 Adaptive
Hz
Defrost
Defrost Thermostat
64-23°F / 17.8 (-5.0)°C
Electrical Rating: 110V to
6.5 Amp
127V AC 60Hz 100V AC 50 Hz
Maximum Current Leakage 0.75 mA
Maximum Ground Path
0.14 Ohms
Resistance
NO LOAD PERFORMANCE
Control Position
70°F / 21°C
Colder and Ambient
Temperature of
Fresh Food, °F / °C
33-39 /1-4
Frozen Food, °F / °C
Run Time %
REFRIGERATION SYSTEM
Refrigerant Charge
Refer to Rating Plate
(R134a)
Compressor @ 115V
600 BTU/hr / 176W
~60 Hz
Minimum Vacuum @ 19 inches / 48 cm
2 minutes
Minimum Equalized Pressure
@70°F / 21°C
37.8 PSIG / 362 kPa
(abs)
@90°F / 32°C
50.7 PSIG / 451 kPa
(abs)
INSTALLATION
Clearance must be provided for air circulation
TOP
SIDES
REAR
.1 inch / 25 mm
3/4 inch / 19 mm
2 inch / 51 mm
REPLACEMENT PARTS
Temperature Control
Defrost Thermostat
Defrost Heater
Condenser Fan Motor
Evaporator Fan Motor
Relay
Drier
Harness Jumper Fuse
Electronic Defrost
Control Board (EDC)
WR09X21005
WR50X22304
WR09X21107
WR17X21162
WR60X10346
WR08X22874
WR86X0096
WR55X21096
WR55X21623
Pub. No. 31-51898
90°F /
32°C
33-41 /
2-4
(-4) -2 / (-4) (-20)-(-16)
-4 /(-20)-(17)
23-33
37-49
– 11 –
Use & Care Manuals and Mini Manuals
Mini Manuals (available on website):
• Pub. No. 31-51904 (245D1691P004): 18’, 28” Wide Mechanical Timer
• Pub. No. 31-51898 (245D1691P001): 18’, 28” Wide EDC
• Pub. No. 31-51875-4 1875D (245D1627P002): 15’ & 16’, 28” Wide Mechanical Timer
• Pub. No. 31-51874-5 (245D1627P001): 15’ & 16’, 28” Wide EDC
Use & Care Manuals (available on website):
• Pub. No. 49-60697-3 (245D1573P001)
15, 16, 18 Cu. Ft. and 28" Top Freezer
Refrigeration and Airflow Diagram
– 12 –
Installation Instructions
REVERSING THE DOOR SWING
Tools needed:
BEFORE START
•
•
Unplug the refrigerator from its electrical outlet.
Empty all door shelves, including the dairy
compartment.
NOTE: Do not let freezer or fresh food door drop to
the floor. To do so could damage the door stops.
• T20 Torx bit driver
• 1/8 in. Allen wrench (provided in handle
package)
• #2 Phillips screw driver (some models)
NOTE: When installing door handles, follow the
instructions that pertain to the type of handles
provided with the unit.
• 'a' instructions are for Stainless Steel Handles
• 'b' instructions are for Plastic Handles
TO REMOVE DOORS
1.
2.
3.
4.
Remove the top hinge.
Lift off the freezer door.
Remove the center hinge pin.
Lean the fresh food door forward and lift the
door off of the lower hinge pin.
5. Be careful not to lose the spacer and washers.
NOTE: Plastic Handle instructions, see the next page.
STAINLESS STEEL HANDLE
6. Remove the handle screws from the top of the
fresh food door. Remove the handle screws from
the bottom of the freezer door.
7. Loosen set screw on the handle with the
provided 1/8 in. Allen wrench.
8. Remove the door handle.
9. Change places between the handle fastener
and plug button on the door front.
10. Move the plug buttons on the top and front of
the door to the opposite side of the door.
11. Transfer the door stop on the bottom of the door.
12. Attach the handle to the fresh food door with
screws at top of the handle. Use 1/8 in. Allen
wrench to tighten set screw at bottom of handle.
13. Attach handle to the freezer door with screws
at bottom of the handle. Use the 1/8 in. Allen
wrench to tighten set screw at top of handle.
14. Attach badge on freezer door opposite of the
handle.
– 13 –
(Continued next page)
REVERSING THE DOOR SWING
PLASTIC HANDLE ASSEMBLY
6. Remove the handle screws from the top of the
fresh food door. Remove the handle screws from
the bottom of the freezer door.
7. Remove the door handle on the fresh food
door by sliding the handle up off of the fastener.
Remove the door handle on the freezer door by
sliding the handle down off of the fastener.
8. Change places between the handle fastener
and plug button on door front.
9. Move the plug buttons on the top and front of
the door to the opposite side of the door.
10. Transfer the door stop on the bottom of the door.
11. Attach handle to the fresh food door by sliding
the handle down onto the fastener and with the
screws at top of handle.
12. Attach the handle to the freezer door by sliding
the handle up onto the fastener and with the
screws at the bottom of the handle.
13. Attach badge on freezer door opposite of the
handle.
6. Install the center hinge bracket on the opposite
side of the opening. (Turn the hinge over to
install.)
TO RE-HANG THE DOORS
1. Remove the hinge pin from the lower hinge
bracket.
2. Remove the lower hinge bracket.
3. Install the bottom hinge bracket on the opposite
side of the opening.
4. Install the lower hinge pin into the hinge bracket
hole to the outside of the refrigerator.
5. Remove the center hinge bracket.
7. Position the fresh food door, tilted forward, over
the lower hinge pin and slide it into place.
8. Install the center hinge pin into the center hinge
bracket and into the hole in the fresh food door.
Make sure the washer is in place over the hinge
pin on top of the bracket.
9. Place the freezer door on top of the center hinge
pin.
10. With the freezer door in place, install the top
hinge into the top of the freezer door. The holes
in the hinge will align with two of the holes on
top of the refrigerator. Install the two screws into
the top hinge.
– 14 –
Product Specifications
Do you hear what I hear? These sounds are normal.
• The new high efficiency compressor may run
faster and longer than an old refrigerator and
might produce a high-pitched hum or pulsating
sound while it is operating.
• There may also be a whooshing sound when the
doors close. This is due to pressure equalizing
within the refrigerator.
• There may be sounds heard associated with
the fans spinning at high speeds. This happens
when the refrigerator is first plugged in, when
the doors are opened frequently or when a large
amount of food is added to the refrigerator or
freezer compartments. The fans are helping to
maintain the correct temperatures.
• There may be cracking or popping sounds
when the refrigerator is first plugged in. This
happens as the refrigerator cools to the correct
temperature.
• The compressor may cause a clicking or chirping
sound when attempting to restart (this could
take up to 5 minutes).
• Expansion and contraction of cooling coils
during and after defrost can cause a cracking or
popping sound.
• On models with an ice maker, after an ice
making cycle, ice cubes dropping into the ice
bucket may be heard.
• The flow of refrigerant through the freezer
cooling coils may make a gurgling noise like
boiling water.
• Water dropping on the defrost heater can cause
a sizzling, popping or buzzing sound during the
defrost cycle.
• A water dripping noise may occur during the
defrost cycle as ice melts from the evaporator
and flows into the drain pan.
• Closing the door may cause a gurgling sound
due to pressure equalization.
– 15 –
Structure
Refrigerator Doors
Fresh Food Door and Hinges
All refrigerator doors have a galvanized treated
finish prior to painting. This treatment gives
an added protection against rust, tropical
environments, and is able to withstand highly
corrosive conditions. The refrigerator doors are a
combination of the inner liner and outer door panel
held together by interior foam. This process makes
both separate pieces one solid sturdy structure.
Both inner and outer doors are now one assembly.
Door Removal
Freezer Door and Hinge
1. Remove all food items from the door(s). Note:
Do not lose washers on the center hinge
pin and lower hinge pin. These washers are
needed for proper door adjustment.
2. Using a 3/8 hex head driver or a #2 Phillips
screw driver, loosen and remove the center
hinge pin.
3. Tilt the fresh food door away from the cabinet
and lift up to clear the lower hinge.
To remove the hinge from the cabinet, remove the
three T20 Torx screws.
Door Removal
1. Remove all food from the inner door liner.
2. Remove two T20 Torx screws and the top hinge
from the cabinet.
3. Open the door and lift it off the center hinge pin.
Removing the lower hinge, then remove the three
T20 Torx screws.
– 16 –
(Continued next page)
Door Stops
Fresh Food Door Stop
Freezer Door Stop
Door Gasket Removal and Replacement
Both the freezer and fresh food door gaskets are
held in place by the inner door panel.
Door Handles
There are three types of handles, and they are
model specific:
•
•
•
Stainless
Plastic
Pocket
The stainless and plastic handles attach similar to
both the Fresh Food and Freezer doors. They are
both secured by two #2 Phillips screws on the top
of the Fresh Food and bottom of the Freezer doors
respectively. The stainless steel handle uses a 1/8
in. Allen wrench to fasten the handles to the doors,
where the plastic handles are slotted and fastened
to a stud on both doors.
1. Pull the old gasket out of the door liner channel.
2. Soak the new gasket in warm water to make it
more pliable.
3. Using the palm of a gloved hand, push the
darted edge of the new gasket into the inner
door retaining channel.
NOTE: The Pocket Handles are foamed in with the
doors and are not replaceable. If a handle is needed,
the door would need to be replaced.
– 17 –
(Continued next page)
Front Mobility Wheels and Leveling Legs
Removal
Base Pan
Warning: Disconnect power to the refrigerator
prior to servicing the mobility wheel assembly. Also,
before moving the refrigerator from its installation,
make sure that the leveling legs are raised to
prevent damage to the flooring.
1.
Remove any items from the Fresh Food
section.
2.
Safely tilt the refrigerator back.
3.
Remove the three 1/4 in. hex head screws and remove the mobility assembly.
The Base Pan is the foundation for the machine
compartment and adds structural strength and
stability to the refrigerator cabinet. It also adds
mobility, and is used for water evaporation. The
base pan supports the following components:
•
•
•
•
Compressor
Condenser/Condenser support
Condenser fan assembly
Wire harness
There are two adjustable legs attached to the
Mobility Wheel assembly. Turn CCW to remove, or
raise the refrigerator and turn CW to re-assemble or
adjust.
The base pan is fastened to the refrigerator cabinet
with two 3/8 in. hex head screws.
NOTE: The base pan and rear mobility wheels are
not available for replacement.
For more information about machine compartment
components, refer to Machine Compartment
section of this service guide.
– 18 –
Control Panel
The control panel is attached to the ceiling of the fresh food section and houses the operational controls for
the refrigerator. The control panel is a functional part that is designed as a conduit that supplies air to the
refrigerator section, and returns the air to the freezer section. In the rear of the control panel, the water from
the evaporator is drained through the control panels drain trough, which is connected to the drain outlet
hose located at the rear of the fresh food section. The control panel houses the following parts:
•
•
•
•
•
•
•
3. Release the Molex connector. Care should be
taken when disconnecting the harness so that
the Control Panel does not fall.
Cold control
EDC board/Defrost control (model dependent)
Light switch
Lamp holder (socket)
Control panel wire harness
EPS duct transition
Cold control knob
Warning: Disconnect power to the refrigerator prior
to disassembling the Control Panel.
The image below reflects the new look Control Panel
for 15’ - 16’ and 18’ - 28” wide product.
Control Panel Components
Control Panel Removal
1. Remove both Quadrex screws (a #2 Phillips
screwdriver can be used to remove Quadrex
screws).
2. Press in on the retainers to release the control
housing assembly.
Control Panel with Electro-Mechanical
Defrost Control
– 19 –
Fresh Food Compartment Air Ducts and Drain Tube
The air supply, freezer return, and control panel retainers are a single piece foamed in transition that
connects the freezer to the fresh food section. This transition allows forced air to be directed from the freezer
to the fresh food section and back to the freezer through the return. The return also is used for removing
water after a defrost cycle, which drains into the control panel drain trough and out of the drain tube outlet.
The retaining clips also help secure the control panel to the ceiling of the fresh food section.
– 20 –
Control Panel
Light Switch
Light Socket
Warning: Disconnect power to the refrigerator prior
to servicing.
Light Socket Removal
Door Switch Removal
1. Remove the control panel (see the Control Panel
Removal section in this Guide).
2. Remove the EDC board cover (if the model has
an EDC board) to access the Door Switch.
3. Push in on the Door Switch tab, and remove the
switch from the Control Housing and unplug.
1. Unscrew the light bulb and remove.
2. Use a small flat blade screwdriver and lift up
on the light socket tab. The light socket can be
serviced without removing the control panel.
3. Disconnect the wire leads from the light socket.
The door switch receives 120 VAC from the line
voltage through the brown wire. When the Fresh
Food door is open, the Door Switch closes and
sends 120 VAC through the red wire to the Fresh
Food 40W Lamp. The Door Switch operation is the
same in the EDC models as it is in the Timer models
with one difference: the EDC model the Door Switch
provides door opening feedback to the control. See
the Adaptive Defrost section in this Guide for more
information.
– 21 –
Cold Control
A Cold Control is used to regulate the operation of the compressor and thus maintain desired food
temperatures. The Cold Control consists primarily of a capillary tube and bellows assembly, a set of normally
closed contacts, and a mechanical linkage.
The Cold Control is adjustable by means of a shaft, which rotates a cam to apply bias pressure against the
bellows. With a knob on the shaft, the user can adjust the temperature setting as desired. Numbers on the
knob indicate relative control settings that vary the temperature.
Pressure within the gas-charged capillary tube and bellows assembly respond to temperature sensed at the
coldest point along the length of the capillary tube. Rising temperature causes the pressure to increase and
expand the accordion-type bellows. The expanded bellows actuates the linkage, which allows the contacts
to close. When the temperature drops, the bellows contract due to a decrease in pressure and the snapaction of the linkage opens the contacts. When the control shaft is rotated to the “off” setting, the cam
manually presses the linkage against the contacts and holds them open.
The temperature control is connected electrically
in series with the compressor. While the control
contacts remain closed, the compressor is
energized until the pre-selected temperature is
reached. The control contacts then open the circuit
to the compressor. The compressor will remain off
until the temperature increases sufficiently to cause
the control contacts to close.
The difference between the off and on temperatures is called the temperature differential. On most controls,
the differential is fixed and, remains constant at all settings. For example, where the temperature limits of
a control at the warm setting are: 30ºF - 21ºF; at mid: 20ºF - 11ºF, and at cold: 10ºF - 1ºF, the control has a
constant 9ºF differential.
– 22 –
(Continued next page)
Cold Control Removal
1. Remove the control console (see the Control
Panel Removal section in this Guide).
2. Remove the temperature adjustment knob.
3. Disconnect the wire leads and ground wire from
the Cold Control.
NOTE: When reinstalling the Cold Control, reconnect
the ground wire and fully insert the Cold Control
capillary into the sleeve.
The Cold Control switches 120 VAC from the brown
wire to the grey to the Defrost Control.
120 VAC is supplied to the Cold Control from L1 to
CC terminal when the K2 relay, located on the EDC
board, is in the compressor run position.
4. Push Cold Control either to the left or right to
clear the retaining tabs. Lift up on the side that
has cleared from the tab and remove.
On electromechanical models, the Cold Control
switches 120 VAC from the brown wire to the gray
to the Defrost Control.
5. Remove (do not discard) the EPS Duct transition
to access the Cold Control capillary.
6. Remove the capillary from the sleeve.
On models with an EDC board, 120 VAC is supplied
to the L1 terminal of the EDC. When the K2 relay is
closed, 120 VAC is supplied to the cold control.
– 23 –
Electro-Mechanical Defrost Control
A defrost circuit is used on all models having the
automatic defrost feature. This feature is often
called NO FROST or FROST FREE, which simply
means that frost is conveniently and automatically
removed without any action required by the
consumer. (Frost always accumulates where
refrigeration takes place.)
The electrical components which comprise the
defrost circuit are:
•
the Heater (or heaters)
•
the Control (often called the “defrost timer")
•
the Defrost Thermostat (sometimes called the
“Bi-Metal")
The defrost control used on most models is a
simple electro-mechanical timer. It consists of a
clock motor, attached to an insulated housing that
contains a cam, and a single pole, double throw
switch. The terminals are clustered together at one
end of the control housing.
The purpose of the defrost control is to regulate the
frequency of the defrost cycles and the duration
of each cycle. This is accomplished by energizing
the clock motor to drive a set of gears that, in turn,
rotate the cam which operates the switch. The
defrost cycle begins when the cam has rotated to
the position where a mark on the cam aligns with
a mark on the control housing. At this position,
terminal 4 switch blade drops off the edge of the
cam. This opens the first set of contacts (terminals
3 and 4) and closes the second set of contacts
(terminals 3 and 2). As the cam continues to rotate,
terminal 3 switch blade will drop off the edge of
the cam. This opens the second set of contacts
(terminals 3 and 2) and closes the first set of
contacts (terminals 3 and 4) thus, ending the defrost
cycle. An audible "SNAP" can be heard each time a
switch blade drops off the edge of the cam (at the
beginning and ending of the defrost cycle).
– 24 –
Defrost Controls
Defrost Control
Electronic Defrost Control (EDC) Board
Removal
Mechanical Defrost Control Removal
1. Remove the control panel (see the Control Panel
Removal section in this Guide).
2. Disconnect the control panel wire harness.
3. Disconnect the wiring harness connector from
the defrost control.
4. Press the locking tabs back and slide the defrost
control out of the control panel.
1. Remove the control panel (see the Control Panel
Removal section in this Guide).
2. Disconnect the control panel wire harness.
3. Remove the two push pins.
4. Remove the cover and flip the control over.
5. Disconnect the EDC wiring and remove EDC
board from the control panel.
The defrost control switches 120 VAC from the
cold control (grey) wire at terminal 3. The purpose
of the defrost control is to regulate the frequency
of defrost cycles and the duration of each cycle.
Defrost time is 15 hours of accumulated compressor
run time. The defrost control stays in defrost for
approximately 33 minutes. The defrost control
provides power to the following:
• Terminal 1 (orange) is neutral for the timer
motor.
• Terminal 2 (blue) 120 VAC to defrost cycle.
• Terminal 3 (brown) 120 VAC to timer (from cold
control)
• Terminal 4 (black) 120 VAC cooling cycle
operation
The EDC board receives 120 VAC through brown at
L1. The EDC controls the following:
1. 120 VAC Line voltage to the cold control through
the K2 relay, L1 (brown) to CC (gray).
2. Defrost heater operation through the K2 relay,
L1 (brown) to DF (blue).
The EDC receives input from the following:
1. Compressor run time through CR (black)
2. Fresh Food door openings through FF (red)
3. Defrost Heater time through DT (pink)
NOTE: Freezer is not monitored, as there is no
freezer door switch on top mount freezers at this
time.
– 25 –
Defrost Control Operations
Defrost Control and EDC Board Operations
Electro-mechanical defrost control function during
the cooling mode.
Electro-mechanical defrost control during defrost
mode.
EDC board function during cooling mode.
EDC board function during defrost mode.
– 26 –
Adaptive Defrost
Introduction
Adaptive defrost control for top mount, no-frost (TMNF) models was introduced in GE manufactured
refrigerators in 2005. With the push for more energy efficient appliances, this type of defrost control is
becoming more widespread on TMNF model refrigerators. The conventional defrost timer has been replaced
by an electronic control defrost board. These refrigerators use less electricity by more precisely controlling
the defrost cycle. The adaptive defrost interval will vary from 12 to 60 hours depending on the compressor
run time and door openings. These models still incorporate a conventional cold control for compressor
operation.
Adaptive defrost means defrosting based on the compressor run time, along with door open times instead of
defrosting after a set time (which is what mechanical timer models do). This provides energy benefits.
In normal operating condition, the board simply provides power to the cold control. The cold control turns
the compressor on/off based off of the temperature set point and corresponding cabinet temperature.
The board knows when the compressor is on via the CR input. The CR input is tied to the compressor (cold
control), so when the compressor turns on, the CR input has feedback voltage.
– 27 –
Electronic Defrost Control (EDC)
The EDC processes:
1. The amount of time the compressor has run.
2. The number of times the fresh food door was open.
3. The length of time the defrost heater was on.
During the defrost mode, the electronic control monitors the defrost heater operation (heater ON time). Once
the heater operation is terminated by the Defrost Thermostat, the electronic control will allow a DWELL TIME
before initiating the next cooling cycle. Dwell time is the elapsed time from the heater termination until the
cooling operation is resumed (approximately 15 minutes). If the Defrost Heater remains on more than 25
minutes (or a maximum of 40 minutes), the EDC board will go directly into the cooling mode and bypass the
DWELL TIME MODE. This cycle would be considered an Abnormal Defrost.
During the cooling operation, the electronic control monitors door opening times and compressor run times.
These times are measured in seconds (1 second of door opening = 286 seconds) and are accumulated until
they add up to 80 hours of total equivalent compressor run time. One door opening at 1 second X 286, is
equivalent to 4 minutes 46 seconds of compressor run time.
Once 80 hours (4600 minutes) of total equivalent compressor run time is reached, the refrigerator will enter
the Defrost Mode. The total equivalent compressor run time is calculated by multiplying the accumulated
amount of time the Fresh Food door was open since the last defrost cycle by a multiplication factor, then
adding to that number the actual amount of time the compressor has been running since the last defrost
cycle.
The MULTIPLICATION FACTOR of 286 seconds is used to compute an equivalent compressor run time for each
time the refrigerator (Fresh Food door) door is open. For example, with a multiplication factor of 286 and a
door open 10 times for one second each time, 2860 seconds of equivalent compressor run time is noted,
(286 X 10). NOTE: To get door opening seconds to minutes, divide the total number of door opening seconds
by 60 (60 seconds = 1 minute). Example: 10 x 286 = 2860 seconds, 2860 / 60 = 47 minutes.
(
Accumulated door open
time (door openings)
X
Multiplication
factor of
286 seconds
)+
Accumulated
compressor
run time (minutes)
=
Total equivalent
compressor
run time (minutes)
EDC Board Diagnostics
Initiating Diagnostic Defrost
To initiate manual defrost, open the fresh food door, then press the door switch located on the control
panel three (3) times within five (5) seconds and close the fresh food door. Pressing this switch in this way
will initiate an immediate defrost unless the control is already in the Defrost or Dwell states. After defrost
is initiated, the normal defrost sequence will follow and the normal rules will determine the start of the
next defrost. NOTE: If the refrigerator has been unplugged, wait 45 seconds before initiating the defrost
diagnostic.
Terminate Diagnostic Defrost
To terminate defrost, with the fresh food door open press the door switch three (3) times within five (5)
seconds when the control is in either the Defrost or Dwell states. Pressing this switch in this way will
terminate the defrost and initiate a first cycle state (time starts at 0).
– 28 –
EDC Process Flow Chart
COOLING OPERATION (Abnormal Adaptive Defrost)
At the end of an abnormal defrost, the electronic control will return the refrigerator to cooling operation.
However, due to an abnormal amount of heater ON time that occurs during the defrost cycle, the control
will initiate the next defrost operation after a fixed 12 hours of accumulated compressor run time (nonadaptive defrost operation). The intent of this cycle is to attempt to clear any ice that may be remaining on
the evaporator.
During this non-adaptive defrost period, only the compressor run time will be monitored. The door open
times will have no bearing on when the next defrost cycle will occur. The refrigerator will operate just like a
conventional defrost system, for a fixed 12 hour period.
If the next defrost is a normal defrost (heaters off in less than 25 minutes), the electronic control will allow the
refrigerator to return to normal adaptive defrost operation. The next defrost will occur after 80 hours of total
equivalent compressor run time. However, if the next defrost is abnormal, the refrigerator will once again
revert to a fixed 12 hour accumulated compressor run time and then enter the defrost cycle (non-adaptive
defrost operation).
– 29 –
EDC Cooling
The compressor operation is controlled by the cold control, which is external to the EDC board. The EDC
board is summing the compressor run time by monitoring the compressor voltage at pin CR.
Freezer door monitoring is not used on these models since there are no lights in the freezer.
NOTE: The 286 seconds of accumulated time per fresh food door opening takes in account for the
lack of a freezer door switch.
– 30 –
EDC Defrost
Defrost
The compressor is turned off and the defrost heaters are turned on by energizing the K2 relay and sending
120 VAC through the DF terminal. During this time, the defrost termination is monitored through the DT
terminal to determine when the defrost thermostat opens. If less than 25 minutes of defrost heater run
time the control will immediately enter the dwell state. If the defrost thermostat does not open during the
prescribed 25 minutes or less, defrost will be terminated by time (max 40 minutes) and the dwell state will be
bypassed.
– 31 –
EDC Dwell
Dwell
During the 15 minute dwell time, the K2 relay continues to keep the compressor off.
When the defrost thermostat opens, the dwell time timer is activated. Except when the defrost
heater on time exceeds 25 minutes.
– 32 –
Freezer Components
Ice Maker
Electro-Mechanical Ice Maker
Some 15’-18’ refrigerators have factory installed ice
makers, but all are ice maker ready.
To manually cycle the ice maker the switch needs
to be in the on position and the rake must be in the
home position. Safely pull the ice maker rake in a
CW direction until a click is heard, then release and
remove hand and the ice maker will cycle.
There are two types of ice makers that may be
encountered in the field:
•
Electro-Mechanical
•
Electronic
Electro-Mechanical ice makers have an on/off slide
switch, and the electronic ice makers have a toggle
on/off switch on the side of the ice maker control
housing.
The Electro-Mechanical Ice Maker is a single fill
ice maker and is cycled at approximately 15°F by
a thermostat attached to the mold body. The ice
maker will harvest 7 cubes at an average cycle time
between 75 - 90 minutes.
Ice Maker Removal (Ice Makers are optional)
1. Unplug the ice maker. Use a small flat blade
screwdriver to release the tabs.
If the ice maker does not cycle, verify that the ice
maker plug is securely plugged in, and that 120 VAC
is present.
Electronic Ice Maker
2. Loosen the two 1/4 in. hex head screws.
3. Lift the ice maker up to clear the screws and
remove the ice maker.
The Electronic Ice Maker is an adaptive fill ice maker
that has onboard diagnostics.
The adaptive fill allows the ice maker to compensate
for low water pressure conditions by way of
monitoring the mold thermistor.
Water entering the ice maker will cause the mold
temperature to change, effecting the resistance of
the thermistor. There are three possible water fill
times.
– 33 –
(Continued next page)
Ice Maker continued
Service Diagnostics for Electronic Ice Maker
After the ice cubes harvest, the mold is pre-chilled to
35°F before starting the fill process. When the mold
temperature reaches 36°F, the ice maker will fill for 5.1
seconds. If the mold rises above 42°F, water reaches
the front of the mold and no further fills are needed.
If there is no change in the temperature then a 2.5
second fill will occur. If temperature does not rise a
third and final time, a fill of 2.4 seconds will be initiated.
During the first 15 seconds that power is first
applied to the icemaker, the Service Diagnostic Test
mode may be entered. The service mode is entered
by pushing the feeler arm from the “out” position to
the “in” position and back again 3 times (and only 3
times) within 15 seconds.
First Fill
Second Fill
Third Fill
5.1 sec.
2.5 sec.
2.4 sec.
Average cycle time, 75 - 90 minutes.
For more information about the Electronic Ice
Maker, refer to Technical Service Guide 31-9063.
– 34 –
Ice Maker Troubleshooting Chart
For more information about the Electronic Icemaker, refer to Technical Service Guide 31-9063.
NOTE: Only the feeler arm, stripper and fill cup are servicable on the ice maker.
– 35 –
Freezer Components
Air Tower Removal
4. Remove the air baffle from the air duct.
1. Remove shelving.
2. Place a small flat blade screwdriver in the air
tower slot and gently push up.
The air baffle controls air distribution to the fresh
food section. The air baffle is non-adjustable and
must be placed back in the supply duct or cooling
issues will occur.
Evaporator Cover Removal
1. Remove the two 1/4 in. hex head screws.
2. From the fan orifice, pull the evaporator cover
outward to remove.
3. Gently push in on either side and lift up. Swing
the bottom outward and slightly pull down for
the air tower tabs to clear the evaporator cover.
– 36 –
Evaporator Fan Motor
The evaporator fan motor is connected electrically in parallel with the compressor and condenser fan
motor. When the cold control contacts are closed, the compressor and evaporator fan motor are energized
simultaneously.
The evaporator fan motor is a AC/DC motor, the motor converts AC voltage to DC voltage. The purpose of
using this motor is for energy efficiency.
To check the evaporator AC/DC fan motor, carefully check for 120 VAC at the fan motor connector. If 120 VAC
is present at the connector and the fan is not operating, replace the fan motor.
Rubber grommets or isolators that are used to mount the fan motor must be in position not only to insure
quiet motor operation, but also to properly center the blade in the orifice. Likewise, the mounting screws
must be tight to properly secure the motor. All wiring should be carefully dressed to avoid obstructing the
fan blade.
NOTE: Motor resistance and VDC cannot be checked due to the motor design.
– 37 –
Freezer Components
Evaporator Fan Removal
1. Remove freezer shelving.
2. Remove the ice maker, if one is installed (see Ice
Maker Removal section in this Guide).
3. Remove the air tower (see Air Tower Removal
section in this Guide).
4. Remove the evaporator cover (see Evaporator
Cover Removal section in this Guide).
NOTE: When reinstalling the evaporator fan motor
and fan blade. make sure the ground wire, fan
grommets, and evaporator fan motor connector are
back in place and firmly connected.
It is extremely important to place the evaporator
fan blade at the prescribed depth. Failure to do so
could cause increased noise, affect air flow and
result in a repeat service call. Set the evaporator
fan blade depth at 1/4 in. (see the image below).
Note the position of the evaporator fan blade when
removing from the motor.
5. Carefully pull the fan off of the motor shaft.
6. Remove the two 5/16 in. hex head screws.
7. Unplug the evaporator fan connector.
– 38 –
Freezer Section Defrost System
Defrost Thermostat
Defrost Thermostat Removal
The defrost thermostat consists of a single pole
switch, a bimetal disc, and a transfer pin within a
metal and plastic case that is sealed with epoxy.
Lead wires, welded to the internal terminals, extend
through the case.
1. Disconnect power to the refrigerator.
The purpose of the defrost thermostat, located on
the evaporator, is to de-energize the heater during
the defrost cycle. The defrost thermostat closes
at 23°F and opens at 64°F. After all frost has been
completely removed from the evaporator, the
temperature of the evaporator begins to rise rapidly.
When the limit temperature of the thermostat is
sensed, the bimetal disc warps and pushes the
transfer pin against a switch blade which opens the
switch contacts. Conversely, when the temperature
of the evaporator has cooled sufficiently, the
bimetal disc warps in the opposite direction. Then
the spring-loaded switch blade pushes the transfer
pin out of the way and closes the contacts.
4. Remove the air tower (see Air Tower Removal
section in this Guide).
2. Remove freezer shelving.
3. Remove the ice maker if one is installed (see Ice
Maker Removal section in this Guide).
5. Remove the evaporator cover (see Evaporator
Cover Removal section in this Guide).
6. Cut the wires at the defrost thermostat (since
the defrost thermostat is being discarded, cut
about 1 in. from the top of the thermostat).
7. Remove the defrost thermostat from the
evaporator.
The defrost thermostat has a metal clip that fastens
it to the evaporator suction line.
The image below represents a electro-mechanical
defrost control which has one defrost thermostat.
EDC control defrost systems have two defrost
thermostats that are ran in series with each other.
It is recommended to replace both defrost
thermostats if an open defrost thermostat is
discovered.
IMPORTANT: When replacing defrost thermostats,
use only approved splicing techniques.
– 39 –
5 Amp Inline Fuse
Defrost Heater
The 5 Amp Fuse opens the line (120 VAC) side of the
defrost circuit and protects the refrigerator from
a shorted/grounded heater. The inline fuse can be
diagnosed by unplugging the connectors at the
defrost heater and the fuse connector. Use an ohm
meter to check continuity.
Defrost heaters are resistive loads and should be
tested for proper resistance as indicated on the
schematic wiring diagram, using a volt/ohm meter.
However, a visual inspection should also be made
and the heater replaced if any of the following
conditions are observed:
5 Amp Inline Fuse Removal
•
Element is open
1. Disconnect power to the refrigerator.
•
Glass tube is broken
2. Access the evaporator section.
•
3. Disconnect the fuse from the defrost heater and
connector located above the evaporator.
Glass tube is opaque with green or black
coating inside
•
Element coils are bunched together
•
End caps or terminals are deteriorated, burnt or
corroded
When replacing a defrost heater, avoid handling the
glass tube with bare hands. Even small quantities
of salt, or other contaminants from the hands
deposited on the surface of the glass will increase
the brittleness, which could result in premature
failure of the heater. Handle the heater by the end
caps. If it should be necessary to grasp the glass
tube, clean it afterward with a damp paper towel or
approved glass cleaner.
If an open fuse is discovered, observe and check
the defrost heater, wire connections at the defrost
heater, and at the defrost control (EDC board/
electro-mechanical defrost control). If faults are
found, replace or repair the components. If no
component or wiring issues are found, only replace
the fuse.
The defrost heater can be checked with a volt/ohm
meter at the EDC board or electro-mechanical
defrost control, depending on the model. If an open
circuit is detected, isolation of the defrost heater will
be needed to verify that the defrost heater is faulty.
Use the schematic for proper check points and
component values.
– 40 –
(Continued next page)
Defrost Heater Removal
8. Carefully bend the aluminum tabs back (located
at each end of the of the defrost heater) and
lower the heater out of the evaporator.
1. Disconnect power to the refrigerator.
2. Remove freezer shelving.
3. Remove the ice maker if one is installed (see Ice
Maker Removal section in this Guide).
4. Remove the air tower (see Air Tower Removal
section in this Guide).
5. Remove the evaporator cover (see Evaporator
Cover Removal section in this Guide).
6. Unplug the Defrost Heater.
NOTE: Evaporator pulled away from the rear wall is
for demonstration purposes. Evaporator does not
need to be pulled out to remove the defrost heater.
Defrost Drain Pan
The defrost drain pan collects melting ice during the
defrost cycle and funnels water to the drain trough
in the fresh food section, where it is sent to the
condenser drain pan where the water is evaporated.
Evaporator Drain Pan Removal
To remove, carefully pull the bottom of the
evaporator forward and lift the drain pan until the
pan lip clears the return duct.
7. Remove the defrost heater holder.
NOTE: Do not operate defrost heaters with the drain
pan removed, as damage to the liner can occur.
After the defrost heater is reinstalled, make sure the
defrost heater holder is back in place.
– 41 –
Defrost Circuit
Defrost Circuit Timer Models
Defrost Circuit EDC Models
– 42 –
Machine Compartment
Machine Compartment Components
Condensor Fan
The purpose of the condenser fan is to efficiently remove heat from the condenser and compressor.
The condenser fan motor is connected electrically in parallel with the compressor. When the cold control
contacts are closed, the compressor and condenser fan motor are energized simultaneously.
The condenser fan motor is a AC/DC motor; the motor converts AC voltage to DC voltage. The purpose of
using this motor is for energy efficiency.
To check the condenser fan motor, safely check for 120 VAC at the fan motor connector BK-OR. If 120 VAC is
present at connector BK-OR and the fan is not operating, replace the fan motor.
Resistance cannot be checked on this device, due to motor design.
*Refer to the model mini manual for the condensor fan motor resistance. (55 Ω / ∞)
– 43 –
Machine Compartment Components
Condenser Fan Assembly Removal
7. Release the plastic fastener from the baffle
(condenser fan motor wire).
1. Disconnect power to the refrigerator.
2. Remove the four 1/4 in. hex head screws from
the rear access cover.
3. Move the water valve out of the way (if
applicable).
4. Remove the one 1/4 in. hex head screw from the
condenser fan assembly.
5. Remove the two 1/4 in. hex head screws from
the rear baffle.
8. Remove the fan blade.
9. Unplug the condenser fan motor connector.
10. Grasp the upper corner of the condenser fan
assembly and move toward the compressor
to allow the assembly to disengage from the
condenser support retainers.
6. Unplug the machine compartment connector.
– 44 –
(Continued next page)
Condenser Fan Assembly Removal continued
Compressor Combo Device
11. Remove the condenser fan assembly from the
machine compartment by grasping the upper
exterior corner and pulling the assembly out on
an angle, making sure to clear the refrigerant
tubing and condenser.
The combo device is a combination relay/overload
device. These combo devices are simply a PTC
(relay) and an overload made together and
contained in one housing.
NOTE: The capacitor is plugged to the combo
device but is a separate part and must be ordered
separately if needed. The capacitor will be covered
in this section.
Solid State Relay
Most refrigerators use a PTC. A PTC is a Positive
Temperature Coefficient Resistor (Relay). This means
that as temperature increases, the resistance
decreases. It is simply a set of contacts pressed
against a solid state, ceramic disc.
NOTE: After installing the condenser fan assembly,
the fan blade must be installed in the proper
direction and the fan depth set at 2 mm, or
approximately 1/16 inches.
The image below shows the direction of the fan
blade and fan depth on the motor shaft. Use the
blade spring clip as a reference to the direction.
If any part of the condenser fan assembly needs
replacing, it is replaced as a whole assembly. The
only exception is the condenser fan blade. The
condenser fan blade can be ordered separately.
The disc is fused with silicon and other elements
that change alignment as electricity passes through
it. The result is that as the current flows through the
PTC and heats it, the resistance of the disc instantly
changes. It goes from 4 ohms, to over 10,000 ohms
in less than a second. When the line voltage sees
this large resistance, all current flows to the run
windings, and the start windings are essentially
taken out of the electrical circuit.
Benefits over mechanical relay:
•
No moving parts
•
No contacts that "make and break"
•
Insect resistant
– 45 –
Overload
Combo Device Removal
The overload provides protection to the compressor
motor by responding to both temperature and
current. The overload consists primarily of a bimetal
element and a set of normally closed contacts. The
auxiliary heater is for a faster response.
1. Disconnect power to the refrigerator.
The overload is connected in series with both
windings of the motor. If the motor fails to start
for any reason, the “high” locked rotor current will
cause the bimetal element to heat, snapping the
contacts open and interrupting current flow through
the motor.
The motor will continue to cycle on the overload so
long as the original reason for tripping persists.
2. Remove the four 1/4 in. hex head screws from
the rear access cover.
3. Remove the combo device retainer (needle nose
pliers work well in removing retainer).
4. Remove the protective sleeve off of the
capacitor.
5. Disconnect the wiring.
6. Disconnect the capacitor from the device.
Run Capacitor
The run capacitor plugs into the combo device and
the same disassembly and safety procedures apply
(ALWAYS DISCONECT POWER).
Run
Capacitor
Combo
device
with Run
Capacitor
connected
Run capacitors are used with single-phase
compressor motors to increase the running
efficiency. The run capacitor is connected in parallel
with the PTC, and is shunted while the PTC cycling
control closes for starting, but is utilized along with
the start winding after the relay contacts open and
so long as the motor operation continues.
– 46 –
Machine Compartment Wire Harness
The new machine compartment wire harness will
come with canoe fasteners attached to harness.
The machine compartment wire harness assembly
comes with the power cord and wiring to the
following machine compartment components:
•
Compressor combo device (black/white)
•
Condenser fan motor (black/white)
•
Water valve (white)
•
Case ground (gray)
•
Unit neutral (orange)
IMPORTANT: When reinstalling the wire harness
back to the refrigerator, make sure that all of the
ground wires, protective sleeve, and electrical
components are securely fastened.
The harness supplies power to the refrigerator
through a Molex connector, located at the right rear
section of the machine compartment.
Checking Combo Device and Compressor
Carefully check the orange and black wires for 120
VAC at the compressor combo device. If power is
present at black and orange at the combo device
perform the following checks:
•
Checking Overload
•
Checking PTC Relay
•
Checking Run Capacitor
•
Checking Compressor Electrically
Checking Overload
Replacing Machine Compartment Wire Harness
1. Disconnect power to the refrigerator.
1. Disconnect power to the refrigerator.
2. Remove the combo device from the compressor.
2. Remove the four 1/4 in. hex head screws from
the rear access cover.
3. Place the multi-meter on ohm’s scale.
3. Disconnect the wiring from the machine
compartment (See Machine Compartment
section in this Guide).
4. Check overload for approximately 1Ω (NOTE: If
overload is warm, allow a few minutes for it to
cool down before checking).
4. Disconnect the ground wires from the case.
5. If overload is open, replace the combo device.
5. Remove the condenser fan assembly (see
Condenser Fan Removal section in this Guide).
IMPORTANT: The overload is a safety device. If the
overload is open, look for these possible reasons:
6. Remove the combo device.
•
Dirty condenser
7. Remove the water valve.
•
Condenser fan motor not running
8. Use needle nose pliers or side cutters to remove
the connectors.
•
Low voltage, less than 105 VAC
•
Refrigerator on an unapproved extension cord
•
Shorted, stalled or grounded compressor
– 47 –
(Continued next page)
Checking PTC Relay
Checking Compressor Electrically
1. Disconnect power to the refrigerator.
1. Disconnect power to the refrigerator.
2. Remove the combo device from compressor.
2. Remove combo device from the compressor.
3. Place meter on ohm’s scale.
3. Place meter on the ohm’s scale.
4. Check PTC relay at pins 5 and 6 on back side of
the relay (the portion that plugs into compressor.
(Resistance should be approximately 6Ω - 11Ω).
4. Take the following three readings (see wiring
diagram for compressor resistance values).
5. If the PTC relay is open, replace the combo
device.
•
Between Run and Start
•
Between Common and Start
Things to check if faulty PTC Relay is found:
•
Between Common and Run
•
Dirty condenser
•
Condenser fan motor not running
•
Low voltage, less than 105 VAC
•
Refrigerator on an unapproved extension cord
•
Shorted, stalled or grounded compressor
Refer to the refrigerator schematic for compressor
resistance values.
5. Place one meter lead to case ground and the
other to any of the three compressor terminals
alternating between the R, C, and S, to check for
a grounded compressor.
6. If the compressor is stalled, shorted, opened, or
internally grounded, the replace the compressor.
Checking Run Capacitor
1. Disconnect power to the refrigerator.
Things to check if faulty compressor is found:
2. Remove the combo device from the compressor.
•
Dirty condenser
3. Place meter to capacitance (set meter to CAP)
and place meter leads to the capacitor. The
meter should display approximately 12 µF.
•
Condenser fan motor not running
•
Low voltage, less than 105 VAC
•
Refrigerator on an unapproved extension cord
4. Replace the run capacitor if open or shorted.
The compressor will start and run without the run
capacitor being in the circuit, but will not run as
efficiently.
Refer to the mini manual for correct electrical resistances
– 48 –
Sealed System
WARNING
•
•
Evacuation and Charging Procedure
Be careful when using a torch inside the plastic
cabinet. Use approved safety equipment and
protect the liner from damage with the heat
shield kit (part #WX5X8926), which includes the
heat shield and thermal paste. The thermal
paste is available separately (part #WX5X8927).
Before cutting or using a torch on refrigerant
tubes, recover the refrigerant from the system,
using approved recovery equipment.
•
Never charge new refrigerant through the purge
valve. This valve is always located on the highpressure side of the system.
•
Never apply heat from any source to a container
of refrigerant. Such action will cause excessive
pressure in the container.
•
Always wear goggles when working with
refrigerants and nitrogen holding charge in
some replacement parts. Contact with these
gases may cause injury.
1. Attach the hose from the R-134a charging
cylinder to the process tube port on the
compressor.
2. Evacuate the system to a minimum 20 in.
vacuum using the refrigerator compressor and
recovery pump, which is attached to the new
drier assembly.
3. Turn off the recovery pump. Close the ball valve
on the hose connected to the high-pressure
side port connection. Add 3 ounces of R-134a
refrigerant to the system. Let the refrigerator
operate and circulate the refrigerant for 5
minutes.
4. Open the ball valve. Recover the purge/sweep
charge using the recovery pump and the
refrigerator compressor until a 20 in. vacuum
is attained. Close the ball valve and remove the
recovery hose.
5. Charge the system with the exact amount of
R-134a refrigerant specified.
6. Disconnect the power cord to the refrigerator.
This allows the pressure to equalize. After 3 to 5
minutes, the low-pressure side will be positive
and then, the hose-to-charging port can be
disconnected.
7. Using an electronic leak detector, check all
brazed joints and both schrader ports. Reinstall
caps to schrader ports.
– 49 –
Sealed System - Evaporator
Evaporator Removal
•
1. Disconnect power to the refrigerator.
Protect wiring from heat during unbrazing
and re-brazing.
12. Cut the suction line off of the evaporator (see
image below).
2. Recover refrigerant.
3. Remove freezer shelving (if applicable).
13. Cut the capillary tube section off (see image
below).
4. Remove ice maker if installed (see Ice Maker
Removal section in this Guide).
14. Unbraze the capillary tube.
5. Remove the air tower (see Air Tower Removal
section in this Guide).
15. Unbraze the suction line.
6. Remove evaporator cover (see Evaporator
Cover Removal section in this Guide).
7. Remove evaporator fan (see Evaporator Fan
Removal section in this Guide).
8. Remove defrost thermostat from the evaporator
(see Defrost Thermostat section in this Guide).
9. Remove the defrost heater (see Defrost Heater
section in this Guide).
10. Disconnect the ground wire from evaporator
and position all wiring to allow for evaporator
removal.
16. Remove the evaporator.
11. Loosen the two 1/4 in. hex head screws from the
evaporator support.
17. Using a file, or cap tube cutter (WX05X10050)
score the capillary tube just above the old
braze and break the braze-covered section
off. This will help prevent the capillary tube
from becoming plugged when re-brazing.
18. Position the new evaporator in the cabinet.
Insert the suction line and the capillary tube
into the evaporator.
19. Braze the suction line to the evaporator.
20. Braze the capillary tube to the evaporator.
Evaporator (Brazing Method)
21. Install a replacement drier.
Caution:
22. Evacuate and recharge the system using
currently accepted procedures.
•
If unbrazing the evaporator, HEAT SHIELD P/N
WR49X10025 must be used to prevent damage
to freezer liner.
•
Add thermal paste (WX5X8927) to the exposed
Liner or any item that heat from a torch may
come in contact with.
– 50 –
(Continued next page)
Sealed System - Evaporator
Evaporator (LOKRING Method)
12. Replace the evaporator using the LOKRING
method (see Pub # 31-9067).
Removing Evaporator:
1. Disconnect power to the refrigerator.
•
Cut the copper lines of the old evaporator
as close as possible to the aluminum
evaporator tubes.
•
Cut the copper lines of the new evaporator
1-1/8 inch from the edge of the aluminum
evaporator tubes.
•
Defrost thermostat can be moved from the
horizontal part of the copper line, to the
vertical part just above the bend.
2. Recover refrigerant.
3. Remove freezer shelving (if applicable).
4. Remove ice maker if installed (see Ice Maker
Removal section in this Guide).
5. Remove the air tower (see Air Tower Removal
section in this Guide).
13. Install a replacement drier.
6. Remove the evaporator cover (see Evaporator
Cover Removal section in this Guide).
14. Evacuate and recharge the system using
currently accepted procedures.
7. Remove evaporator fan (see Evaporator Fan
Removal section in this Guide).
8. Remove the defrost thermostat from the
evaporator (see Defrost Thermostat Removal
section in this Guide).
9. Remove the defrost heater (see Defrost Heater
Removal section in this Guide).
10. Disconnect the ground wire from the evaporator
and position all wiring to allow for evaporator
removal.
11. Loosen the two 1/4 in. hex head screws from the
evaporator support.
CAUTION: Tubing must be clean and free from burrs
when using LOKRING.
NOTE: LOKRING connector P/N WR97X10021 must
be used. Two LOKRING connectors are required.
– 51 –
DPO Evaporator / LokRing Installation
IMPORTANT SAFETY INFORMATION
7. Disconnect the power cord.
Before cutting or using a torch on refrigerant
tubes, recover the refrigerant from the system
using approved recovery equipment.
8. Remove the evaporator fan assembly by
taking out both screws and disconnecting
the orange, black and green wire leads.
Never charge new refrigerant through the
purge valve. This valve is always located on the
high pressure side of the system.
9. Disengage the defrost thermostat from the
evaporator. Disconnect both wire leads to
the defrost heater.
Never appy heat from any source to a container
of refrigerant. Such action will cause excessive
pressure in the container.
10. Cut the copper jumper tubes as close to
the epoxy joints as possible (see illustration
below). Use a tubing cutter to make this cut.
DO NOT use a hacksaw.
Always wear approved safety goggles when
working with refrigerants and nitrogen holding
charge in replacement compressor. Contact
with these gases may cause injury.
Part Numbers:
• WR97X10014: 3/8" LokRing Union
• WR88X16: LokPrep sealant/cleaner
• WX5X1: LokRing Tool with 3/8" Jaw
1. Disconnect power to the refrigerator.
2. Remove the rear access cover in order to
gain access to the machine compartment.
3. Recover the refrigerant from the inoperative
sealed system using approved recovery
equipment.
11. Loosen (2) mounting screws that fasten the
evaporator to the rear wall of the freezer.
Remove the defective evaporator.
4. Remove the shelves and ice trays, or
icemaker (if used), from the freezer
compartment, while the refrigerant is being
recovered.
5. Remove the evaporator cover. Remove
the screws from the base of the air tower,
remove the air tower and foam nozzle.
Remove screws from the upper left and right
of evaporator cover and screws attached to
the evaporator fan bracket.
6. Remove the evaporator cover and freezer
floor.
– 52 –
12. Cut the copper evaporator tubing as far
from the epoxy joints as possible. Do not
remove the epoxy joint. See illustration
below. Use a tubing cutter to make this cut.
DO NOT use a hacksaw.
14. Deburr the tubing ends (see previous
illustration) to remove any residue left from
the tubing cutters, using ScotchBrite or
fine emery cloth. Care should be taken to
prevent residue from entering the cut tubing
ends, which could contaminate the system.
15.Apply a few drops of LokPrep, a specially
formulated anaerobic sealant that fills in
any surface scratches. This is extremely
important to a successful, leak free joint.
13. Install the replacement evaporator by
hanging it on the left mounting screws.
Install the evaporator over the right
mounting screw. Tighten (2) screws to hold
the evaporator in place. Care should be
taken to prevent any foreign matter from
entering the evaporator and aluminum
tubes.
16. Insert the tubing ends into the LokRing
union connector as far as they will go
(internal stop). Then rotate the connector a
full 360° to distribute the LokPrep evenly.
– 53 –
17. Compress the LokRings by placing the
jaws of the LokRing tool against the
outer edges of the LokRings, as shown
below. Then squeeze the handles of the
assembly tool together, driving the LokRing
connectors together to the external stop.
Allow approximately 5 minutes prior to
pressurizing the system.
18. Reroute the heater wires behind the
evaporator tubes on the right side. Place the
defrost thermostat back on the evaporator
tube. Attach the terminals to the new
defrost calrod heater.
19. Remount the evaporator fan with mounting
screws. Reattach all wires to the fan.
Replace the freezer floor and evaporator
cover, using the original mounting screws.
20.Install the new foam nozzle and air tower.
21.Reinstall the shelves and ice trays,
or icemaker (if used) in the freezer
compartment.
22.Install a drier, in accordance with
instructions included with the replacement
drier.
23.NOTE: A WR86X10 valve should have been
previously installed on the low pressure
process tube at the compressor.
24.Dress the tubing to prevent rattling.
25.Evacuate and charge the system, using the
original refrigerant type only, and original
factory charge quantity (see model/serial
plate).
– 54 –
Sealed System - Heat Exchanger
The heat exchanger consist of a suction line and a capillary tube that are brazed together. The heat
exchanger is the means that connects the evaporator to the compressor through the suction line and to
the outlet of the drier by way of the capillary tube. The function of the heat exchanger is to transfer heat
from the warm liquid flowing through the capillary to the cool vapor flowing through the suction tube. The
heat exchange occurs where the capillary is soldered to the outside of the suction tube. This arrangement
improves the efficiency of the system. By reducing the heat of the capillary, the boiling point of the liquid
entering the evaporator is lowered. Increasing the heat of the suction tube increases the density of the vapor
entering the compressor and also helps to prevent the suction tube from sweating.
NOTE: The heat exchanger is foamed into the cabinet of the refrigerator. However, if any part of the heat
exchanger (suction or capillary tube) fails due to restriction or leak, a replacement heat exchanger can be
installed, order part number WR85X10077.
– 55 –
Sealed System - Compressor
Compressor Motor
9. Reposition the new compressor.
The compressor motor drives a piston to compress
refrigerant gas. As the piston travels downward
it creates a vacuum to the suction line drawing
in the refrigerant until the piston is to its lowest
point. On the up stroke of the piston it creates a
positive pressure, pushing the reed open and forcing
refrigerant out to the discharge line; thus providing
the means for refrigeration. The motor rests on
springs that are mounted to the compressor shell.
This motor has two windings. One is a start winding
and the other a run winding. The windings are
connected together internally, forming a common
connection. A lead is connected to one end of each
winding and to the common connection.
10. Braze or Lokring the discharge tube to the
compressor discharge port.
These three leads are then connected to glasssealed terminals that extend through the
compressor case. The terminals are clustered in a
triangle (pyramid) pattern and, reading from left to
right, are identified: Start, Common and Run.
11. Braze or Lokring the suction tube to the suction
port of the compressor.
12. Braze or Lokring the drier to the hot gas loop
and capillary tubes.
13. Evacuate and recharge the system using
currently accepted procedures.
Replacing the Compressor
NOTE: Make sure the suction tube grommet is
secured to the suction tube. See the image below.
1. Disconnect power to the refrigerator.
2. Remove the four 1/4 in. hex head screws from
the rear access cover.
3. Recover the refrigerant.
4. Remove the combo device retainer (see Combo
Device section in this Guide).
5. Unbraze the suction tube.
6. Unbraze the discharge tube.
7. Remove the four compressor retaining clips.
8. Remove the compressor.
– 56 –
Sealed System - Condenser
Condenser Removal
There are two types of condensers, one for Estar,
and one for Non-Estar.
1. Disconnect power to the refrigerator.
2. Remove the five 1/4 in. hex head screws from
the rear access cover.
•
Energy star has 8 condenser tubing passes
•
Non-Energy star has 6 condenser tubing passes
**When replacing the condenser, an Energy star
condenser (8 pass condenser) will be sent for Energy
star models and Non-Energy star models, unit
charge will not change.
3. Recover the refrigerant.
4. Move the water valve out of the way (if
applicable).
5. Remove the condenser fan assembly (see
Condenser Fan Assembly Removal section in
this Guide).
6. Loosen the condenser fastening strap, using a
#2 Phillips screw driver.
7. Disengage the condenser strap from the base
plate.
11. Position the new condenser to the condenser
support.
12. Tighten the condenser strap using a #2 screw
driver.
13. Braze or Lokring the hot gas line to condenser.
14. Braze or Lokring the discharge tube to the
compressor.
15. Install a replacement drier.
8. Unbraze the discharge line from the compressor.
16. Evacuate and recharge the system.
9. Cut the hot gas line, leaving enough room
to braze the tubing or connect lokring (Cut
as close to the braze joint as possible). (See
Service Guide 31-9067 for additional Lokring
information).
10. Remove the condenser.
The condenser support is the platform that the
condenser sits on and is secured to the base plate
by the condenser fastening strap.
– 57 –
Sealed System - Dryer
Condenser continued
Drier
Rear view of the condenser, and the condenser
strap connected to the base pan
The drier is part of the refrigerators sealed system.
The purpose of the drier is to remove noncondensable such as moisture and small debris that
may have been introduced into the system during
production or sealed system repairs.
Replacing Dryer:
1. Disconnect power to the refrigerator.
2. Remove the five 1/4 in. hex head screws from
the rear access cover.
3. Recover refrigerant.
4. Cut the hot gas line section of the drier out using
tubing cutters.
5. Using a file or cap tube cutters (WX05X10050),
score the cap tube and bend tubing until the
cap tube separates. NOTE: Make sure that the
cap tube ID is free from obstructions.
6. Braze or Lokring the drier to the hot gas line and
capillary tubes.
7. Evacuate and recharge the system using
currently accepted procedures.
– 58 –
Sealed System Brazed Joints
Joint
4
12
21
21A
33
122
123
124
125
289
290
291
Connecting Tubing
Joint Size
(Replacement) Dryer
0.251
(Replacement) Dryer
0.251
HGL Jumper (I.D.)
0.170
HGL Jumper (I.D.)
0.194
Compressor Discharge port (I.D.)
0.194
EVAP
0.321
EVAP
0.321
Tube Jumper Suc (I.D.)
0.317
Tube Jumper cap (I.D.)
0.082
Suction Jumper (I.D.)
0.319
Compressor Process port (I.D.)
0.256
Compressor suction port (I.D.)
0.319
Connecting Tubing
HGL (O.D.)
Cap Tube (O.D.)
HGL (O.D.)
Condenser (O.D.)
Condenser (O.D.)
Tube jumper cap (O.D.)
Tube jumper Suc (O.D.)
Suction tube (O.D.)
Tube cap (O.D.)
Suction tube (O.D.)
Process tube (O.D.)
Suction Jumper
– 59 –
Joint Size
0.156
0.076
0.156
0.188
0.188
0.312
0.312
0.312
0.076
0.312
0.250
0.312
Material
Copper/Copper
Copper/Copper
Copper/Copper
Copper/Copper
Copper/Steele
Copper/Copper
Copper/Copper
Copper/Copper
Copper/Copper
Copper/Copper
Copper/Copper
Copper/Copper
Top Mount Electronic Defrost
– 60 –
Top Mount Electronic Defrost
– 61 –
Top Mount Mechanical Timer
– 62 –
Top Mount Mechanical Timer
– 63 –
Warranty
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– 64 –
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