CONSUMER SERVICES TECHNICAL EDUCATION GROUP PRESENTS R-92 WHIRLPOOL & KITCHENAID IN-DOOR ICE SYSTEM JOB AID Part No.
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.
TABLE OF CONENTS Page GENERAL ............................................................................................................................... 1-1 Safety First ......................................................................................................................... 1-1 PRODUCT INTRODUCTION .................................................................................................. 2-1 Overview ..............................................................................
— 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.
WARNING 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.
PRODUCT INTRODUCTION OVERVIEW 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.
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. 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.
Ice Stripper 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. Ice Level Shutoff 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.
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. Major changes have been made to the power train. The motor has been redesigned and relocated to the freezer door.
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 enSpring-Loaded Pin gage when the container is placed on the door, the motor drive shaft coupling will be depressed.
— NOTES — 2-6
THEORY OF OPERATION 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.
— NOTES — 3-2
COMPONENT ACCESS COMPONENT LOCATIONS Ice Maker Door Infrared Emitter Water Fill Nozzle Ice Maker Freezer Door Infrared Receiver Ice Bin Ice Container Auger Coupling Motor Drive Coupling Hex Drive Shaft Motor 4-1
REMOVING THE ICE MAKER & THE WATER FILL TUBE d) Remove the wire shield screw from the bottom of the ice maker. WARNING Wire Shield Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. 1. 2. Wire Shield Screw e) From the rear of the ice maker, lift the top of the wire shield slightly and pull it back to release it from the ice maker.
h) If you do not want to completely remove the ice maker rotate the ice maker so the square end with the motor faces the front, and hang the flange of the ice maker on the track that is attached to the freezer mullion. b) Slowly pull the end of the water fill nozzle out of the fitting in the top of the freezer liner, then continue to pull the rest of the tube out of the liner. It will require some force to remove the first foot or so of tube from the liner.
c) Install a length of flexible tubing on the spout of the squeeze bottle. d) Insert the end of the flexible tubing into the water fill nozzle as far as ice blockage. e) Squeeze the bottle and allow the hot water to melt all of the ice. b) Position the water fill nozzle so that the bend is toward the mullion, and insert the inner half of the grooved shoulder into the square cutout of the liner.
REMOVING THE EMITTER & RECEIVER MODULES c) Pull the module out and remove the connector from the board. WARNING Connector Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. 3. 1. Disconnect the unit from the electrical supply. NOTE: If either the emitter or receiver board fails, both of the boards will have to be replaced.
REMOVING & REINSTALLING THE MOTOR d) Disconnect the harness connector from the motor terminals. WARNING Harness Connector Screw (1 of 4) Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. 1. 2. Disconnect the unit from the electrical supply. To remove the motor: a) Open the freezer door. b) Remove the ice container from the freezer door.
3. To reinstall the motor: a) Remove the two screws from the hex drive shaft coupling holder and remove the coupling assembly. d) Plug the harness connector into the motor. NOTE: The connector is designed to fit only one way on the motor terminals. e) Position the motor housing cover so that the raised center faces the motor, and mount it in place with the two screws you removed earlier.
h) Replace the ice container on the freezer door plate. NOTE: The coupling in the ice container does not have to align with the coupling on the end of the hex drive shaft when the ice container is installed. They will engage as soon as the ice dis- penser is activated. At that time, the motor will turn, and the spring-loaded coupling on the end of the hex drive shaft will pop up and engage the ice container coupling (you will hear a “snap” when the coupling pops up and engages).
ACCESSING THE SELECTOR SWITCH PACK & DISPENSER SWITCHES 3. WARNING Remove the screws from the ice and water dispenser compartment front panel and turn it over. The selector switch pack and dispenser switches are now accessible for testing. Ice Dispenser Switch Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. 1. 2. Disconnect the unit from the electrical supply.
— NOTES — 4-10
DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS OPTICS DIAGNOSTICS MODE The optics system can have one of two types of optics board designs installed: the original design, or the 2002 design. Use the following flow chart to determine which of the board designs are installed. Once this is determined, you will be directed to perform the appropriate optics diagnostics procedure. Diagnostics are used to determine whether the optics circuits are operating properly.
OPTICS DIAGNOSTICS FOR ORIGINAL DESIGN BOARDS KIT #4388635 SUBS TO #4389102 EMITTER—PART #2198585 RECEIVER—PART #2198586 5. To initiate an optics check, perform the following steps: 1. Open the freezer door. 2. Remove enough ice from the ice bin so that the ice level is at least one inch below the U-shaped cutouts in the bin. Open the freezer door and activate the freezer door switch 3 times. NOTE: This step must be completed within 10 seconds of opening the freezer door.
5. 6. 7. Open the freezer door and actuate the freezer door switch 3 times. NOTE: This step must be completed within 10 seconds of opening the freezer door. Close the freezer door within 20 seconds of completing step 5. Wait for a minimum of 5 seconds, and a maximum of 50 seconds, then open the freezer door, and view the status LED on the infrared receiver module for the error code. NOTE: You will have 60 seconds to open the freezer door, and 2 seconds from then to view the LED output code.
OPTICS DIAGNOSTICS FOR 2002 DESIGN BOARDS KIT #4389102 EMITTER—PART #2220398 RECEIVER—PART #2220402 4. To initiate an optics check, perform the following steps: 1. Open the freezer door. 2. View the status LED. It should flash twice, pause for 1 second, and repeat the cycle for as long as the door is open. NOTES: • If the LED is not flashing, the ice maker may be in the 5 minute “harvest” mode. If so, push in on the freezer door switch with your finger, and observe the LED.
COMPONENT DIAGNOSTICS MODE 3. Slide the ice maker out of the mounting rails and leave the wiring harness connected. 4. Jumper the thermostat, as shown below. 5. Connect power to the unit. 6. Remount the ice maker, making sure that the water fill tube is inside the fill cup. 7. Make sure there is a clear path across the bin for the infrared beam to travel to the receiver sensor. 8. Close the freezer door and wait 5 seconds to allow the optics relay to close. 9.
OPTICS DIAGNOSTICS MODE CHARTS NOTES: 1. Optics Diagnostics will not respond: • For 5 minutes after the ice maker begins a “harvest” cycle. To reset the control, wait until the ice maker “parks,” then unplug the refrigerator for 5 seconds, and repeat the test. • While the control board is running self-checks. Reset the control, as above. 2. The ice maker control must be in the “ON” position. 3. The ice bin must be on the door and the ice level below the notched openings.
COMPONENT DIAGNOSTICS MODE CHART — Chart C — Component Diagnostics Mode For Original & 2002 Design Boards COMPONENT DIAGNOSTICS MODE (RUN OPTICS DIAGNOSTICS PROCEDURE FIRST) 1. Disconnect the power supply. 2. Slide the ice maker out and remove the cover. 3. Jumper holes “T” and “H” to bypass the bimetal and start a harvest. 4. Reconnect the power supply. 5. Close the freezer door to align the optics and a harvest cycle will begin in 5 seconds. 6. Open the freezer door and observe the ice maker.
5-8 Optics Diagnostic Mode (optics test only) TEST Correct wiring and retest. Make sure ice maker is “parked.” Unplug refrigerator for 5 seconds to reset optics control and retest. Replace emitter and receiver boards and retest. LED is defective. Close freezer door, wait for at least 5 seconds, and retest. Retest and view LED within 2 seconds of opening freezer door. LED was not viewed within 2 seconds of opening freezer door.
5-9 5 second LED on steady. Flapper door is held closed. LED is defective. Incorrect wiring at emitter or receiver board. Optics performing self-tests (will not perform diagnostic tests during this time). Ice maker is in 5 minute “harvest” cycle. RESULT POSSIBLE CAUSE 2 LED pulses, repeated. Ice maker slide control turned OFF (closed). Dirt on optics. Frost on optics lenses. Flapper door is open and is blocking the emitter beam. Failed optics. Optics Diagnostic Mode No LED pulses.
5-10 Ice Maker Checks Ice Maker Control Circuit TEST Thermostat jumper not removed. Ejector bar does not stop at “home” position. Run optics test and recheck ice maker. Close freezer door to start harvest. Clear optics path. Replace emitter and receiver boards and retest. Plug ice maker in. Replace ice maker harness. Check continuity in wiring harness and door switch. Replace ice maker module. Reposition jumper. Replace ice maker. Optics check not run before testing ice maker.
TROUBLESHOOTING THE MOTOR f) Disconnect/reconnect the 6-pin harness to the motor 3 - 5 times to remove any oxidation buildup on the connector pins. g) Check power in the circuit (see “Checking The Switch Pack on page 5-14 ). WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. NOTE: Refer to the “Motor Failure Modes Chart” at the bottom of the page. 1. Motor does not hum or rotate.
NOTE: When you are instructed to make a reading at the motor connector, press the tips of the red and black test leads into the indicated harness connector slots so they touch the bare metal wire connectors. Reach around the front of the door and press the ice dispenser lever to activate the dispenser switch. WARNING Electrical Shock Hazard Voltage is present during these tests.
3. 4. 5. 6. Press the Unlocked button on the ice and water dispenser front panel. Touch the AC meter test leads to wire harness pins 3 and 5, then press the ice dispenser lever. The meter should read 115 VAC. Touch the DC meter’s black test lead to wire harness pin 6, and the red test lead to pin 7, then press the ice dispenser lever. The meter should read +115 VDC ±10%. Press the Crushed ice button on the ice and water dispenser front panel. 7.
2. WARNING Electrical Shock Hazard Voltage is present during these tests. CHECKING THE SWITCH PACK To check voltages at the switch pack: NOTE: All of the wires must be connected to the pins on the switch pack to obtain the following readings, including the wire to the pin being measured. Also, the freezer door light switch must be in the closed (taped down) position before performing any voltage checks.
3. 4. To check to make sure that DC voltage is being supplied to the switch pack: a) Press the Unlocked button. b) Touch the DC voltmeter’s black test lead to PK/BK and the red test lead to OR/ BU, then press the ice dispenser lever. The meter should read +115 VDC ±10%. To check the Crushed and Cube ice switches: a) Press the Unlocked and the Crushed buttons on the ice and water dispenser front panel.
2. WARNING To install a wire terminal, position the terminal with the slot facing the retainer tab, and slide it into the connector. Press down on the retainer tab to lock it in place. Wire Terminal Slot Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. Motor Connector SERVICING THE HARNESS & MOTOR CONNECTOR Both the motor connector and the wire harness are serviceable.
WIRING DIAGRAMS & STRIP CIRCUITS WHIRLPOOL WIRING DIAGRAM ICE DISPENSER MOTOR (SEE NOTE 2) NOTES: 1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position. 2. The dispenser has a built-in inverter board which converts the 115 VAC to 115 VDC. The OR/BU wire is the positive (+) side of the DC signal, and the PK/BK wire is the negative (–) side.
KITCHENAID WIRING DIAGRAM ICE DISPENSER MOTOR (SEE NOTE 2) NOTES: 1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position. 2. The dispenser has a built-in inverter board which converts the 115 VAC to 115 VDC. The OR/BU wire is the positive (+) side of the DC signal, and the PK/BK wire is the negative (–) side. The BR/WH and RD/WH wires switch polarity, depending on the crushed/cubed switch position, (see the following table).
STRIP CIRCUITS CRUSHED MODE N L1 BK Light Interlock Switch Dispenser Lock Switch BU/BK Ice Lever Switch GY BU Voltage Rectifier Bridge Converts 115 VAC to 115 VDC Crushed Ice Selection RD/WH OR/BU + PK/BK – OR/BU Cubed Ice Selection + BR/WH Motor CW Rotation CUBED MODE N L1 BK Light Interlock Switch Dispenser Lock Switch BU/BK Ice Lever Switch GY BU Voltage Rectifier Bridge Converts 115 VAC to 115 VDC 6-3 PK/BK – BR/WH RD/WH Motor CCW Rotation
— NOTES — 6-4
CONFIRMATION OF LEARNING EXERCISES 1. Trace the circuit for the crushed ice operation by closing the necessary switches. Refer to the Wiring Diagram NOTES at the bottom of the page. L1 To Light Switch N ICE DISPENSER MOTOR (SEE NOTE 2) NOTES: 1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position. 2. The dispenser has a built-in inverter board which converts the 115 VAC to 115 VDC.
2. Trace the circuit for the cubed ice operation by closing the necessary switches. Refer to the Wiring Diagram NOTES at the bottom of the page. L1 To Light Switch N ICE DISPENSER MOTOR (SEE NOTE 2) NOTES: 1. Freezer door is open, ice dispenser selection in Cubed mode, and dispenser lock switch in Locked position. 2. The dispenser has a built-in inverter board which converts the 115 VAC to 115 VDC. The OR/BU wire is the positive (+) side of the DC signal, and the PK/BK wire is the negative (–) side.
PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION SOURCES IN THE UNITED STATES: FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL: FOR WHIRLPOOL PRODUCTS: 1-800-253-1301 FOR KITCHENAID PRODUCTS: 1-800-422-1230 FOR ROPER PRODUCTS: 1-800-447-6737 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER’S HOME CALL: THE TECHNICAL ASSISTANCE LINE: 1-800-253-2870 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED SERVICER FOR LITERATURE ORDERS: PHONE: 1-800-851-4605 IN CANADA: FOR PRODUCT SPECIFICATIONS A
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