Whirlpool R-92 Manuale utente

CONSUMER SERVICES TECHNICAL

EDUCATION GROUP PRESENTS

R-92

JOB AID

Part No. 4322658A

WHIRLPOOL & KITCHENAID

IN-DOOR ICE SYSTEM

- ii -

FORWARD

This Job Aid, “Whirlpool & KitchenAid In-Door Ice System,” (P rt No. 4322658A), provides the

technici n with inform tion on the oper tion nd service of the Whirlpool & KitchenAid In-Door

Ice System. It is to be used s tr ining Job Aid nd Service M nu l. For specific inform tion on

the model being serviced, refer to the “Use nd C re Guide,” or “Tech Sheet” provided with the

Refriger tor/Freezer.

The Wiring Di gr ms used in this Job Aid re typic l nd should be used for tr ining purposes

only. Alw ys use the Wiring Di gr m supplied with the product when servicing the unit.

GOALS AND OBJECTIVES

The go l of this Job Aid is to provide det iled inform tion th t will en ble the service technici n to

properly di gnose m lfunctions nd rep ir the In-Door Ice System.

The objectives of this Job Aid re to:

• Underst nd nd follow proper s fety prec utions.

• Successfully troubleshoot nd di gnose m lfunctions.

• Successfully perform necess ry rep irs.

• Successfully return the In-Door Ice System to proper oper tion l st tus.

WHIRLPOOL CORPORATION ssumes no responsibility for ny rep irs m de

on our products by nyone other th n Authorized Service Technici ns.

- iii -

TABLE OF CONENTS

GENERAL............................................................................................................................... 1-1

S fety First ......................................................................................................................... 1-1

PRODUCT INTRODUCTION .................................................................................................. 2-1

Overview ............................................................................................................................ 2-1

THEORY OF OPERATION ..................................................................................................... 3-1

COMPONENT ACCESS ......................................................................................................... 4-1

Component Loc tions ........................................................................................................ 4-1

Removing The Ice M ker & The W ter Fill Tube............................................................... 4-2

Removing The Emitter & Receiver Modules ...................................................................... 4-5

Removing & Reinst lling The Motor .................................................................................. 4-6

Accessing The Selector Switch P ck & Dispenser Switches ............................................ 4-9

DIAGNOSTICS & TROUBLESHOOTING .............................................................................. 5-1

Di gnostics ........................................................................................................................ 5-1

Optics Di gnostics Mode ............................................................................................... 5-1

Optics Di gnostics For Origin l Design Bo rds ............................................................. 5-2

Optics Di gnostics For 2002 Design Bo rds ................................................................. 5-4

Component Di gnostics Mode ....................................................................................... 5-5

Optics Di gnostics Mode Ch rts .................................................................................... 5-6

Component Di gnostics Mode Ch rt ............................................................................. 5-7

Troubleshooting Ch rt A—Origin l Optics Design ............................................................ 5-8

Troubleshooting Ch rt B—2002 Optics Design ................................................................. 5-9

Troubleshooting Ch rt C—Component Di gnostics Mode .............................................. 5-10

Troubleshooting The Motor.............................................................................................. 5-11

WIRING DIAGRAMS & STRIP CIRCUITS ............................................................................. 6-1

Whirlpool Wiring Di gr m .................................................................................................. 6-1

KitchenAid Wiring Di gr m ................................................................................................ 6-2

Strip Circuits ...................................................................................................................... 6-3

CONFIRMATION OF LEARNING EXERCISES ..................................................................... 7-1

Page

- i -

— NOTES —

1-1

This is the safety alert symbol.

This symbol alerts you to hazards that can kill or hurt you and others.

All safety messages will follow the safety alert symbol and either the word

“DANGER or “WARNING. These words mean:

Electrical Shock Hazard

Plug into a grounded 3-prong outlet.

Do not remove ground prong.

Do not use an adapter.

Do not use an extension cord.

Failure to ollow these instructions can

result in death, ire, or electrical shock.

Electrical Shock Hazard

Disconnect power be ore servicing.

Replace all panels be ore operating.

Failure to do so can result in death or

electrical shock.

GENERAL

SAFETY FIRST

Your sa ety and the sa ety o 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.

DANGER

WARNING

All safety messages will tell you what the potential hazard is, tell you how to reduce the chance

of injury, and tell you what can happen if the instructions are not followed.

You can be killed or seriously injured i you don’t

immediately ollow instructions.

You can be killed or seriously injured i you don’t

ollow instructions.

ELECTRICAL POWER SUPPLY &

GROUNDING REQUIREMENTS

WARNING

1-2

Electrical Shock Hazard

Connect green ground wire to ground

screw.

Failure to do so can result in death or

electrical shock.

WARNING

IMPORTANT

Electrostatic Discharge (ESD)

Sensitive Electronics

ESD problems are present everywhere.

ESD may damage or weaken the elec-

tronic control assembly. The new control

assembly may appear to work well a ter

repair is inished, but ailure may occur at

a later date due to ESD stress.

• Use an antistatic wrist strap. Connect the

wrist strap to the green ground connec-

tion point, or to an unpainted metal sur-

face in the appliance.

- OR -

• Touch your finger repeatedly to a green

ground connection point, or to an un-

painted metal surface in the appliance.

• Before removing the part from its pack-

age, touch the antistatic bag to a green

ground connection point, or to an un-

painted metal surface in the appliance.

• Avoid touching electronic parts, or termi-

nal contacts. Handle the electronic con-

trol assembly by the edges only.

• When repackaging the failed electronic

control assembly in an antistatic bag,

observe the previous instructions.

2-1

PRODUCT INTRODUCTION

OVERVIEW

The primary objective of the In-Door Ice Sys-

tem is to increase the usable space in the

freezer compartment of the current freestand-

ing side-by-side refrigerator/freezer. The solu-

tion is to relocate the ice maker the ice con-

tainer and drive mechanism and replace this

eye-level volume with a cantilever shelving sys-

tem. The following description is intended to

relate the changes that have been made from

the current side-by-side ice & water dispenser

configuration. The description is divided into

three categories: Ice Making Ice Storage &

Ice Dispensing.

ICE MAKING

The ice maker module and mold have not been

changed from the current models. However

the location mounting method air delivery

water delivery ice stripper and ice level shutoff

have all been redesigned.

Location & Mounting

The ice maker has been relocated to the top

front of the freezer liner and has been rotated

90˚. Due to code requirements the ice maker

heater area is now protected by a plastic (PVC)

mounting bracket. The bracket is attached to

the ice maker with three mounting screws and

is held in place by grooved tracks on either

side of the freezer liner.

Mounting

Bracket

Grooved

Track

Grooved

Track

Screw

(1 of 3)

Air D liv ry

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 di-

rects approximately 50% of the freezer air for-

ward 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 strip-

per.

Air Duct

2-2

The water tube is made of polypropylene with

an overmolded santoprene nozzle. Due to the

rigid nature of the polypropylene this tube is

mated to a more flexible polyethylene tube with

a John Guest fitting high on the back panel.

This change of material is necessary to pre-

vent kinking when the tubing is attached to the

water valve.

Wat r D liv ry

Water is delivered to the ice maker mold by

means of a “tube-within-a-tube” design. A con-

duit system consisting of three separate pieces

(liner fitting conduit back panel fitting) is

foamed into place in the cabinet.

This conduit provides a pathway from the

freezer liner to the back panel. The majority of

this system is routed above the refrigerator liner

to prevent the water tubing from freezing. The

tubing that delivers the water is routed through

the conduit and is secured by snapping into

place at the freezer liner fitting.

Back Panel Fitting

John

Guest

Fitting

Water

Tube

Water Nozzle

2-3

Ic Stripp r

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.

Ic L v l 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. A manual

shutoff option is still available on the right side

of the freezer liner. This feature consists of a

plastic slide that covers the receiver sensor and

blocks the infrared beam.

Infrared Emitter

Ejector Blades

Ice Stripper & Ramp

Infrared

Receiver

Manual

Shutoff

Status LED

5-Cavity Ice Maker For

22 Cu. Ft. Models

2-4

ICE STORAGE

The ice container has been redesigned and

relocated to the freezer door. It is secured in

place on the door liner with a sliding spring-

loaded latch mounted to a plate with two pins.

The mounting plate is foamed-in-place on the

door. The ice container is easily removed and

replaced on the door regardless of the auger

orientation.

The ice container is removed by pressing a

release button on the right side and lifting.

Removal instructions are printed on the con-

tainer.

Other changes to the ice container consist of

a vertical rod ice auger and a clear polycar-

bonate upper section. The vertical orientation

of the bin helps prevent “stale ice” areas be-

cause the ice is a “first in—first out” system

which helps keep the ice fresher. Also the ice

container can be completely emptied.

ICE DISPENSING

Major changes have been made to the power

train. The motor has been redesigned and re-

located to the freezer door. The cube/crush

selector solenoid and its related linkage have

been eliminated and a drive shaft/spring-

loaded coupling have been added.

Motor

The motor is now located on the freezer door

in a foamed-in-place enclosure under the “dis-

penser bubble” area of the inner door panel.

The motor is mounted to a plastic mounting

bracket which in turn is mounted to the en-

closure with four mounting screws.

The motor operates on 115 volts DC (115 volts

AC is delivered to the motor where it is con-

verted within the motor assembly to DC). This

gives the motor a higher RPM than the earlier

dispenser motors and results in a faster ice

delivery rate in both the cubed and crushed

modes.

Crushed ice is delivered by turning the motor

in a clockwise direction and cubed ice is de-

livered when the motor turns in a counterclock-

wise direction.

Pins Plate

Auger Coupling

Ice

Container

Release

Button

Ice

Auger

Motor

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