Amana SBDE522VW User manual

16021711
Revision 0
July 2002
Service
Service Manual for Amana® models
This Base Manual covers nternational
Side by Side Refrigerators
Refer to individual Technical Sheet for
information on specific models.
International
Side by Side
Refrigerators

16021711 Rev. 0 2
Pride and workmanship go into every product to provide our customers with quality products. It is possi le, however,
that during its lifetime a product may require service. Products should e serviced only y a qualified service
technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools,
parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE
APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS.
Important Notices for Consumers and Servicers
!
WARNING
To avoid risk of serious injury or death, repairs should not e attempted y unauthorized personnel, dangerous
conditions (such as exposure to electrical shock) may result.
Maytag will not e responsi le for any injury or property damage from improper service procedures. If performing
service on your own product, assume responsi ility for any personal injury or property damage which may result.
To locate an authorized servicer, please consult your telephone ook or the dealer from whom you purchased this
product. For further assistance, please contact:
MAYTAG APPLIANCES SALES COMPANY OR U.S. and Canada 1-800-462-9824
ATTN:Maytag CAIR ® Center CALL U.S. customers using TTY for deaf, hearing
P.O. Box 2370 impaired, call 1-800-688-2080
Cleveland, TN 37320-2370
If outside the United States contact:
MAYTAG APPLIANCES SALES COMPANY
ATTN: Maytag CAIR® Center
P.O. Box 2370
Cleveland, TN 37320-2370
Telephone: [phone]
Recognize Safet S mbols, Words, and Labels
DANGER
!
DANGERImmediate hazards which WILL result in severe personal injury or death.
WARNING
!
WARNINGHazards or unsafe practices which COULD result in severe personal injury or death.
CAUTION
!
CAUTIONHazards or unsafe practices which COULD result in minor personal injury or product or property
damage.
Important Information
CAUTION
!

3 16021711 Rev. 0
Important Information .................................................. 2
Product Design ............................................................. 4
Component Testing .......................................................
Service Procedures .................................................... 10
Service Equipment ..................................................... 10
Drier Replacement ...................................................... 10
Refrigerant Precautions ............................................... 11
Line Piercing Valves .................................................... 11
Open Lines .................................................................. 11
Compressor Operational Test ...................................... 11
Dehydrating Sealed Refrigeration System .................. 12
Leak Testing ............................................................... 12
Testing Systems Containing a
Refrigerant Charge................................................ 12
Testing Systems Containing
No Refrigerant Charge ......................................... 12
Restrictions ................................................................. 13
Symptoms ............................................................ 13
Testing for Restrictions ......................................... 13
Evacuation and Charging ........................................... 14
Evacuation ........................................................... 14
Charging .............................................................. 1
Refrigerant Charge................................................ 1
HFC134a Service Information ..................................... 16
Health, Safety, and Handling ................................ 16
Comparison of CFC12 and HFC134a Properties . 16
Replacement Service Compressor ............................. 17
Compressor Testing Procedures .......................... 17
Brazing ....................................................................... 17
Refrigerant Flow ...........................................................18
Cabinet Air Flow One Way ..........................................19
Cabinet Air Flow Two Way ............................................ 20
Ice and Water Dispenser Diagram ................................21
Water Valves Diagram................................................22
Typical External Sweat Pattern ................................23
Troubleshooting Chart .............................................24
System Diagnosis ........................................................27
Disassembly Procedures
Refrigerator Compartment ...................................... 30
Upper Light Socket & Lens................................... 30
Freezer Cold Control ............................................ 30
Defrost Timer..........................................................30
Adaptive Defrost Control ...................................... 30
Damper Control.......................................................31
Water Filter Assembly.............................................31
Water Tank Assembly..............................................31
Crisper Cover and Socket .................................... 31
Freezer Compartment
Freezer Light Socket ............................................ 31
Auger Motor Assembly ......................................... 31
Auger Motor ......................................................... 31
Auger Motor Capacitor............................................32
Evaporator Fan Motor Assembly .......................... 32
Evaporator Fan Motor and Fan Blade.....................32
Evaporator Removal...............................................32
Defrost Terminator (Thermostat) .......................... 32
Defrost Heater...................................................... 32
Ice Maker Removal.................................................33
Machine Compartment
Water Valves ........................................................ 33
Condenser Fan Motor and Blade ............................ 33
Compressor ...........................................................33
Condensate Drain Tube .......................................... 33
Condensate Drain Pan ........................................... 33
Overload/Relay ...................................................... 34
Condenser ............................................................. 34
Bottom of Cabinet
Front Leveling Rollers .......................................... 34
Rear Leveling Rollers ........................................... 34
Cabinet Doors
Door Gaskets ....................................................... 34
Dispenser Facade (Electronic Model) .................... 34
Dispenser Ice Chute Door ......................................3
Dispenser Light Socket .......................................... 3
Dispenser D/C Solenoid ......................................... 3
Dispenser Water Tube ........................................... 3
High Voltage Board (Electronic Model) ................... 3
Ice N Water Systems
Troubleshooting of button Dispenser .................. 36
Troubleshooting of Electronic Dispenser ................ 39
Appendix A
Owners Manual ...... .............................................A-2
Table of Contents

16021711 Rev. 0 4
Product Design
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test
procedures require power to be connected. Discharge capacitor through a resistor before attempting to service.
Ensure all earthing wires are connected before certifying unit as repaired and/or operational.
!
WARNING
Refrigeration System
Compressor forces high temperature vapor into fan
cooled tube and wire condenser where vapor is cooled
and condensed into high pressure liquid by circulation
of air across condenser coil. (See Refrigerant Flow
Diagram, page 18)
High pressure liquid passes into post-condenser loop
which helps to prevent condensation around freezer
compartment opening and through molecular sieve
drier and into capillary tube. Small inside diameter of
capillary offers resistance, decreasing pressure, and
temperature of liquid discharged into evaporator.
Capillary diameter and length is carefully sized for
each system.
Capillary enters evaporator at top back. Combined
liquid and saturated gas flows through back to bottom
of coil and into suction line. Aluminum tube evaporator
coil is located in freezer compartment where
circulating evaporator fan moves air through coil and
into fresh food compartment.
Large surface of evaporator allows heat to be
absorbed from both fresh food and freezer
compartments by airflow over evaporator coil causing
some of the liquid to evaporate. Temperature of
evaporator tubing near end of running cycle may vary
from -2 ° to -31.6°C.
Saturated gas is drawn off through suction line where
superheated gas enters compressor. To raise
temperature of gas, suction line is placed in heat
exchange with capillary.
Temperature Controls
Freezer compartment temperature is regulated by air
sensing thermostat at rear back of fresh food
compartment which actuates compressor. Control
capillary is inserted in well which routes capillary into
freezer. Control should be set to maintain freezer
temperature between -17.7° to -18.9°C.
Fresh food compartment temperature is regulated an air
damper control governing amount of refrigerated air
entering fresh food compartment from freezer. Fresh
food compartment temperature should be between 3.3°
and 4.4°C.
Defrost Timer System (some models)
Every 8 hours of compressor run time defrost timer
activates radiant electric defrost heater suspended
from evaporator. After 33 minutes of defrost cycle
time, timer restores circuit to compressor.
Defrost terminator (thermostat) is wired in series with
defrost heater. Terminator opens and breaks circuit
when preset high temperature is reached. After
defrost thermostat opens, thermostat remains open
until end of defrost cycle when cooling cycle starts and
terminator senses present low temperature and
closes.
Defrost heater is suspended on left side of evaporator
coil and across bottom to keep defrost drain free
flowing during defrost. Defrost water is caught in
trough under evaporator coil and flows through drain
hole in liner and drain tubing into drain pan. Air
circulated by condenser fan over pan evaporates
water.
Adaptive Defrost System (some models)
The ADC adapts the compressor run time between
defrosts to achieve optimum defrost intervals by
monitoring the cold control and length the defrost
heater is on.

Component Testing
!WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test
procedures require power to be connected. Discharge capacitor through a resistor before attempting to service.
Ensure all earthing wires are connected before certifying unit as repaired and/or operational.
16021711 Rev. 05
Component Description Test Procedures
Compressor When compressor electrical circuit is
energized, the start winding current
causes relay to heat. After an amount of
starting time, the start winding circuit
turns off. The relay will switch off the
start winding circuit even though
compressor has not started (for example,
when attempting to restart after
momentary power interruption).
With “open” relay, compressor will not
start because there is little or no current
to start windings. Overload protection will
open due to high locked rotor run winding
current.
With “shorted” relay or capacitor,
compressor will start and overload
protector will quickly open due to high
current of combined run and start
windings.
With open or weak capacitor,
compressor will start and run as normal
but will consume more energy.
Resistance test
1. Disconnect power to unit.
2. Discharge capacitor by shorting across terminals with a resistor for 1 minute.
NOTE: (Some compressors do not have a run capacitor.)
3. Remove leads from compressor terminals.
4. Set ohmmeter to lowest scale.
5. Check for resistance between
Terminals “S” and “C”, start winding
Terminals “R” and “C”, run winding
If either compressor winding reads open (infinite or very high resistance) or
dead short (0 ohms), replace compressor.
Ground test
1. Disconnect power to refrigerator.
2. Discharge capacitor, if present, by shorting terminals through a resistor.
3. Remove compressor leads and use an ohmmeter set on highest scale.
4. Touch one lead to compressor body (clean point of contact) and other probe
to each compressor terminal.
• If reading is obtained, compressor is grounded and must be replaced.
Operation test
If voltage, capacitor, overload, and motor winding tests do not show cause for
failure, perform the following test:
1. Disconnect power to refrigerator.
2. Discharge capacitor by shorting capacitor terminals through a resistor.
3. Remove leads from compressor terminals.
4. Wire a test cord to power switch.
5. Place time delayed fuse with UL rating equal to amp rating of motor in test
cord socket. (Refer to Technical Data Sheet)
6. Remove overload and relay.
7. Connect start, common and run leads of test cord on appropriate terminals of
compressor.
8. Attach capacitor leads of test cord together. If capacitor is used, attach
capacitor lead to a known good capacitor of same capacity.
Test configuration
9. Plug test cord into multimeter to determine start and run wattage and to check
for low voltage, which can also be a source of trouble indications.
10.With power to multimeter, press start cord switch and release.
• If compressor motor starts and draws normal wattage, compressor is
okay and trouble is in capacitor, relay/overload, freezer temperature
control, or elsewhere in system.
• If compressor does not start when direct wired, recover refrigerant at high
side. After refrigerant is recovered, repeat compressor direct wire test. If
compressor runs after recovery but would not run when direct wired
before recover, a restriction in sealed system is indicated.
• If compressor does not run when wired direct after recovery, replace faulty
compressor.
C
R
S
Fuses
Capacitor
Compressor
Switch
To AC supply

Component Testing
!WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test
procedures require power to be connected. Discharge capacitor through a resistor before attempting to service.
Ensure all earthing wires are connected before certifying unit as repaired and/or operational.
16021711 Rev. 0 6
Component Description Test Procedures
Capacitor
or
Run capacitor connects to relay
terminal 3 and L side of line.
Some compressors do not require a run
capacitor; refer to the Technical Data
Sheet for the unit being serviced.
1.Disconnect power to refrigerator.
2.Remove capacitor cover and disconnect capacitor wires.
3.Discharge capacitor by shorting across terminals with a resistor for 1 minute.
4.Check resistance across capacitor terminals with ohmmeter set on “X1K”
scale.
• Good—needle swings to 0 ohms and slowly moves back to infinity.
• Open—needle does not move. Replace capacitor.
• Shorted—needle moves to zero and stays. Replace capacitor.
• High resistance leak—needle jumps toward 0 and then moves back to
constant high resistance (not infinity).
Condenser Condenser is a tube and wire
construction located in machine
compartment.
Condenser is on high pressure discharge
side of compressor. Condenser function
is to transfer heat absorbed by refrigerant
to ambient.
Higher pressure gas is routed to
condenser where, as gas temperature is
reduced, gas condenses into a high
pressure liquid state. Heat transfer takes
place because discharged gas is at a
higher temperature than air that is
passing over condenser. It is very
important that adequate air flow over
condenser is maintained.
Condenser is air cooled by condenser
fan motor. If efficiency of heat transfer
from condenser to surrounding air is
impaired, condensing temperature
becomes higher. High liquid temperature
means liquid will not remove as much
heat during boiling in evaporator as
under normal conditions. This would be
indicated by high than normal head
pressures, long run time, and high
wattage. Remove any lint or other
accumulation, that would restrict normal
air movement through condenser.
From condenser the refrigerant flows into
a post condenser loop which helps
control exterior condensation on flange,
center mullion, and around freezer door.
Refrigerant the flows through the drier to
evaporator and into compressor through
suction line.
Leaks in condenser can usually be detected by using an electronic leak detector
or soap solution. Look for signs of compressor oil when checking for leaks. A
certain amount of compressor oil is circulated with refrigerant.
Leaks in post condenser loop are rare because loop is a one-piece copper tube.
For minute leaks
1. Separate condenser from rest of refrigeration system and pressurize
condenser up to a maximum of 16.2 bars with a refrigerant and dry nitrogen
combination.
2. Recheck for leaks.
WARNING
!
To avoid severe personal injury or death from sudden eruption of high
pressures gases, observe the following:
Protect against a sudden eruption if high pressures are required for leak
checking.
Do not use high pressure compressed gases in refrigeration systems
without a reliable pressure regulator and pressure relief valve in the
lines.
WARNING
!
To avoid electrical shock which can cause severe personal injury or death,
discharge capacitor through a resistor before handling.

Component Testing
!WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test
procedures require power to be connected. Discharge capacitor through a resistor before attempting to service.
Ensure all earthing wires are connected before certifying unit as repaired and/or operational.
16021711 Rev. 07
Component Description Test Procedures
Overload / Relay When voltage is connected and relay is
cool, current passes through relay to start
winding.
After a short time, current heats the
resistor in relay and resistance will rise
blocking current flow through relay.
Start winding remains in the circuit through
run capacitor.
Solid state relay plugs directly on
compressor start and run terminals. Relay
terminals 2 and 3 are connected within
relay. Run capacitor is connected to relay
terminal 3. L2 side of 120 VAC power is
connected to relay terminal 2.
1. Disconnect power to the refrigerator.
2. Remove relay cover and disconnect leads.
3. Check resistance across terminals 2 and 3 with an ohmmeter:
Normal = 3 to 12 ohms
Shorted = 0 ohms
Open = infinite ohms
Freezer temperature control is a capillary
tube operating a single pole, single throw
switch.
Freezer temperature control controls run
cycle through defrost timer.
Check for proper calibration with thermocouple capillary in air supply well by
recording cut-in and cut-out temperatures at middle setting. Refer to tech sheet
for model being serviced for expected temperatures.
Check control contacts are opening by disconnecting electrical leads to control
and turning control knob to coldest setting. Check for continuity across
terminals.
Altitude Counter in Feet
Meters (Feet)
Above
Sea Level
Turn Screw
Clockwise (Angular
Degrees)
Freezer
temperature control
Altitude Adjustment
When altitude adjustment is required on a
G.E. control, turn altitude adjustment
screw 1/7 turn counter clockwise for each
304 meters increase in altitude up to 3048
meters. One full turn equals 3048 meters
maximum.
In most cases the need for altitude
adjustments can be avoided by simply
turning temperature control knob to colder
setting.
610 (2,000)
1218 (4,000)
1829 (6,000)
2438 (8,000)
3048 (10,000)
30
81
129
174
216
Ice Maker Optional on some models.
See “Ice Maker” section for service
information.
ECM condenser
motor
Condenser fan moves cooling air across
condenser coil and compressor body.
Condenser fan motor is in parallel circuit
with compressor.
Check resistance across coil.
Evaporator fan
motor
Evaporator fan moves air across
evaporator coil and throughout refrigerator
cabinet.
1. Disconnect power to unit.
2. Disconnect fan motor leads.
3. Check resistance from ground connection solder. Trace to motor frame must
not exceed .05 ohms.
4. Check for voltage at connector to motor with unit in refrigeration mode and
compressor operating.
0
300
270
240
210
180 150
120
90
60
30
330

Component Testing
!WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test
procedures require power to be connected. Discharge capacitor through a resistor before attempting to service.
Ensure all earthing wires are connected before certifying unit as repaired and/or operational.
16021711 Rev. 0 8
Component Description Test Procedures
Refrigerator light
switch
Single pole, single throw switch
completes circuit for light when door is
open.
Check resistant across terminals.
Switch arm depressed
“NO” terminals Open
Switch arm up
“NO” terminals Closed
Freezer light /
Interlock switch
Single pole, Double throw switch
completes circuit for light when door is
open. Completes circuit for dispenser
when door is closed
Check resistant across terminals.
Switch arm depressed
“NO” terminals Open
”NC” terminals Closed
Switch arm not depressed
“NC” terminals Open
“NO” terminals Closed
Drier Drier is placed at post condenser loop
outlet and passes liquefied refrigerant to
capillary.
Desiccant (20) 8 x 12 4AXH - 7 M>S> -
Grams
Drier must be changed every time the system is opened for testing or
compressor replacement.
NOTE: Drier used in R12 sealed system is not interchangeable with
drier used in R134a sealed system. Always replace drier in R134a
system with Amana part number B2150504.
Before opening refrigeration system, recover HFC134a refrigerant for safe
disposal.
1. Cut drier out of system using the following procedure. Do not unbraze drier.
2. Applying heat to remove drier will drive moisture into the system.
3. Score capillary tube close to drier and break.
4. Reform inlet tube to drier allowing enough space for large tube cutter.
5. Cut circumference of drier 31.75cm below condenser inlet tube joint to drier.
6. Remove drier.
7. Apply heat trap paste on post condenser tubes to protect grommets from high
heat.
8. Unbraze remaining part of drier. Remove drier from system.
9. Discard drier in safe place. Do not leave drier with customer. If refrigerator is
under warranty, old drier must accompany warranty claim.
Defrost timer Timer motor operates only when freezer
control is closed.
After specified amount of actual
operating time, inner cam in timer throws
the contacts from terminal 4, compressor
circuit, to terminal 2, defrost
thermostat/defrost heater circuit.
After specified defrost cycle time, timer
cam resets the circuitry through terminal
4 to compressor.
1. To check timer motor winding, check for continuity between terminals 1 and 3
of timer.
2. Depending on rotating position of the cam, terminal 1 of timer is common to
both terminal 2, the defrost mode, and terminal 4, the compressor mode.
There should never be continuity between terminals 2 and 4.
3. With continuity between terminals 1 and 4, rotate timer knob clockwise until
audible click is heard. When the click is heard, reading between terminals 1
and 4 should be infinite and there should be continuity between terminals 1
and 2.
4. Continuing to rotate time knob until a second click is heard should restore
circuit between terminals 1 and 4.
Adaptive defrost
control (ADC)
The ADC adapts the compressor run
time between defrosts to achieve
optimum defrost intervals by monitoring
the cold control and length the defrost
heater is on.
Refer to specific Technical Data Sheet with unit for troubleshooting procedure.
WARNING
!
To avoid death or severe personal injury, cut drier at correct location.
Cutting drier at incorrect location will allow desiccant beads to scatter. If
spilled, completely clean area of beads.

Component Testing
!WARNING
To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit, unless test
procedures require power to be connected. Discharge capacitor through a resistor before attempting to service.
Ensure all earthing wires are connected before certifying unit as repaired and/or operational.
16021711 Rev. 09
Component Description Test Procedures
Water valve Controls water flow to the ice maker.
Controlled by thermostat in ice maker.
See Ice Maker Section for further
information.
Check resistance across coil windings.
Evaporator Inner volume of evaporator allows liquid
refrigerant discharged from capillary to
expand into refrigerant gas.
Expansion cools evaporator tube and fin
temperature to approximately –28.9
° C
transferring heat from freezer section to
refrigerant.
Passing through suction line to
compressor, the refrigerant picks up
superheat (a relationship between
pressure and temperature that assures
complete vaporization of liquid
refrigerant) as the result of capillary tube
soldered to suction line.
Refrigerant gas is pulled through suction
line by compressor, completing
refrigeration cycle.
Test for leaks in evaporator with electronic leak detector or with soap solution.
Compressor oil is circulated with refrigerant; check for oil when checking for
leaks.
For minute leaks
1. Separate evaporator from rest of refrigeration system and pressurize
evaporator up to a maximum of 9.65 bar with a refrigerant and dry nitrogen
combination.
2. Recheck for leaks.
Evaporator defrost
heater
Activated when defrost thermostat,
defrost timer, and freezer control
complete circuit through heater.
Check resistance across heater.
To check defrost system :
1. Thermocouple defrost thermostat and plug refrigerator into wattmeter.
2. Turn into defrost mode. Wattmeter should read specified watts (according to
Technical Data Sheet).
3. When defrost thermostat reaches specified temperature
± 9 ° C( ± 5 ° F) (see
Technical Data Sheet), thermostat should interrupt power to heater.
Thermostat Thermostat is in a series circuit with
terminal 2 of defrost timer, and defrost
heater. Circuit is complete if evaporator
fan motor operates when cold.
Controls the circuit from freezer
thermostat through defrost terminator to
defrost heater. Opens and breaks circuit
when thermostat senses preset high
temperature.
Test continuity across terminals.
With power off and evaporator coil below freezing, thermostat should show
continuity when checked with ohmmeter. See “Heater, evaporator (defrost)”
section for additional tests.
After defrost thermostat opens, thermostat remains open until end of defrost
cycle and refrigerator starts cooling again. Defrost thermostat senses a preset
low temperature and resets (closes).
Damper Control Damper control balances the air delivery
between refrigerator and freezer
compartments providing temperature
control for refrigerator.
Internal capillary activates damper
control and door closes restricting flow of
air from freezer compartment to
refrigerator compartment.
Subject capillary to appropriate temperature (refer to Technical Data Sheet for
model being serviced).
Damper door should close to within .6cm of completely shut.
If altitude adjustment is required, turn altitude adjustment screw 1/8 turn
clockwise for each 305 meters increase in altitude.
There are no electrical connections to damper control. See Technical Data Sheet
for damper specifications for unit being serviced.
WARNING
!
To avoid severe personal injury or death from sudden erruption of
high pressurres gases, observe the following:
•Protect against a sudden eruption if high pressures are required
for leak checking.
•Do not use high pressure compressed gases in refrigeration
systems without a reliable pressure regulator and pressure relief
valve in the lines.

16021711 Rev. 0 10
Drier Replacement
Before opening refrigeration system, recover
HFC134a refrigerant for safe disposa .
Every time sea ed HFC134a system is repaired, drier
fi ter must be rep aced with, part # B2150504.
Cut drier out of system by comp eting the fo owing
steps. Do not unbraze drier fi ter. App ying heat to
remove drier wi drive moisture into system.
To avoid risk of severe persona injury or death, cut
drier at correct ocation. Cutting drier at incorrect
ocation wi a ow desiccant beads to scatter.
Comp ete y c ean area of beads, if spi ed.
1. Score capi ary tube c ose to drier and break.
2. Reform in et tube to drier a owing enough space
for arge tube cutter.
3. Cut circumference of drier at 3.2cm, be ow
condenser in et tube joint to drier.
4. Remove drier.
5. App y heat trap paste on post condenser tubes to
protect grommets from high heat.
6. Unbraze remaining part of drier. Remove drier
from system.
7. Discard drier in safe p ace. Do not eave drier with
customer. If refrigerator is under warranty, o d
drier must accompany warranty c aim.
Service Procedures
Service Equipment
Listed be ow is equipment needed for proper servicing
of HFC134a systems. Verify equipment is confirmed
by manufacturer as being compatib e with HFC134a
and ester oi system.
Equipment must be exc usive y used for HFC134a.
Exc usive use of equipment on y app ies to ita ic items.
Evacuation pump
Check with vacuum pump supp ier to verify equipment
is compatib e for HFC134a. Robinair, Mode 15600
2 stage, 6 cubic feet per minute pump is
recommended.
Four-way manifold gauge set, with low loss hoses
Leak detector
Charging cylinder
Line piercing saddle valve
(Schroeder va ves). Sea s must be HFC134a and
ester oi compatib e. Line piercing va ves may be used
for diagnosis but are not suitab e for evacuation or
charging, due to minute ho es pierced in tubing. Do
not eave mechanica access va ves on system.
Va ves eventua y wi eak. Mo ecu es of HFC134a are
sma er than other refrigerants and wi eak where
other refrigerants wou d not.
Swagging tools
Flaring tools
Tubing cutter
Flux
Sil-Fos
Silver solder
Oil for swagging and flaring
Use on y part # R0157532
Copper tubing
Use on y part # R0174075 and # R0174076
Dry nitrogen
99.5% minimum purity, with -40°C or ower dew point
Crimp tool
Tube bender
Micron vacuum gauge
Process tube adaptor it
Heat trap paste
ICI appliance grade HFC134a
To avoid risk of e ectrica shock, persona injury, or death, disconnect e ectrica power source to unit, un ess test
procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting
to service. Ensure a earthing wires are connected before certifying unit as repaired and/or operationa .
!
WARNING
WARNING
!

11 16021711 Rev. 0
Refrigerant Precautions
WARNING
!
To avoid risk of persona injury, do not a ow
refrigerant to contact eyes or skin.
CAUTION
!
To avoid risk of property damage, do not use
refrigerant other than that shown on unit seria
number identification p ate.
OTE: A precautionary measures recommended by
refrigerant manufacturers and supp iers app y
and shou d be observed.
Line Piercing Valves
Line piercing va ves can be used for diagnosis, but
are not suitab e for evacuating or charging due to
ho es pierced in tubing by va ves.
OTE: Do not eave ine piercing va ves on system.
Connection between va ve and tubing is not
hermetica y sea ed. Leaks wi occur.
Open Lines
During any processing of refrigeration system, never
eave ines open to atmosphere. Open ines a ow water
vapor to enter system, making proper evacuation more
difficu t.
Compressor Operational Test
(short term testing on y)
If compressor vo tage, capacitor, over oad, and motor
winding tests are successfu (do not indicate a fau t),
perform the fo owing test:
1.Disconnect power to unit.
2.Discharge capacitor by shorting capacitor
termina s through a resistor.
OTE: Not a units have run capacitor.
3.Remove eads from compressor termina s.
4.Attach test cord to compressor windings.
 Common ead on test cord attaches to C termina
on compressor.
 Start ead on test cord attaches to S termina on
compressor.
 Run ead on test cord attaches to M termina on
compressor.
Service Procedures
C
R
S
Fuses
Capacitor
Compressor
Switch
To AC supply
Attaching Capacitor for Compressor Test
5. Connect a known good capacitor into circuit as shown
above. For proper capacitor size and rating, see
technica data sheet for unit under test.
OTE: Ensure test cord cab es and fuses meet
specifications for unit under test (see Technica
Sheet for unit under test).
6. Rep ace compressor protector cover secure y.
7. P ug test cord into out et, then press and re ease start
cord switch.
CAUTION
!
To avoid risk of damage to compressor windings,
immediate y disconnect (unp ug) test cord from power
source if compressor does not start. Damage to
compressor windings occurs if windings remain
energized when compressor is not running.
If compressor runs when direct wired, it is working
proper y. Ma function is e sewhere in system.
If compressor does not start when direct wired, recover
system at high side. After the system is recovered,
repeat compressor direct wire test.
If compressor runs after system is recovered (but
wou d not operate when wired direct before recovery) a
restriction in sea ed system is indicated.
If motor does not run when wired direct after recovery,
rep ace fau ty compressor.
To avoid risk of e ectrica shock, persona injury, or death, disconnect e ectrica power source to unit, un ess test
procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting
to service. Ensure a earthing wires are connected before certifying unit as repaired and/or operationa .
!
WARNING

16021711 Rev. 0 12
Dehydrating Sealed Refrigeration System
Moisture in a refrigerator sea ed system exposed to
heat generated by the compressor and motor reacts
chemica y with refrigerant and oi in the system and
forms corrosive hydroch oric and hydrof uoric acids.
These acids contribute to breakdown of motor winding
insu ation and corrosion of compressor working parts,
causing compressor fai ure.
In addition, s udge, a residue of the chemica reaction,
coats a surfaces of sea ed system, and wi eventua y
restrict refrigerant f ow through capi ary tube.
To dehydrate sea ed system, evacuate system (see
paragraph Evacuation).
Lea Testing
DANGER
!
To avoid risk of serious injury or death from vio ent
exp osions, NEVER use oxygen or acety ene for
pressure testing or c ean out of refrigeration
systems. Free oxygen wi exp ode on contact with
oi . Acety ene wi exp ode spontaneous y when put
under pressure.
It is important to check sea ed system for refrigerant
eaks. Undetected eaks can ead to repeated service
ca s and eventua y resu t in system contamination,
restrictions, and premature compressor fai ure.
Refrigerant eaks are best detected with ha ide or
e ectronic eak detectors.
Testing Systems Containing a Refrigerant Charge
1. Stop unit operation (turn refrigerator off).
2. Ho ding eak detector exp oring tube as c ose to
system tubing as possib e, check a piping, joints,
and fittings.
OTE: Use soap suds on areas eak detector cannot
reach or re iab y test.
Testing Systems Containing o Refrigerant Charge
1. Connect cy inder of nitrogen, through gauge
manifo d, to process tube of compressor and iquid
ine strainer.
2. Open va ves on nitrogen cy inder and gauge manifo d.
A ow pressure to bui d within sea ed system.
3. Check for eaks using soap suds.
If a eak is detected in a joint, do not to attempt to repair
by app ying additiona brazing materia . Joint must be
disassemb ed, c eaned and rebrazed. Capture refrigerant
charge (if system is charged), unbraze joint, c ean a
parts, then rebraze.
If eak is detected in tubing, rep ace tubing. If eak is
detected in either coi , rep ace fau ty coi .
Service Procedures
!
WARNING
To avoid risk of e ectrica shock, persona injury, or death, disconnect e ectrica power source to unit, un ess test
procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting
to service. Ensure a earthing wires are connected before certifying unit as repaired and/or operationa .

13 16021711 Rev. 0
Service Procedures
!
WARNING
To avoid risk of e ectrica shock, persona injury, or death, disconnect e ectrica power source to unit, un ess test
procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting
to service. Ensure a earthing wires are connected before certifying unit as repaired and/or operationa .
Restrictions
Symptoms
Restrictions in sea ed system most often occur at
capi ary tube or fi ter drier, but can exist anywhere on
iquid side of system.
Restrictions reduce refrigerant f ow rate and heat
remova rate. Wattage drops because compressor is
not circu ating norma amount of refrigerants.
Common causes of tota restrictions are moisture,
poor y so dered joints, or so id contaminants. Moisture
freezes at evaporator in et end of capi ary tube. So id
contaminants co ect in fi ter drier.
If restriction is on ow side, suction pressure wi be in a
vacuum and head pressure wi be near norma .
If restriction is on high side, suction pressure wi be in
a vacuum and head pressure wi be higher than
norma during pump out cyc e.
Refrigeration occurs on ow pressure side of partia
restriction. There wi be a temperature difference at
the point of restriction. Frost and/or condensation wi
be present in most cases at the point of restriction.
A so, system requires onger to equa ize.
S ight or partia restriction can give the same
symptoms as refrigerant shortage inc uding ower than
norma back pressure, head pressure, wattage, and
warmer temperatures.
Tota restriction on the discharge side of compressor,
when restriction is between compressor and first ha f
of condenser, resu ts in higher than norma head
pressure and wattage whi e ow side is being pumped
out.
Testing for Restrictions
To determine if a restriction exists:
1. Attach gauge and manifo d between suction and
discharge sides of sea ed system.
2. Turn unit on and a ow pressure on each side to
stabi ize. Inspect condenser side of system. Tubing
on condenser shou d be warm and temperature
shou d be equa throughout (no sudden drops at any
point a ong tubing).
 If temperature of condenser tubing is consistent
throughout, go to step 4.
 If temperature of condenser tubing drops sudden y
at any point, tubing is restricted at point of
temperature drop (if restriction is severe, frost may
form at point of restriction and extend down in
direction of refrigerant f ow in system). Go to step 5.
3. Visua y check system for kinks in refrigeration ine
which is causing restriction. Correct kink and repeat
step 2.
4. Turn unit off and time how ong it takes high and ow
pressure gauges to equa ize:
 If pressure equa ization takes onger than 10
minutes, a restriction exists in the capi ary tube or
drier fi ter. Go to step 5.
 If pressure equa ization takes ess than 10 minutes,
system is not restricted. Check for other possib e
causes of ma function.
5. Recover refrigerant in sea ed system.
OTE: Before opening any refrigeration system,
capture refrigerant in system for safe disposa .
6. Remove power from unit.
CAUTION
!
To avoid risk of persona injury or property damage,
take necessary precautions against high
temperatures required for brazing.
7. Remove and rep ace restricted device.
8. Evacuate sea ed system.
9. Charge system to specification.
OTE: Do not use captured or recyc ed refrigerant in
units. Captured or recyc ed refrigerant voids any
and/or compressor manufacturer's warranty.
OTE: Charge system with exact amount of refrigerant.
Refer to unit namep ate for correct refrigerant
charge. Inaccurate y charged system wi cause
future prob ems.

16021711 Rev. 0 14
Evacuation and Charging
CAUTION
!
To avoid risk of fire, sea ed refrigeration system
must be air free. To avoid risk of air contamination,
fo ow evacuation procedures exact y.
OTE: Before opening any refrigeration system, EPA
regu ations require refrigerant in system to be
captured for safe disposa .
Proper evacuation of sea ed refrigeration system is an
important service procedure. Usab e ife and
operationa efficiency great y depends upon how
comp ete y air, moisture and other non-condensab es
are evacuated from sea ed system.
Air in sea ed system causes high condensing
temperature and pressure, resu ting in increased
power requirements and reduced performance.
Moisture in sea ed system chemica y reacts with
refrigerant and oi to form corrosive hydrof uoric and
hydroch oric acids. These acids attack motor windings
and parts, causing premature breakdown.
Before opening system, evaporator coi must be at
ambient temperature to minimize moisture infi tration
into system.
Evacuation
To evacuate sea ed refrigeration system:
1. Connect vacuum pump, vacuum tight manifo d set
with high vacuum hoses, thermocoup e vacuum
gauge and charging cy inder as shown in i ustration.
Evacuation shou d be done through I.D. opening of
tubes not through ine piercing va ve.
2. Connect ow side ine to compressor process tube.
3. Connect high side ine to drier/process tube.
4. Evacuate both simu taneous y. With va ve C and F
c osed, open a other va ves and start vacuum pump.
Vacuum Pump
.6 cm Copper
Tubing
Compressor Compressor
Process
Tube
Charging Hose
Thermistor
Vacuum Gauge Low Side Gauge
E
Valve
B
D
Valve
High Side Gauge
Charging Hose
Drier/Process Tube
F
Valve
Charging
Cylinder
C
A
Equipment Setup For Evacuation And Charging
5. After compound gauge ( ow side) drops to
approximate y .98 bar (29 inches gauge), open va ve
C to vacuum thermocoup e gauge and take micron
reading.
OTE: A high vacuum pump can on y produce a good
vacuum if oi in pump is not contaminated.
6. Continue evacuating system unti vacuum gauge
registers 600 microns.
7. At 600 microns, c ose va ve A to vacuum pump and
a ow micron reading in system to ba ance. Micron
eve wi rise.
 If in 2 minutes, micron eve stabi izes at 1000
microns or be ow, system is ready to be charged.
 If micron eve rises above 1000 microns and
stabi izes, open va ve A and continue evacuating.
 If micron reading rises rapid y and does not
stabi ize, a eak sti exists in system.
C ose va ve A to vacuum pump and va ve C to
vacuum gauge. Invert charging cy inder and open
charging cy inder va ve F to add partia charge for
eak checking. With eak detector, check manifo d
connections and system for eaks. After ocating
eak, capture refrigerant, repair eak, and begin at
step 1.
Service Procedures
!
WARNING
To avoid risk of e ectrica shock, persona injury, or death, disconnect e ectrica power source to unit, un ess test
procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting
to service. Ensure a earthing wires are connected before certifying unit as repaired and/or operationa .

15 16021711 Rev. 0
Charging
OTE: Do not use captured or recyc ed refrigerant in
units. Captured or recyc ed refrigerant voids any
warranty.
OTE: Charge system with exact amount of refrigerant.
Refer to unit seria p ate for correct refrigerant
charge. Inaccurate y charged system wi cause
future prob ems.
To charge system:
1. C ose va ves A to vacuum pump and C to vacuum
gauge and E to ow side manifo d gauge.
2. Set sca e on dia -a-charge cy inder for corresponding
HFC134a pressure reading.
3. Open va ve F to charging cy inder and et exact
amount of refrigerant f ow from cy inder into system.
C ose va ve.
Low side gauge pressure shou d rise short y after
opening charging cy inder va ve as system pressure
equa izes through capi ary tube.
If pressure does not equa ize, a restriction typica y
exists at capi ary/drier braze joint.
4. If pressure equa izes, open va ve E to ow side
manifo d gauge and pinch off high side drier process
tube.
5. Start compressor and draw remaining refrigerant from
charging hoses and manifo d into compressor
through compressor process tube.
6. To check high side pinch-off drier process tube. C ose
va ve D to high side gauge. If high side pressure
rises, repeat high side pinch-off and open va ve D.
Repeat unti high side pinch-off does not eak.
7. Pinch-off compressor process tube and remove
charging hose. Braze stub c osed whi e compressor is
operating.
8. Disconnect power. Remove charging hose and braze
high side drier process tube c osed.
9. Recheck for refrigerant eaks.
Service Procedures
!
WARNING
To avoid risk of e ectrica shock, persona injury, or death, disconnect e ectrica power source to unit, un ess test
procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting
to service. Ensure a earthing wires are connected before certifying unit as repaired and/or operationa .
Refrigerant Charge
Refrigerant charge in a capi ary tube systems is
critica and exact amount is required for proper
performance. Factory charges are shown on seria
p ate.
OTE: Do not use refrigerant other than shown on
seria p ate.

16021711 Rev. 0 16
To minimize contamination, exercise extreme care
when servicing HFC134A sea ed systems.
No trace of other refrigerants is a owed in HFC134a
systems. Ch orinated mo ecu es in other refrigerants
such as CFC12, etc. wi ead to capi ary tube
p ugging.
Ester oi is used in HFC134a systems. Do not use
minera oi . HFC134a and minera oi s cannot be
mixed. If minera oi s were used in HFC134a systems,
ubricant wou d not return to compressor and wou d
cause ear y compressor fai ure. If significant amount of
oi has been ost from compressor, rep ace oi rather
than adding oi .
 Ester oi s used in HFC134a systems are so
hydroscopic that by the time an inadequate system
performance is detected, oi wi be saturated with
moisture.
 CFC12 has much higher to erance to system
processing materia s, such as drawing compounds,
rust inhibitors, and c eaning compounds, than
HFC134a. Such materia s are not so ub e in HFC134a
systems. If materia s were to be washed from system
surfaces by ester oi s, they cou d accumu ate and
eventua y p ug capi ary tube.
 Care must be taken to minimize moisture entering
HFC134a system. Do not eave compressor or system
open to atmosphere for more than 10 minutes.
Excessive moisture in HFC134a system wi react with
compressor oi and generate acid.
 Compressor must be rep aced when performing ow
side eak repair.
Drier fi ter must a ways be rep aced with service drier
fi ter, part #B2150504.
Important: Unbrazing drier fi ter from tubing wi drive
moisture from desiccant and into system, causing
acids to form. Do not unbraze fi ter drier from tubing. If
CFC12 service drier was insta ed in HFC134A system,
drier cou d over oad due to excessive moisture.
 HFC134a compatib e copper tubing, part #R0174075
(6.35mm O.D. X 457mm ength) and part #R0174076
(7.24mm O.D. X 610mm ength) must be used when
rep acing tubing.
 Avoid system contamination by using Towerdraw E610
evaporating oi , part # R0157532, when f aring,
swagging, or cutting refrigeration tubing.
Service Procedures
HFC134a Service Information
HFC134a is a ternative refrigerant for CFC12.
HFC134a has an ozone dep etion potentia (ODP)
factor of 0.0 and a g oba warming potentia (GWP)
factor of 0.27. HFC134a is not f ammab e and has
acceptab e toxicity eve s. HFC134a is not
interchangeab e with CFC12. There are significant
differences between HFC134a and CFC12 which must
be considered when hand ing and processing
refrigeration system.
Health, Safety, and Handling
Hea th, safety and hand ing considerations for
HFC134A are virtua y no different than those for
CFC12.
Comparison of CFC12 and HFC134a Properties
Health, Safety, and
Handling CFC12 HFC134a
Allowable overall
exposure limit 1,000 ppm Same
Vapor exposure to skin No effect Same
Liquid exposure to skin Can cause frostbite Same
Vapor exposure to eye Very slight eye irritant Same
Liquid exposure to eye Can cause frostbite Same
Above minimum exposure
limit Can cause Asphyxiation, Tachycardia, and Cardia
Arrhythmias
Same
Safety and handling Wear appropriate skin
and eye protection. Use
with adequate
ventilation.
Same
Spill management Remove or extinguish
ignition or combustion
sources. Evacuate or
ventilate area.
Same
Fire explosion hazards May decompose if
contact with flames and
heating elements.
Container may explode
if heated due to resulting
pressure rise.
Combustion products
are toxic.
Same
Disposal procedures Recycle or reclaim. Same
To avoid risk of e ectrica shock, persona injury, or death, disconnect e ectrica power source to unit, un ess test
procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting
to service. Ensure a earthing wires are connected before certifying unit as repaired and/or operationa .
!
WARNING
CAUTION
!
Properties/Characteristics CFC12 HFC134a
Ozone Depletion Potential
(ODP) 1.0* 0.0*
Global Warming Potential
(GPW) 3.2* 0.27*
Molecular weight 121 102
Boiling point at 1 atmosphere -22°F (-30°C) -15°F
(-126°C)
Vapor pressure at 77°F
(25°C) 5.51 bar 5.65 bar
Liquid density at 77°F (25°C) 82 lb/ft375 lb/ft3
Flammability No No
High-side system operating
Pressure at 65°F (18°C) HFC134a approximately 3 psig higher than CFC12
Low-side system operating
Pressure at 65°F (18°C) HFC134a approximately 2 psig lower than CFC12

17 16021711 Rev. 0
To avoid death or severe persona injury, never use
oxygen, air or acety ene for pressure testing or
c ean out of refrigeration system. Use of oxygen,
air, or acety ene may resu t in vio ent exp osion.
Oxygen may exp ode on contact with oi and
acety ene wi spontaneous y exp ode when under
pressure.
Replacement Service Compressor
HFC134a service compressors wi be charged with
ester oi and pressurized with dry nitrogen. Before
rep acement compressor is insta ed, pu out 1 rubber
p ug. A pop from pressure re ease shou d be heard. If
a pop sound is not heard, do not use compressor.
Positive pressure in compressor is vita to keep
moisture out of ester oi . Do not eave compressor
open to atmosphere for more than 10 minutes.
Compressor Testing Procedures
Refer to Technica Data Sheet Temperature
Re ationship Chart for operating watts, test points,
and temperature re ationship test for unit being tested.
 Temperature testing is accomp ished by using 3 ead
thermocoup e temperature tester in specific ocations.
Test point T-1 is out et on evaporator coi and T-2 is
in et. Test point T-3 is suction tube temperature
midway between where armaf ex ends and suction
port of compressor (approximate y 304mm from
compressor).
 Thermocoup e tips shou d be attached secure y to
specified ocations.
 Do not test during initia pull down. A ow one off cyc e
or ba anced temperature condition to occur before
proceeding with testing.
 Refrigerator must operate minimum of 20 minutes
after thermocoup es are insta ed.
 Turn contro to co der to obtain required on time.
 Wattage reading must be recorded in conjunction with
temperature test to confirm proper operation.
 Suction and head pressures are isted on
Temperature and Re ationship Chart. Norma y these
are not required for diagnosis but used for confirmation
on systems which have been opened.
Service Procedures
To avoid risk of e ectrica shock, persona injury, or death, disconnect e ectrica power source to unit, un ess test
procedures require power to be connected. Discharge capacitor through a 10,000 ohm resistor before attempting
to service. Ensure a earthing wires are connected before certifying unit as repaired and/or operationa .
!
WARNING
Brazing
CAUTION
!
To avoid risk of persona injury or property damage,
take necessary precautions against high
temperatures required for brazing.
Satisfactory resu ts require c ean iness, experience,
and use of proper materia s and equipment.
Connections to be brazed must be proper y sized, free
of rough edges, and c ean.
Genera y accepted brazing materia s are:
Copper to copper joints: SIL-FOS (a oy of 15
percent si ver, 80 percent copper, and 5 percent
phosphorous). Use without f ux. Recommended
brazing temperature is approximate y 760°C. Do not
use for copper to steel connection.
Copper to steel joints: SILVER SOLDER (a oy of 30
percent si ver, 38 percent copper, 32 percent zinc).
Use with f uoride based f ux. Recommended brazing
temperature is approximate y 649°C
Steel to steel joints: SILVER SOLDER (see copper
to stee joints).
Brass to copper joints: SILVER SOLDER (see
copper to stee joints).
Brass to steel joints: SILVER SOLDER (see copper
to stee joints).
WARNING
!

16021711 Rev. 0 18
Refrigerant Flow
Side by Side
Refrigerant Flow Diagram
EVAPORATOR
COMPRESSOR
PROCESS TUBE
CONDENSER
EVAPORATOR
INLET
FLANGE LOOP
EVAPORATOR OUTLE
T
SUCTION LINE
HIGH SIDE
DRIER
CAPILLARY TUBE
PROCESS TUBE
COMPRESSOR DISCHARGE LINE

19 16021711 Rev. 0
Cabinet Air Flow
Side by Side
Cabinet Air Flow Diagram
With One Way Condenser Air Flow
FREEZER BACK
(AIR BAFFLE)
AIR SUPPLY
(IN FOAM)
REFRIGERATOR AIR
RETURN TUNNEL
CONDENSER
COMPRESSOR
LARGE BEVERAGE CHILLER
AIR SUPPLY
EVAPORATOR
EVAPORATOR
FAN ASSEMBLY
REFRIGERATOR AIR
SUPPLY TUNNEL
TO FRESH FOOD
COMPARTMENT CONTROLS
CONDENSER FAN
ASSEMBLY
DELI
AIR SUPPLY
SIDE BY SIDE
AIRFLOW DIAGRAM
SMALL BEVERAGE CHILLER
AIR SUPPLY
(SOME MODELS)
(SOME MODELS)

16021711 Rev. 0 20
Cabinet Air Flow
Side by Side
Cabinet Air Flow Diagram
With Two Way Condenser Air Flow
FREEZER BACK
(AIR BAFFLE)
AIR SUPPLY
(IN FOAM)
REFRIGERATOR AIR
RETURN TUNNEL
CONDENSER FAN
ASSEMBLY
COMPRESSOR
CONDENSER
EVAPORATOR
LARGE BEVERAGE CHILLER
AIR SUPPLY
(SOME MODELS)
DELI
AIR SUPPLY
EVAPORATOR
FAN ASSEMBLY
REFRIGERATOR AIR
COMPARTMENT CONTROLS
SUPPLY TUNNEL
TO FRESH FOOD
SMALL BEVERAGE CHILLER
AIR SUPPLY
(SOME MODELS)