Kuppersbusch ? ???KE9600-0-2T User manual

Refrigerator
KE 9600-0-2T

Service Manual: H8-94-01
Responsible: U. Laarmann KÜPPERSBUSCH HAUSGERÄTE AG
E-mail: [e-mail]
Tel.: [phone] Customer Service
Fax: [phone] Postfach 100 132
Date: 17.09.2014 45801 Gelsenkirchen

Service Manual 3
For internal use only
Contents
1. Safety instructions ......................................................................................................... 5
2. Repair instructions......................................................................................................... 6
3. Appliance dimensions ................................................................................................... 6
4. Components of the refrigerator .................................................................................... 7
5. Instructions for handling and installation.................................................................... 7
5.1 Introduction............................................................................................................ 9
5.2 Components of the electrical system ................................................................ 10
5.3 Compressor......................................................................................................... 12
5.4 Freezer fan motor (Freezer compartment fan motor).......................................... 12
5.5 Condenser fan motor........................................................................................... 13
5.6 Sensors ............................................................................................................... 14
5.7 Freezer compartment sensor .............................................................................. 15
5.8 Fridge compartment sensor ................................................................................ 15
5.9 Fridge compartment evaporator sensor .............................................................. 16
5.10 Defrost sensor ..................................................................................................... 16
5.11 Freezer defrost heater......................................................................................... 16
5.12 Thermal fuse ....................................................................................................... 17
5.13 PTC relay ............................................................................................................ 18
5.14 Thermic ............................................................................................................... 18
5.15 Flange heater ...................................................................................................... 18
5.16 Door switch.......................................................................................................... 18
5.17 Replacing the lamp.............................................................................................. 19
5.18 Electronic control board....................................................................................... 20
5.19 Icematic sensor ................................................................................................... 22
5.20 Ice quantity sensor/Icematic switch/Icematic arm ............................................... 22
5.21 Icematic motor..................................................................................................... 22
5.22 Water valve group ............................................................................................... 23
5.23 Ice crusher motor ................................................................................................ 24
5.24 Solenoid for ice type............................................................................................ 24
5.25 Solenoid to open the ice lid ................................................................................. 24
5.26 Ice lid heater........................................................................................................ 25
5.27 Water dispenser heater switch ............................................................................ 26
5.28 Blue light LED board ........................................................................................... 26
5.29 Ionizer.................................................................................................................. 26
5.30 Display................................................................................................................. 27
6. Function ........................................................................................................................ 30
6.1 Defrosting ............................................................................................................ 30
6.1.1 Freezer defrosting ................................................................................... 30
6.1.2 Fridge defrosting ..................................................................................... 30
6.1.3 Calculating the cycle time and cycle number .......................................... 30
6.2 Initial operation and power failure ....................................................................... 31
6.3 Fast freeze .......................................................................................................... 32
6.4 Quick cool............................................................................................................ 32
6.5 High temperature alarm....................................................................................... 32
6.6 Vacation .............................................................................................................. 32
6.7 Eco-Fuzzy (special economy function)................................................................ 33
6.8 Key lock............................................................................................................... 33
6.9 Water dispenser illumination ............................................................................... 33
6.10 Water/Ice type selection ...................................................................................... 33

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6.11 Water/Ice dispenser............................................................................................. 33
6.12 Ice Off ..................................................................................................................33
6.13 Water filter ...........................................................................................................33
6.14 Setting the water amount for the Icematic ...........................................................34
6.15 Making ice ...........................................................................................................34
7. Service test....................................................................................................................35
8. Error codes.................................................................................................................... 37
8.1 Failure diagrams..................................................................................................38
8.2 Refrigerator - Electrical circuit diagram ..............................................................41
8.3 Possible failures ..................................................................................................42
8.3.1 The appliance does not cool ................................................................... 42
8.3.2 PCB failure ..............................................................................................42
8.3.3 No image on the display..........................................................................42
8.3.4 Sensor failure ..........................................................................................42
8.3.5 Heater failure...........................................................................................42
9. Structural parts of the refrigerator .............................................................................. 43
9.1 Water and ice dispenser...................................................................................... 43
9.2 Icematic ...............................................................................................................44
9.3 Ice stock drive assembly .....................................................................................45
9.4 Ice drive motor assembly.....................................................................................46
9.5 Freezer fan .......................................................................................................... 47
9.6 Fridge fan ............................................................................................................47
9.7 Home freezer (HF)...............................................................................................48
9.8 Multiflow and diffuser cover .................................................................................48
9.9 Freezer upper evaporator cover ..........................................................................48
9.10 Freezer lower evaporator cover...........................................................................49
9.11 Front legs and lower door hinge ..........................................................................49
9.12 Lower ventilation cover........................................................................................50
9.13 Water valve - Jug and tap connections ............................................................... 50
9.14 Attaching and removing the control board ..........................................................51
9.15 Servicing the drain heater....................................................................................51
10. Troubleshooting and failure identification ................................................................. 52
11. Installing the wall spacer ............................................................................................. 55
12. Changing the evaporator sensor ................................................................................ 55
13. Icematic sensor problem ............................................................................................. 57

Service Manual 5
For internal use only
1. Safety instructions
Danger!
Repairs may only be carried out by a qualified electrician!
Improper repairs may lead to risks and damages for the user!
It is essential that you observe the following instructions in order to prevent electric shocks:
• The casing and the frame may be live in the event of faults! Disconnect the appliance from the mains
prior to carrying out any repair work!
• Touching live components inside the appliance may cause dangerous currents to flow through your
body!
• Do not damage the parts where the refrigerant is circulating with drilling or cutting tools. The
refrigerant that might blow out when the gas channels of the evaporator, pipe extensions or surface
coatings are punctured may cause skin irritations and eye injuries.
• Disconnect the appliance from the mains prior to carrying out any repair work!
• Whein inspecting live parts, a residual current circuit breaker must always be used!
• Always ensure that an earthed conductor is properly connected! The ground wire resistance must not
exceed that specified in the standard! It is vital for ensuring the safety of persons and the functioning
of the appliance.
• On completion of repairs, an inspection must be carried out in accordance with VDE 0701
[Association of German Electrical Engineers] or the corresponding regulations for your country! On
completion of repairs, a function and impermeability inspection must be carried out.
• Do not touch any of the components in the appliance. The modules are also live!
• Observe instructions on electrostatic hazards!
• Wear safety goggles and protective gloves when handling refrigerants. Rinse your eyes with a lot of
water if refrigerant splashes into them.
It is essential that you observe the following instructions:
• The appliances must be disconnected from the mains prior to all repairs. If inspections must be
carried out on live appliances, make sure you use a residual current circuit breaker.
Caution!
Sharp edges: Use protective gloves.
Components may be electrostatic!
Observe handling regulations!

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2. Repair instructions
• Never attempt to carry out repairs by “randomly replacing” components!
• Always proceed systematically and observe the technical documentation that goes with the
appliance!
• Do not plug in your appliance before removing all packaging materials and protective transport
elements.
• To prevent horizontal handling and in order to ensure complete distribution of the condenser oil, keep
the appliance in upright position for 4 hours before operating.
• Electronic circuit boards are generally not repaired; instead they are completely replaced with original
spare parts. Exceptions are documented separately.
• Pipe connections in cooling circuits are not to be soldered. Lokring connections are to be used.
• Carry out a leak test and a functional test on the cooling circuit.
• The dehumidifier is to be replaced before evacuation and filling during any intervention in the cooling
circuit.
• It is essential to replace the compressor and the dehumidifier when repair work resulting from suction
leaks in the cooling circuit is carried out. Humidity which gets into the cooling circuit will cause
irreparable damage to the oil in the compressor.
3. Appliance dimensions
Depth: 740 mm
Width: 925 mm
Height: 1800 mm

Service Manual 7
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4. Components of the refrigerator
1. Freezer compartment
2. Fridge compartment
3. Fridge compartment
interior light
4. Butter and cheese lid
5. Fan
6. Ionizer
7. Fridge compartment glass
shelves
8. Egg tray
9. Fridge compartment door
racks
10. Wine rack
11. Bottle holder
12 Bottle shelves
13. Crisper compartments
14. Crisper cover
15. Adjustable front legs
16. Blue light
17. Water reservoir
18. Ventilation lid
19. Freezer compartment drawers
20. Freezer compartment glass shelves
21. Ice duct lid
22. Freezer compartment interior light
23. Fresh freeze compartment
24. Ice container
5. Instructions for handling and installation
Handling instructions
This appliance should be transported only in upright position. Delivery package should not be damaged
during transportation.
If the appliance is to be transported in horizontal position, it should only be leaned towards left hand side
when you are facing the front of the appliance. After bringing it into upright position, it should be left for
at least 4 hours without being operated in order to have it settled.
Failure to obey above instructions may result in damage on the appliance. In case of failure to obey these
instructions, producer shall not be held responsible.

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The appliance must be protected against rain, humidity and other atmospheric effects.
Pay attention not to damage your floor, the pipes, wall coverings etc., when installing your appliance.
The appliance should not be carried by pulling at the door or door handle.
Discharge the water in the drain tray before moving the appliance. For detailed information, see
“Cleaning and Maintenance” section.
Do not sit or climb onto the appliance since the design of the appliance is not suitable for such actions.
You may injure yourself or damage the appliance.
IMPORTANT: To prevent cutting or damaging the power cable, make sure that the cable is not
pinched under the appliance during and after moving it.
Installation
The volume of the room where the product will be installed should not be less than 10 m³.
Do not install the appliance in a cold room where the temperature may fall below +4 °C at nights and/or
especially in winter season.
This refrigerator/deep freezer has been designed to operate in ambient temperatures between +5 °C and
+32 °C. For this reason, in case of installing the appliance in a cold place without heating facility (e.g.
garage outside the house), it will not operate and the freezer compartment will get warmer which will end
up with decreased preserving times for frozen foods.
Do not install the appliance near ovens or radiators or under direct sunlight since they will cause the
appliance operate more difficultly. In case of placing the appliance near a heat source or freezer, make
sure that the following minimum clearances are provided:
From ovens 50 mm
From radiators 25 mm
From freezers 25 mm
From the wall 50 mm

Service Manual 9
For internal use only
5.1 Introduction
The KE-9600-02T is a microprocessor-controlled, no-frost refrigerator with two compartments, namely
the freezer and the fridge compartments. All functions and temperature controls of the refrigerator are
made in accordance with the desire of the user thanks to the microprocessor. The software in the
microprocessor controls the cooling and water system elements (compressor, fans, heaters, valves, ice
box, solenoids, ice crusher motor and ionizer) of the refrigerator. Cooling of the refrigerator is provided
by circulating the air in it continuously for the freezer and the fridge separately over the evaporators by
means of the fan. No frosting or icing occurs inside the usable areas of no-frost refrigerators as it does
in conventional refrigerators. The frosting that occurs on the evaporator which is out of the usable area
is melted by means of heaters automatically activated under the control of the microprocessor at certain
intervals to be determined by the control algorithm. Thus, the snow and the ice accumulated on the
evaporator are melted without making any operation by the user to enable the refrigerator operate more
efficiently.
Exterior view
Interior view

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5.2 Components of the electrical system
freezer compartment
door switch
evaporator fan
defrost sensor
freezer compartment
lighting
thermal fuse
freezer sensor
defrost heater
flange heater
compressor
condenser fan
control circuit board
display circuit board
ice dispenser
freezer compartment fridge compartment
water dispenser key
(microswitch)
blue light
freezer compartment
fridge compartment
fridge door switch
fridge heating element
fridge air sensor
fridge compartment
evaporator sensor
ionizer
evaporator fan
fridge compartment
lighting

Service Manual 11
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Component list
No. Component Pieces
1 Compressor 1
2 Defrost heater 1
3 Freezer fan 1
4 Condenser fan 1
5 Sensors (freezer evaporator, freezer air,
fridge evaporator, fridge air, icematic) 5
6 Fresh food fan 1
7 Flange heater 1
8 Fridge evaporator heater 1
9 Thermal fuse 1
10 PTC relay 1
11 Thermic 1
12 Door switch (freezer, fridge) 2
13 Bulb and holder with O ring 2
14 Ionizer 1
15 Blue led board (optional) 1
16 Water valve group (inlet, water, ice) 1
17 Icematic motor 1
18 Ice selection solenoid 1
19 Ice lid solenoid 1
20 Ice lid heater 1
21 Water dispenser key (microswitch) 1
22 Ice pipe heater 1
23 Water dispenser heater 1
24 Ice crusher motor 1
25 Supply line filter 1

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5.3 Compressor
Refrigerant circulation is enabled by the
compressor. Electric supply is made via a protective
thermic. The auxiliary coil which is activated for a
short time during first start-up of the compressor is
deactivated by PTC.
5.4 Freezer fan motor (Freezer compartment fan motor)
It is mounted on the inner body of refrigerator behind the rear cover of evaporator. It ensures circulation
of the freezer compartment air in the freezer compartment by passing it continuously over the
evaporator.
Power (W)
Operating voltage 208 – 220 V
Operating current
Full load current
Starting current
Voltage range 220 V, 50 Hz
Power 12 W
Voltage range 220 V, 50 Hz
Power 2 W
fan
motor
fan motor
socket

Service Manual 13
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5.5 Condenser fan motor
It is located at the bottom of the cabin. It prevents excessive heating of the condenser and drops
condensation pressure to increase the efficiency of the fridge. It is connected parallel to the compressor,
runs when the compressor starts and stops when it stops.
Voltage range 220 V, 50 Hz
Power 3 W
condenser
fan motor condenser
fan motor
socket

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5.6 Sensors
The sensor resistance decreases as the temperature rises. Sensors on the refrigerator body detect the
temperature of their surrounding area and transmit this to the electronic control circuit board. Heat-
resistance variance table for the sensors is below:
Temperature (°C) RT/R25 R deviation Resistance (kO)
-40 33.25 2.64 332.50
-35 24.01 2.40 240.10
-30 17.53 2.16 175.30
-25 12.93 1.93 129.30
-20 9.636 1.71 96.36
-15 7.249 1.49 72.49
-10 5.503 1.29 55.03
-5 4.214 1.08 42.14
0 3.251 0.89 32.51
5 2.532 0.70 25.32
10 1.986 0.52 19.86
15 1.568 0.34 15.68
20 1.248 0.17 12.48
25 1.000 0.00 10.00
30 0.8051 0.16 8.051
35 0.6528 0.32 6.528
40 0.5325 0.47 5.325
45 0.4368 0.62 4.368
50 0.3602 0.77 3.602
55 0.2986 0.91 2.986
60 0.2488 1.05 2.488
65 0.2083 1.18 2.083
70 0.1752 1.31 1.752
75 0.1480 1.44 1.480
80 0.1256 1.57 1.256
85 0.1070 1.69 1.070
90 0.09154 1.81 0.9154
95 0.07861 1.93 0.7861
100 0.06775 2.04 0.6775
105 0.05860 2.15 0.586
110 0.05086 2.26 0.5086
115 0.04430 2.37 0.443
120 0.03870 2.47 0.387
125 0.03391 2.57 0.3391
130 0.02931 2.67 0.2931
135 0.02628 2.77 0.2628
140 0.02323 2.86 0.2323
145 0.02059 2.95 0.2059
150 0.01831 3.05 0.1831
155 0.01631 3.15 0.1631

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5.7 Freezer compartment sensor
It detects the temperature in the freezer compartment
and transmits this to the microprocessor. Values
taken from this sensor are compared with the cut-in
and cut-out values of the temperature set for the
freezer compartment to run or stop the compressor
and the freezer compartment fan motor.
5.8 Fridge compartment sensor
It detects the temperature in the fridge compartment
and transmits this to the microprocessor. Values
taken from this sensor are compared with the cut-in
and cut-out values of the temperature set for the
fridge compartment to run or stop the compressor, the
fridge compartment fan motor and the fridge
compartment rear wall heater.
freezer
freezer
sensor
sensor
fridge air sensor
E0 error

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5.9 Fridge compartment evaporator sensor
It is located in the insulation and cannot be replaced. It is used to detect the tail evaporator temperature
of the fridge compartment.
5.10 Defrost sensor
It is located on the evaporator at the capillary outlet. It detects the temperature on the evaporator and
transmits this to the microprocessor. Defrost is terminated according to the temperatures received from
this sensor. .
5.11 Freezer defrost heater
The heater under the freezer evaporator is activated and deactivated by the electronic board at times of
defrost. Thus, it periodically defrosts icing accumulated on the evaporator.
Voltage 220 V
Power 125 W
fridge
evaporator sensor
fridge
heater
defrost sensor

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5.12 Thermal fuse
It is located on the evaporator. It cuts the current to
the heater to deactivate the defrost heater in order to
prevent the defrost heater remain activated
continuously and cause damage on the refrigerator,
environment and foods inside. The thermal fuse is
disposable and therefore it must be replaced once it
is blown.
Type 220 V 72 °C
defrost heater
defrost heater socket
thermal
fuse
dual

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5.13 PTC relay
Its resistance increases as the temperature rises. It ensures primary start-up of the compressor by
activating the compressor's auxiliary coil, then it deactivates the auxiliary coil by being heated with the
current flowing over it.
5.14 Thermic
It is a component that opens the circuit when heated. It opens the circuit at a certain temperature and
cuts the current to the compressor in order to protect the compressor coils against excessive heating.
When the temperature of the compressor drops below a certain value, it re-completes the circuit to
operate the compressor.
5.15 Flange heater
It is used to prevent perspiration on the contact
surface of the freezer door seals.
5.16 Door switch
The freezer door switch is located on the upper plastic
wall inside the freezer body, and the fridge door
button is on the side plastic wall inside the fridge
body. The freezer switch is normally closed circuit.
When the freezer door is opened, it is short circuited
and a signal goes to the control circuit board. Thus,
the fan stops if it is running. If necessary, it runs again
when the door is closed. The fridge switch is also a
normally closed circuit. When the fridge door is
opened, it is short circuited and a signal goes to the
control circuit board. Thus, the fridge lamp lights and
the fan stops if it is running. When the door is closed,
the light goes off and the fan starts running if
necessary.
Reaction time 5-15 seconds
Minimum time between two thermic
blow-ups
211 seconds, constant cooling,
voltage = 198 V
thermal
fuse
dual
thermal
fuse
dual

Service Manual 19
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5.17 Replacing the lamp
• Switch off the appliance and pull out the
plug.
• Remove all the shelves and drawers.
• Use a flat screwdriver to carefully ease the
lamp cover off on both sides. Make sure
that the plastic casing and the sealing are
not damaged.
• Replace the LED circuit board.
• Put the appliance plug into the socket again
and switch the appliance on.
• If the lamp works, push the plastic casing
back into the catches on the back.
• The control circuit board will need to be
replaced if the lamp does not work. The
control circuit board is located outside the
appliance, in a plastic box on the top right.
thermal
fuse
dual

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5.18 Electronic control circuit board
The control circuit board is placed in the plastic box towards the rear wall on the upper plate of the fridge.
• The display is located on the water dispenser group on the freezer door.
• Sensor connector: for sensor connections.
• Freezer sensor
• Defrost sensor
• Fridge sensor
• Fridge evaporator sensor
• Icematic sensor
• DC power connector:
• Icemactic motor and key
• For lid heater 12 V DC connection
• Power connector - 1
• L
• N
• Freezer door switch
• Fridge door switch
• Compressor
• Water pipe, flange, dispenser, lid heaters
• Fridge fan
• Defrost heater
• Water dispenser key (microswitch)
• Fridge heater
• Power connector - 2
• Neutral wire
• Main valve (inlet)
• Water valve (water)
• Ice valve
• Ice crusher motor
• Ice selection solenoid
• Ice lid solenoid
• Ionizer
• Display connector: provides the serial communication between the display and the control circuit
board.
• Triacs are used to drive the components.
• Intenal/external memory (flash type microcontroller): used to store some data after power failure.
• Serial communication port (edge): used by the designers to enable communication with the PCB.