Whirlpool MULLION EVAPORATOR DESIGN User manual

I
CONSUMER SERVICES TECHNICAL
EDUCATION GROUP PRESENTS AM-4
ORPORATION
APARTMENT MAINTENANCE SERIES
Job Aid
Part No. 4322309
“OLD DESIGN”
14 cu. ft.
“NEW DESIGN”
14 cu. ft.
“MID-LINE DESIGN”
16 thru 22 cu. ft.
“MULLION EVAPORATOR
DESIGN”
12 cu. ft.
TOP-MOUNT
REFRIGERATOR/FREEZERS

II
INTRODUCTION
This Job Aid, “APARTMENT MAINTENANCE SERIES: Servicing Refrigerators,” (Part Number LIT
4322309) has been compiled to provide the most recent information on design, features, operation,
troubleshooting and repair procedures of 12 through 22 cu. ft. top-mount refrigerator/freezers.
Four distinct series of top-mount refrigerator/freezers will be covered. See Page V for more details:
1) 12 cu. ft. “Mullion Evaporator Design” - These units are available as Roper Brand only
and have the evaporator located in the mullion divider between the freezer and refrigerator
sections. There are louvers located at the front of the freezer floor.
1) 14 cu. ft. “Old Design” - These units were manufactured through the early part of 1997
and are equipped with electric mullion heaters. There is an escutcheon box at the upper
rear of the freezer section with louvers across the top of the box.
2) 14 cu. ft. “New Design” - These units were manufactured from 1993 to the present and are
currently designated Model “F” and are equipped with heat loops and a stack condenser.
There is an air tower located on the back wall of the freezer with horizontal louvers on the
sides of the tower.
3) 16, thru 22 cu. ft. “Mid-Line Design” - These units were manufactured from 1994 to the
present and are equipped with heat loops and forced air condensers. There is an air tower
located on the back wall of the freezer with a curved face and vertical louvers.
This Job Aid is not intended to replace or substitute for the Service Manuals, Use and Care Guides
or Tech Sheets associated with any of the models covered. Particular attention should be given to
the Tech Sheets provided with each individual unit for the latest engineering design changes.
GOALS AND OBJECTIVES
The goal of this Job aid is to provide detailed information that will enable the service technician to
properly diagnose malfunctions and repair 12 through 22 cu. ft. top-mount refrigerator/freezers.
The objectives of this Job Aid are:
The service technician will --
• Understand proper safety precautions.
• Successfully troubleshoot and diagnose malfunctions.
• Successfully perform necessary repairs.
• Successfully return the unit to proper operational status.
TO THE INSTRUCTOR/INDEPENDENT STUDENT
At the end of certain sections of this Job Aid you will find a “Confirmation of Learning Exercise.”
You will need a pencil or pen and in some cases two “Hi-Light” markers to complete these exer-
cises. Certain exercises may require that service procedures be performed, if an appropriate
appliance is available.
WHIRLPOOL CORPORATION ASSUMES NO RESPONSIBILITY
FOR ANY REPAIRS MADE ON OUR PRODUCTS BY ANYONE
OTHER THAN AUTHORIZED SERVICE TECHNICIANS.
© 1998 Whirlpool Corporation, Benton Harbor, MI 49022
CO RP O R A T ION

III
TABLE OF CONTENTS
INTRODUCTION.............................................................................................II
GOALS AND OBJECTIVES ...........................................................................II
TO THE INSTRUCTOR/INDEPENDENT STUDENT ......................................II
TABLE OF CONTENTS.................................................................................III
SAFETY ........................................................................................................ IV
PRODUCT IDENTIFICATION ........................................................................ V
SECTION ONE -SECTION ONE -
SECTION ONE -SECTION ONE -
SECTION ONE - Mullion Evaporator Design 12 cu. ft. Top-Mount
INSTALLATION CONSIDERATIONS .......................................................1
THEORY OF OPERATION........................................................................ 4
COMPONENT ACCESS............................................................................6
WIRING DIAGRAMS and STRIP CIRCUITS ..........................................10
SECTION TWOSECTION TWO
SECTION TWOSECTION TWO
SECTION TWO - Old Design 14 cu. ft. Top-Mount
INSTALLATION CONSIDERATIONS .....................................................13
THEORY OF OPERATION......................................................................17
COMPONENT ACCESS..........................................................................19
WIRING DIAGRAMS and STRIP CIRCUITS ..........................................24
SECTION THREESECTION THREE
SECTION THREESECTION THREE
SECTION THREE - New Design 14 cu. ft. Top-Mount
INSTALLATION CONSIDERATIONS .....................................................33
THEORY OF OPERATION......................................................................37
COMPONENT ACCESS..........................................................................39
WIRING DIAGRAMS and STRIP CIRCUITS ..........................................46
SECTION FOURSECTION FOUR
SECTION FOURSECTION FOUR
SECTION FOUR - Mid-Line Design 16 & 22 cu. ft. Top-Mount
INSTALLATION CONSIDERATIONS .....................................................49
THEORY OF OPERATION......................................................................53
COMPONENT ACCESS..........................................................................55
WIRING DIAGRAMS and STRIP CIRCUITS ..........................................64
SECTION FIVE - TROUBLESHOOTING AND DIAGNOSISSECTION FIVE - TROUBLESHOOTING AND DIAGNOSIS
SECTION FIVE - TROUBLESHOOTING AND DIAGNOSISSECTION FIVE - TROUBLESHOOTING AND DIAGNOSIS
SECTION FIVE - TROUBLESHOOTING AND DIAGNOSIS
GENERAL ...............................................................................................71
SEALED SYSTEM DIAGNOSIS .............................................................72
TROUBLESHOOTING CHART...............................................................73
TYPICAL TESTING PROCEDURES.......................................................80
SECTION SIX - TECH TIPSSECTION SIX - TECH TIPS
SECTION SIX - TECH TIPSSECTION SIX - TECH TIPS
SECTION SIX - TECH TIPS
REPLACING ELECTROMECHANICAL TIMERS ...................................89
DOOR GASKET REPLACEMENT ..........................................................90
SERVICING THE ADAPTIVE DEFROST CONTROL .............................94
SERIAL AND MODEL NUMBER DESIGNATORS .................................95

IV
SAFETY
• The power cord must be plugged into a 3-prong grounding-type
wall receptacle, grounded in accordance with the National
Electrical Code, ANSI/NFPA 70 - latest edition, and local codes
and ordinances.
• It is the personal responsibility of the consumer to have a proper
3-prong wall receptacle installed by a qualified electrician.
• DO NOT, UNDER ANY CIRCUMSTANCES, REMOVE THE
POWER CORD GROUNDING PRONG.
• A separate adequately fused and grounded circuit should be
available for this appliance.
• Do not remove any grounding wires
from individual components while
servicing, unless the component is
to be removed and replaced.
It is
extremely important to replace all
grounding wires when components
are replaced.
To avoid the risk of electrical shock,
property damage, personal injury or death:
! WARNING
Grounding
Type
Wall
Receptacle
Power Supply
Cord
with 3-Prong
Grounding Plug
ELECTRIC SHOCK HAZARD
Disconnect the electrical power before servicing any components .
Failure to do so can result in death or electrical shock.
! WARNING

V
PRODUCT IDENTIFICATION
12 cu. ft. “Mullion Evaporator Design” -
Distinguishing Characteristics:
• Air return louvers located at the front of
the freezer floor.
• A stack condenser on the back of the
unit.
• Has heat loop mullion and stile heat.
• Evaporator located in the divider be-
tween the freezer and refrigerator sec-
tions.
• Roper brand only
12 & 14 cu. ft. “Old Design” -
Distinguishing Characteristics:
• Air discharge louvers located at the top
rear of the freezer section.
• A stack condenser on the back of the
unit.
• Has electric mullion and stile heaters.
• Evaporator vertically mounted behind
rear panel of freezer compartment.
• May be equipped with Adaptive Defrost
Control.
14 cu. ft. “New Design” -
Distinguishing Characteristics:
• Air tower at the rear of the freezer section
with horizontal louvers.
• Has heat loop mullion and stile heat.
• A stack condenser on the back of the
unit.
• Model “F” designation
• Manufactured from 1993 to present
16, thru 22 cu. ft. “Mid-Line Design” -
Distinguishing Characteristics:
• Air tower at the rear of the freezer section
with vertical louvers.
• Has heat loop mullion and stile heat.
• A forced air condenser at the bottom of
the unit.
• Manufactured from 1994 to present.
Four distinct series of top-mount refrigerator/freezers will be covered in the Job Aid. Each series can
be identified by a number of distinguishing features:
A) Air circulation in the freezer compartment
B) Type of condenser
C) Location of the Evaporator
D) Method of outside condensation control
Air Tower
with
Vertical Louvers
Air Tower
with
Horizontal Louvers
Louvers Across
Top Rear
Louvers at Front of
Freezer Floor
Component Access - Section One, page 6.
Wiring Diagram - Section One, page 10.
Component Access - Section Two, page 19.
Wiring Diagram - Section Two, page 24.
Adaptive Defrost Control - Section Six, page 92.
Component Access - Section Three, page 36.
Wiring Diagram - Section Three, page 46.
Component Access - Section Four, page 55.
Wiring Diagram - Section Four, page 64.

VI
-- NOTES --

1
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
Section One
Mullion Evaporator Design
12 cu. ft. Top-Mount
It is critical that the refrigerator/freezer be properly leveled. Both the back and front of the unit should
be carefully leveled before it is turned on.
1. Place a board across the rear of the installed position and set a level on the board.
(Fig. 2)
2. Place shims where the rear rollers will sit to level the board.
3. Remove the board and leave the shims in place.
4. Place the unit in its installed position.
Leveling the Refrigerator/Freezer
INSTALLATION CONSIDERATIONS
Measure the opening at the location in which the refrigerator/freezer is to be installed and make
sure the following minimum clearance dimensions are followed.
Top: At least 3” (7.5cm) clearance between
the overhead cabinet and the refrigerator/
freezer top. (Dimension A) (Fig. 1)
Sides: At least 1” (2.5cm) clearance on each side
of the refrigerator/freezer. (Dimension B)
(Fig. 1)
Back: At least ½” (1.25cm) clearance between
the condenser (“Old Design” 14 cu. ft.
Top-Mount) and the wall.
B
A
Fig 1
B
Fig. 2
Board
Level
Minimum Clearance

2
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
Once the unit is located in the final installed location and the rear of the unit is level, proceed to
level the front.
NOTE: Using a spirit level, the front of the unit should be ½ bubble higher than the back.
1. Use a flat blade screwdriver to rotate the front roller leveling screws in the appropriate direction
to level the unit side to side.
(Fig. 3 & 4))
2. Use a level and check to make sure the rollers are set so the unit is level side to side and ½
bubble higher in front.
LOWER
RAISE Leveling
Screw
Leveling
Screw
VIEW OF ROLLER WITH HINGE IN PLACEVIEW OF ROLLER WITH NO HINGE
Fig. 3
Fig. 4
Electrical Requirements
A 115 V, 60 Hz, 15 TO 20 Amp fused circuit utilizing a 3-wire grounding receptacle meeting all
national and local electrical codes is required. It is recommended that a separate circuit serving
only this appliance be provided.
• The power cord must be plugged into a 3-prong grounding-type
wall receptacle, grounded in accordance with the National
Electrical Code, ANSI/NFPA 70 - latest edition, and local codes
and ordinances.
• It is the personal responsibility of the consumer to have a proper
3-prong wall receptacle installed by a qualified electrician.
• DO NOT, UNDER ANY CIRCUMSTANCES, REMOVE THE
POWER CORD GROUNDING PRONG.
• Do not remove any grounding wires
from individual components while
servicing, unless the component is
to be removed and replaced.
It is
extremely important to replace all
grounding wires when components
are replaced.
To avoid the risk of electrical shock,
property damage, personal injury or death:
! WARNING
Grounding Type
Receptacle
3-Prong
Grounding Plug

3
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
DOOR SWING REVERSAL
1. Open the refrigerator door and remove the toe panel at the bottom of the unit.
2. Remove the top hinge.
(Fig. 5)
3. Remove the freezer door.
4. Remove the center hinge.
(Fig. 5)
5. Remove the refrigerator door.
6. Remove the bottom hinge.
(Fig. 5)
7. Lay the freezer door on a flat protected surface and remove the door handle. (Fig. 5)
8. Reinstall the freezer door handle on the opposite side of the door.
9. Lay the refrigerator door on a flat protected surface and remove the door handle.
(Fig. 5)
10. Reinstall the refrigerator door handle on the opposite side of the door.
11. Move the bottom hinge to the opposite side of the cabinet and reinstall it.
12. Set the refrigerator door on the bottom hinge and close the door to keep it in place.
13. Reinstall the center hinge.
14. Set the freezer door in the center hinge and close the door to keep it in place.
15. Reinstall the top hinge.
16. To align the refrigerator door:
a) DO NOT ADJUST THE BOTTOM HINGE. Use the bottom hinge as an establishing point.
b) Loosen the center hinge
(Figs. 5) and align the refrigerator door with the cabinet edge.
c) Tighten the center hinge.
17. To align the freezer door:
a) If the refrigerator door is properly aligned,
DO NOT ADJUST THE CENTER HINGE.
b) Loosen the top hinge
(Fig. 5) and align
the top of the freezer door with the top
of the cabinet.
c) Tighten the top hinge.
Fig. 5
Cover
Top Hinge
Shim
Hinge Hole Plug
Hinge Bushing
Plug
Handle
Handle
Insert
Fiber Washer
Door Stop
Bottom
Hinge
Handle
Hole Plug
Fiber Washer
Door Stop
Center Hinge
Plastic Washer

4
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
THEORY OF OPERATION
TEMPERATURE CONTROL
Temperature control is provided by an adjustable thermostat located behind the control panel es-
cutcheon in the refrigerator compartment.
(Fig. 6) This thermostat influences the temperatures in
both the freezer section and the refrigerator section. There is no damper to adjust air flow between the
two sections.
DEFROST HEATER
The defrost heat is provided by a quartz tube radiant heater (Fig. 7) lying underneath the evaporator
coils in the divider mullion.
(Fig. 8) A coiled wire element is encased in a quartz tube. Special care
must be taken when handling this heater element to insure that the quartz tube does not come in
contact with any contaminants such as skin oil, perspiration or lubricants. Always wear a pair of clean
gloves when handling the defrost heater assembly. Contaminating the surface of the quartz tube will
cause premature failure.
Fig. 6
Fig. 7
Fig. 8

5
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
HEAT LOOP
HEAT LOOP ROUTING
The heat loop is routed from the condenser outlet up the right side of the cabinet to the right stile (A).
It then loops through the mullion between the refrigerator and freezer sections (B) and up around the
freezer section (C& D), where it then returns to component compartment (E) and connects to the
sealed system at the filter-drier.
(Fig. 9)
A
B
C
D
E
Fig. 9

6
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
COMPONENT ACCESS
COMPRESSOR
DRIP PAN/
COMPRESSOR
BASE
EVAPORATOR
FAN
DEFROST
HEATER
CONDENSER
THERMOSTAT
BI-METAL
EVAPORATOR
ELECTRIC SHOCK HAZARD
Disconnect the electrical power before servicing any components.
Failure to do so can result in death or electrical shock.
! WARNING
Fig. 10

7
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
The compressor and related components are located at the bottom back of the refrigerator/freezer
in an open compartment.
DEFROST DRAIN
The drain tube from the freezer section is routed down the outside back of the cabinet underneath
the condenser to the component tray at the bottom. The component tray serves as the drain pan.
1. Remove the screws from the four (4) clips securing the condenser to the back of the cabinet
and lean the condenser away from the cabinet far enough to gain access to the drain tube.
2. Loosen the clamp securing the drain hose to the outlet on the back of the cabinet.
3. Remove the screw from the clip securing the lower portion of the drain hose to the cabinet.
4. When replacing the drain hose be sure to put a loop in it near the connection to the freezer.
The loop creates a trap which prevents warm air and moisture from migrating into the freezer
compartment.
SERVICING THE COMPRESSOR
1. Remove the four (4) screws securing the component tray to the cabinet. There are two screws
on each side of the unit.
2. Carefully slide the component tray out from the refrigerator/freezer far enough for the compres-
sor to clear the back of the cabinet. Watch that the tubing is not kinked when sliding the tray
out.
3. Follow standard Sweep Charge Procedures for replacing the compressor.
4. Slide the component tray back into the unit and secure it with to the cabinet the four (4) screws
removed earlier.
COMPONENT
TRAY
MOUNTING BOLTS
FILTER
DRIER
DRAIN
TUBE
COMPRESSOR
CAPILLARY
TUBE
HEAT
EXCHANGER
HEAT LOOP
CONDENSER
Servicing Components in the Compressor Compartment
Fig. 11

8
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
Accessing Freezer Compartment Components
The center rail covering the mullion between the freezer and refrigerator compartments and the
freezer floor must be removed to gain access to components in the freezer compartment.
1. Remove both doors and the center hinge. Also remove the screws on the other side of the
center rail.
2. Press in on the left side of the center rail while sliding it to the left. This will release the right end
of the center rail from the cabinet.
3. Slide the center rail to the right to release the left end from the cabinet.
4. Carefully slide the freezer floor out of the freezer compartment.
5. Lift the Styrofoam evaporator housing cover and aluminum heater shield from the bottom of the
freezer compartment.
The evaporator is surrounded by Styrofoam insulation inside the compartment separator.
Servicing the Evaporator Fan Motor
1. Disconnect the two (2) wire connectors from the evaporator fan motor.
2. Remove the two (2) screws securing the evaporator fan motor bracket to the fan scroll.
3. The fan blade is pressed onto the motor shaft. The motor shaft should not extend past the fan
blade hub.
Servicing Components in the Freezer Compartment
DEFROST
HEATER
(Under Evaporator)
EVAPORATOR
FAN MOTOR
HEAT
LOOP
EVAPORATOR
HEAT
SHIELD
CENTER
RAIL
BRACKET
Fig. 12

9
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
DEFROST
HEATER
BRACKET
TABS
WIRE
CONNECTOR
DEFROST HEATER
DRIP COVER
Servicing the Defrost Heater
1. Disconnect the wire connectors from both ends of the defrost heater.
2. Carefully lift up on the evaporator far enough to expose the defrost heater and drip cover.
3. Carefully bend the tabs on the defrost heater mounting brackets up to release the defrost heater
drip cover and remove the drip cover.
4. Remove the defrost heater from the mounting brackets.
5. Place the new defrost heater in the mounting brackets.
NOTE: Do not touch the glass tube of the defrost heater with bare hands. Body oils
and other contaminants will cause the glass tube to break when it gets hot.
Wear a pair of clean soft gloves.
6. Reinstall the defrost heater drip cover and secure it in place by bending the mounting bracket
tabs down.
Fig. 13

10
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
WIRING DIAGRAM
STRIP CIRCUITS
COOLING CYCLE
Compressor Circuit (at instant of start)

11
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
Compressor Circuit (running)
Defrost Timer Motor Circuit
Evaporator Fan Motor Circuit
DEFROST CYCLE
Defrost Timer and Defrost Heater Circuit
REFRIGERATOR LIGHT
Refrigerator Light Circuit

12
MULLION EVAPORATOR DESIGN 12 cu. ft. Top-Mount
-- NOTES --

13
OLD DESIGN 12 & 14 cu. ft. Top-Mount
Section Two
Old Design
12 & 14 cu. ft. Top-Mount
It is critical that the refrigerator/freezer be properly leveled. Both the back and front of the unit should
be carefully leveled before it is turned on.
1. Place a board across the rear of the installed position and set a level on the board.
(Fig. 15)
2. Place shims where the rear rollers will sit to level the board.
3. Remove the board and leave the shims in place.
4. Place the unit in its installed position.
Leveling the Refrigerator/Freezer
INSTALLATION CONSIDERATIONS
Measure the opening at the location in which the refrigerator/freezer is to be installed and make
sure the following minimum clearance dimensions are followed.
Top: At least 3” (7.5cm) clearance between
the overhead cabinet and the refrigerator/
freezer top. (Dimension A) (Fig. 14)
Sides: At least 1” (2.5cm) clearance on each side
of the refrigerator/freezer. (Dimension B)
(Fig. 14)
Back: At least ½” (1.25cm) clearance between
the condenser (“Old Design” 14 cu. ft.
Top-Mount) and the wall.
B
A
Fig. 14
B
Fig. 15
Board
Level
Minimum Clearance

14
OLD DESIGN 12 & 14 cu. ft. Top-Mount
Once the unit is located in the final installed location and the rear of the unit is level, proceed to
level the front.
NOTE: When leveling the front of the unit, the front should be ½ bubble higher than the back.
1. Use a flat blade screwdriver to rotate the front roller leveling screws in the appropriate direction
to level the unit side to side.
(Fig. 16 & 17)
2. Use a level and check to make sure the rollers are set so the unit is level side to side and ½
bubble higher in front.
LOWER
RAISE Leveling
Screw
Leveling
Screw
VIEW OF ROLLER WITH HINGE IN PLACEVIEW OF ROLLER WITH NO HINGE
Fig. 16
Fig. 17
Electrical Requirements
A 115 V, 60 Hz, 15 TO 20 Amp fused circuit utilizing a 3-wire grounding receptacle meeting all
national and local electrical codes is required. It is recommended that a separate circuit serving
only this appliance be provided.
• The power cord must be plugged into a 3-prong grounding-type
wall receptacle, grounded in accordance with the National
Electrical Code, ANSI/NFPA 70 - latest edition, and local codes
and ordinances.
• It is the personal responsibility of the consumer to have a proper
3-prong wall receptacle installed by a qualified electrician.
• DO NOT, UNDER ANY CIRCUMSTANCES, REMOVE THE
POWER CORD GROUNDING PRONG.
• Do not remove any grounding wires
from individual components while
servicing, unless the component is
to be removed and replaced.
It is
extremely important to replace all
grounding wires when components
are replaced.
To avoid the risk of electrical shock,
property damage, personal injury or death:
! WARNING
Grounding Type
Receptacle
3-Prong
Grounding Plug