Whirlpool R-92 User manual

CONSUMER SERVICES TECHNICAL
EDUCATION GROUP PRESENTS
R-92
JOB AID
Part No. 4322658A
WHIRLPOOL & KITCHENAID
IN-DOOR ICE SYSTEM

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FORWARD
This Job Aid, “Whirlpool & KitchenAid In-Door Ice System,” (P rt No. 4322658A), provides the
technici n with inform tion on the oper tion nd service of the Whirlpool & KitchenAid In-Door
Ice System. It is to be used s tr ining Job Aid nd Service M nu l. For specific inform tion on
the model being serviced, refer to the “Use nd C re Guide,” or “Tech Sheet” provided with the
Refriger tor/Freezer.
The Wiring Di gr ms used in this Job Aid re typic l nd should be used for tr ining purposes
only. Alw ys use the Wiring Di gr m supplied with the product when servicing the unit.
GOALS AND OBJECTIVES
The go l of this Job Aid is to provide det iled inform tion th t will en ble the service technici n to
properly di gnose m lfunctions nd rep ir the In-Door Ice System.
The objectives of this Job Aid re to:
• Underst nd nd follow proper s fety prec utions.
• Successfully troubleshoot nd di gnose m lfunctions.
• Successfully perform necess ry rep irs.
• Successfully return the In-Door Ice System to proper oper tion l st tus.
WHIRLPOOL CORPORATION ssumes no responsibility for ny rep irs m de
on our products by nyone other th n Authorized Service Technici ns.
Copyright © 2002, Whirlpool Corpor tion, Benton H rbor, MI 49022

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TABLE OF CONENTS
GENERAL............................................................................................................................... 1-1
S fety First ......................................................................................................................... 1-1
PRODUCT INTRODUCTION .................................................................................................. 2-1
Overview ............................................................................................................................ 2-1
THEORY OF OPERATION ..................................................................................................... 3-1
COMPONENT ACCESS ......................................................................................................... 4-1
Component Loc tions ........................................................................................................ 4-1
Removing The Ice M ker & The W ter Fill Tube............................................................... 4-2
Removing The Emitter & Receiver Modules ...................................................................... 4-5
Removing & Reinst lling The Motor .................................................................................. 4-6
Accessing The Selector Switch P ck & Dispenser Switches ............................................ 4-9
DIAGNOSTICS & TROUBLESHOOTING .............................................................................. 5-1
Di gnostics ........................................................................................................................ 5-1
Optics Di gnostics Mode ............................................................................................... 5-1
Optics Di gnostics For Origin l Design Bo rds ............................................................. 5-2
Optics Di gnostics For 2002 Design Bo rds ................................................................. 5-4
Component Di gnostics Mode ....................................................................................... 5-5
Optics Di gnostics Mode Ch rts .................................................................................... 5-6
Component Di gnostics Mode Ch rt ............................................................................. 5-7
Troubleshooting Ch rt A—Origin l Optics Design ............................................................ 5-8
Troubleshooting Ch rt B—2002 Optics Design ................................................................. 5-9
Troubleshooting Ch rt C—Component Di gnostics Mode .............................................. 5-10
Troubleshooting The Motor.............................................................................................. 5-11
WIRING DIAGRAMS & STRIP CIRCUITS ............................................................................. 6-1
Whirlpool Wiring Di gr m .................................................................................................. 6-1
KitchenAid Wiring Di gr m ................................................................................................ 6-2
Strip Circuits ...................................................................................................................... 6-3
CONFIRMATION OF LEARNING EXERCISES ..................................................................... 7-1
Page

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— NOTES —

1-1
This is the safety alert symbol.
This symbol alerts you to hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word
“DANGER or “WARNING. These words mean:
Electrical Shock Hazard
Plug into a grounded 3-prong outlet.
Do not remove ground prong.
Do not use an adapter.
Do not use an extension cord.
Failure to ollow these instructions can
result in death, ire, or electrical shock.
Electrical Shock Hazard
Disconnect power be ore servicing.
Replace all panels be ore operating.
Failure to do so can result in death or
electrical shock.
GENERAL
SAFETY FIRST
Your sa ety and the sa ety o others is very important.
We have provided many important safety messages in this Job Aid and on the appliance. Always
read and obey all safety messages.
DANGER
WARNING
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance
of injury, and tell you what can happen if the instructions are not followed.
You can be killed or seriously injured i you don’t
immediately ollow instructions.
You can be killed or seriously injured i you don’t
ollow instructions.
ELECTRICAL POWER SUPPLY &
GROUNDING REQUIREMENTS
WARNING
WARNING

1-2
Electrical Shock Hazard
Connect green ground wire to ground
screw.
Failure to do so can result in death or
electrical shock.
WARNING
IMPORTANT
Electrostatic Discharge (ESD)
Sensitive Electronics
ESD problems are present everywhere.
ESD may damage or weaken the elec-
tronic control assembly. The new control
assembly may appear to work well a ter
repair is inished, but ailure may occur at
a later date due to ESD stress.
• Use an antistatic wrist strap. Connect the
wrist strap to the green ground connec-
tion point, or to an unpainted metal sur-
face in the appliance.
- OR -
• Touch your finger repeatedly to a green
ground connection point, or to an un-
painted metal surface in the appliance.
• Before removing the part from its pack-
age, touch the antistatic bag to a green
ground connection point, or to an un-
painted metal surface in the appliance.
• Avoid touching electronic parts, or termi-
nal contacts. Handle the electronic con-
trol assembly by the edges only.
• When repackaging the failed electronic
control assembly in an antistatic bag,
observe the previous instructions.

2-1
PRODUCT INTRODUCTION
OVERVIEW
The primary objective of the In-Door Ice Sys-
tem is to increase the usable space in the
freezer compartment of the current freestand-
ing side-by-side refrigerator/freezer. The solu-
tion is to relocate the ice maker the ice con-
tainer and drive mechanism and replace this
eye-level volume with a cantilever shelving sys-
tem. The following description is intended to
relate the changes that have been made from
the current side-by-side ice & water dispenser
configuration. The description is divided into
three categories: Ice Making Ice Storage &
Ice Dispensing.
ICE MAKING
The ice maker module and mold have not been
changed from the current models. However
the location mounting method air delivery
water delivery ice stripper and ice level shutoff
have all been redesigned.
Location & Mounting
The ice maker has been relocated to the top
front of the freezer liner and has been rotated
90˚. Due to code requirements the ice maker
heater area is now protected by a plastic (PVC)
mounting bracket. The bracket is attached to
the ice maker with three mounting screws and
is held in place by grooved tracks on either
side of the freezer liner.
Mounting
Bracket
Grooved
Track
Grooved
Track
Screw
(1 of 3)
Air D liv ry
Air is delivered to the ice maker mold through
a duct. This duct hooks onto the rear air duct
at the back of the liner and is secured to the
top of the liner with two screws. The duct di-
rects approximately 50% of the freezer air for-
ward to the ice maker mold. The mounting
bracket mentioned in the previous section
also serves as an air director and directs the
air that is delivered by the duct under the mold
and allows it to escape just under the ice strip-
per.
Air Duct

2-2
The water tube is made of polypropylene with
an overmolded santoprene nozzle. Due to the
rigid nature of the polypropylene this tube is
mated to a more flexible polyethylene tube with
a John Guest fitting high on the back panel.
This change of material is necessary to pre-
vent kinking when the tubing is attached to the
water valve.
Wat r D liv ry
Water is delivered to the ice maker mold by
means of a “tube-within-a-tube” design. A con-
duit system consisting of three separate pieces
(liner fitting conduit back panel fitting) is
foamed into place in the cabinet.
This conduit provides a pathway from the
freezer liner to the back panel. The majority of
this system is routed above the refrigerator liner
to prevent the water tubing from freezing. The
tubing that delivers the water is routed through
the conduit and is secured by snapping into
place at the freezer liner fitting.
Back Panel Fitting
John
Guest
Fitting
Water
Tube
Water Nozzle

2-3
Ic Stripp r
The ice stripper has been modified in order to
direct ice into the new ice container. The main
differences from the current stripper are: an
increased ramp and a directing wall at the fill
cup end.
Ic L v l Shutoff
The mechanical shutoff arm on the older ice
makers has been replaced with an electronic
ice level control system. This system is located
on either side of the freezer liner and utilizes
infrared light technology to sense the level of
ice in the door-mounted ice container. A manual
shutoff option is still available on the right side
of the freezer liner. This feature consists of a
plastic slide that covers the receiver sensor and
blocks the infrared beam.
Infrared Emitter
Ejector Blades
Ice Stripper & Ramp
Infrared
Receiver
Manual
Shutoff
Status LED
5-Cavity Ice Maker For
22 Cu. Ft. Models

2-4
ICE STORAGE
The ice container has been redesigned and
relocated to the freezer door. It is secured in
place on the door liner with a sliding spring-
loaded latch mounted to a plate with two pins.
The mounting plate is foamed-in-place on the
door. The ice container is easily removed and
replaced on the door regardless of the auger
orientation.
The ice container is removed by pressing a
release button on the right side and lifting.
Removal instructions are printed on the con-
tainer.
Other changes to the ice container consist of
a vertical rod ice auger and a clear polycar-
bonate upper section. The vertical orientation
of the bin helps prevent “stale ice” areas be-
cause the ice is a “first in—first out” system
which helps keep the ice fresher. Also the ice
container can be completely emptied.
ICE DISPENSING
Major changes have been made to the power
train. The motor has been redesigned and re-
located to the freezer door. The cube/crush
selector solenoid and its related linkage have
been eliminated and a drive shaft/spring-
loaded coupling have been added.
Motor
The motor is now located on the freezer door
in a foamed-in-place enclosure under the “dis-
penser bubble” area of the inner door panel.
The motor is mounted to a plastic mounting
bracket which in turn is mounted to the en-
closure with four mounting screws.
The motor operates on 115 volts DC (115 volts
AC is delivered to the motor where it is con-
verted within the motor assembly to DC). This
gives the motor a higher RPM than the earlier
dispenser motors and results in a faster ice
delivery rate in both the cubed and crushed
modes.
Crushed ice is delivered by turning the motor
in a clockwise direction and cubed ice is de-
livered when the motor turns in a counterclock-
wise direction.
Pins Plate
Auger Coupling
Ice
Container
Release
Button
Ice
Auger
Motor