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S/M No: RNU20IB001
Refrigerator
FRN-U20IB* FRS-U20IB*
FRN-U20DB* FRN-U20EB* FRS-U20DB* FRS-U20EB*
FRN-U20FB* FRN-U20GB* FRS-U20FB* FRS-U20GB*
FRU-577I~
FRU-547D/E~
FRU-547F/G~
Caution
: In this Manual, some parts can be changed for improving, their performance without notice in the parts list. So, if you need the latest parts information,please refer to PPL(Parts Price List) in Service Information Center
- May, 2006
CONTENTS
1. WARNINGS AND PRECAUTIONS FOR SAFETY ----------------------------2 2. EXTERNAL VIEW 2-1. External Size ---------------------------------------------------3 2-2. Name of Each Parts ------------------------------------------6 2-3. Cold Air Circulation ----------------------------------------------8 3. SPECIFICATION --------------------------------------------------9 4. OPERATION AND FUNCTIONS --------------------------------------11 5. CIRCUIT OPERATION 5-1. Power Circuit Diagram --------------------------------------------31 5-2. Function of Each Sensor ------------------------------------------32 5-3. Relay Function --------------------------------------------------34 5-4. Fan Function ---------------------------------------------------36 6. DIAGRAM 6-1. Wiring Diagram --------------------------------------------------37 6-2. Circuit Diagram of Main PCB ---------------------------------------39 7. COMPONENT LOCATE VIEW -----------------------------------------43 8. HOW TO CHECK EACH PARTS 8-1. Hose Ice Maker Tube ---------------------------------------------45 8-2. Bracket Geared Motor ---------------------------------------------46 8-3. Dispenser Micro Switch --------------------------------------------47 8-4. Dispenser Solenoid Valve ------------------------------------------48 8-5. Main PCB ------------------------------------------------------49 8-6. Ice Maker ------------------------------------------------------51 9. TROUBLE DIAGNOSIS 9-1. Power Failure ----------------------------------------------------53 9-2. Freezer Compartment ---------------------------------------------54 9-3. Refrigerator Compartment ------------------------------------------60 9-4. Operation Noise of Refrigerator --------------------------------------65 9-5. Door -----------------------------------------------------------71 10. COOLING CYCLE HEAVY REPAIR 10-1. Summary of Heavy Repair ------------------------------------------72 10-2. Precaution during Heavy Repair --------------------------------------73 10-3. Practical Work for Heavy Repair --------------------------------------74 10-4. Standard Regulations for Heavy Repair --------------------------------76 10-5. Brazing Reference Drawing -----------------------------------------77 11. INSTALLATION GUIDE 11-1. Installation Preparation -------------------------------------------- 78 11-2. If the Refrigerator can not enter the Door ------------------------------ 79 11-3. Refrigerator Leveling & Door Adjustment -------------------------------80 11-4. Water Line Installation --------------------------------------------- 82 11-5. Dispenser Water Flow --------------------------------------------- 84 12. EXPLODED VIEW & PARTS LIST -------------------------------------85
1
1. WARNINGS AND PRECAUTIONS FOR SAFETY
Please observe the following safety precautions in order to use safely and correctly the refrigerator and to prevent accident and danger during repair. 1. Be care of an electric shock. Disconnect power cord from wall outlet and wait for more than three minutes before replacing PCB parts. Shut off the power whenever replacing and repairing electric components. 2. When connecting power cord, please wait for more than five minutes after power cord was disconnected from the wall outlet. 3. Please check if the power plug is pressed down by the refrigerator against the wall. If the power plug was damaged, it may cause fire or electric shock. 4. If the wall outlet is over loaded, it may cause fire. Please use its own individual electrical outlet for the refrigerator. 5. Please make sure the outlet is properly earthed, particularly in wet or damp area. 6. Use standard electrical components when replacing them. 7. Make sure the hook is correctly engaged. Remove dust and foreign materials from the housing and connecting parts. 8. Do not fray, damage, machine, heavily bend, pull out or twist the power cord. 9. Please check the evidence of moisture intrusion in the electrical components. Replace the parts or mask it with insulation tapes if moisture intrusion was confirmed. 10. Do not touch the icemaker with hands or tools to confirm the operation of geared motor. 11. Do not let the customers repair, disassemble and reconstruct the refrigerator for themselves. It may cause accident, electric shock, or fire. 12. Do not store flammable materials such as ether, benzene, alcohol, chemicals, gas, or medicine in the refrigerator. 13. Do not put flower vase, cup, cosmetics, chemicals, etc., or container with full of water on the top of the refrigerator. 14. Do not put glass bottles with full of water into the freezer. The contents shall freeze and break the glass bottles. 15. When you scrap the refrigerator, please disconnect the door gasket first and scrap it where children are not accessible.
2
2. EXTERNAL VIEWS
2-1. External Size - FRS(N)-U20IB
3
- FRS(N)-U20DB / EB
4
- FRS(N)-U20FB / GB
5
2-2. Name of Each Parts
- Basic Model
1 2 3 4
6
7 8 9 10 11 5 12
- Wine Rack is option
Freezer Compartment 1. Freezer light 2. Freezer pocket 3. Ice tray 4. Freezer shelf 5. Freezer case Refrigerator Compartment 6. Dairy pocket 7. Refrigerator light 8. Chilled case 9. Movable Egg case 10. Refrigerator shelf 11. Refrigerator pocket 12. Refrigerator case
6
- Full option Model
1 2 3 4 5 6
7
8 9 10 11 12 13
-Full option Model illustrated. -Features are model dependent.
Freezer Compartment 1. Ice cubes storage case 2. Freezer light 3. Water/Ice Dispenser 4. Freezer shelf 5. Freezer pocket 6. Freezer case Refrigerator Compartment 7. Dairy pocket 8. Refrigerator light 9. Wine Rack 10. Movable Egg case 11. Refrigerator shelf 12. Refrigerator pocket 13. Magic room (option)
7
2-3. Cold Air Circulation
Freezer Compartment
Refrigerator Compartment
8
3. SPECIFICATION
3-1. Specification
Item Model Name Total ISO Gross Volume (Li) Freezer Refrigerator Total ISO Storage Volume (Li) Freezer Refrigerator Weight External Dimension (Width x Depth x Height) Evaporator C Y C L E Condenser Dryer Capillary Tube FRS(N)U20IB 570 Li 209 Li 361 Li 537 Li 198 Li 339 Li 104kg FRS(N)U20DB 541 Li 184 Li 357 Li 504 Li 170 Li 334 Li 113kg Specification FRS(N)U20EB 525 Li 178 Li 337 Li 504 Li 170 Li 334 Li 115kg FRS(N)U20FB 541Li 184 Li 357 Li 504 Li 170 Li 334 Li 115kg FRS(N)U20GB 536 Li 184 Li 352 Li 500 Li 170 Li 330 Li 117kg
903 mm x 734.5mm x 1790 mm Fin Type Fan Cooling System Molecular Sieve XH-9 ID0.7 × T0.55 × L2200
Description Compressor Part Code Refrigerant ( g ) SWITCH P RELAY AS Description Part Code
HPL30YG-5 395S130R50 R-134a (190g) 308NHB, S330 3018129810
MK183Q-L2U 3956183D50 R-134a (190g)
MK4A5Q-R1U 3956145250 R-600a (76g)
265RHB, S330 3011402100
( ) is the specification for the model which use R-600a(refrigerant)
9
Item Model Name D E F O R E S T D-Sensor F-Sensor
Specification ( 220~240V Models only ) Basic Model PBN-43 PBN-38 Dispenser Model
R-Sensor
PBN-43
Defrost Heater H E A T E R Main Duct Heater Louver Heater Dispenser Heater Water Pipe Heater Main Fuse (Power cord) E L E C T R I C A L P A R T S Fuse Temp (Defrost) F-Fan Motor R-Fan Motor Condenser Fan Motor F-Lamp R-Lamp Door Switch , F / R -
AC220V / 192W AC220V / 7W AC220V / 8W AC220V / 5W AC220V / 5W AC250V 15A AC250V , 10A , 77 DC13V / 2050±100 rpm DC13V / 1950±100 rpm DC13V / 1100±100 rpm AC230~240V / 25W (2EA) AC230~240V / 25W (2EA) SP201R-7DL / SP201R-7DR (SPF101B-2D / SPF101B-1D)
10
4. OPERATION AND FUNCTIONS
4-1. Display
4-1-1. Basic Model
INPUT CONTROL OBJECT
FRZ.TEMP, REF.TEMP
Inner Control (Lamp-LED)
CONTENTS
REMARKS
Temperature adjustment button for freezer compartment.
Temperature adjustment button for refrigerator compartment.
1. "FRZ.TEMP" Button 1) Temperature control of Freezer compartment 2) 5 step mode of successive temperature mode. 3) Initial mode by power input : "3" Whenever pressing button, setting is repeated in the order of Medium(3) Medium Max(4) Max(5) Min(1) Medium Min(2). Medium Min 2 Medium Max 4
Temperature Chang Temp indication
Min 1
Mid 3
Max 5
2. "REF.TEMP" button. 1) Temperature control of Refrigerator compartment 2) 5 step mode of successive temperature mode. 3) Initial mode by power input : "3" Whenever pressing button, setting is repeated in the order of Medium(3) Medium Max(4) Max(5) Min(1) Medium Min(2). Medium Min 2 Medium Max 4
Temperature Change Temp indication
Min 1
Mid 3
Max 5
The actual inner temperature varies depending on the food status, as the indicated setting temperature is a target temperature, not actual temperature within refrigerator. Refrigeration function is weak in the initial time. Please adjust temperature as above after using refrigerator for minimum2~3 days.
11
4-1-2. Dispenser Model
INPUT Front PCB button FREEZER SET, REFRIGERATOR SET SUPER FREEZER, SUPER REFRIGERATOR RESET FILTER, WATER / ICE, ICE MAKER LOCK ,LOCK CONTENTS CONTROL OBJECT
FCP C-LED
REMARKS
Water filter reset Super freezer
Dispenser select button
Ice maker lock button
Lock button
Super Refrigerator Temperature adjustment button for refrigerator compartment.
Temperature adjustment button for freezer compartment.
1. Display control FCP-LED 88 DISPLAY (SET TEMP.) SUPER FREEZER,SUPER REFRIGERATOR ICON FUZZY, DEODORIZER ICON WATER / CUBED ICE/ CRUSHED ICE ICON LOCK ICON ICE MAKER LOCK ICON FILTER CHANGE ICON Control Initial mode : Freezer & Refrigerator set Medium (-19/4) Dial Always ON Dial Dial Dial After six month, LED ON
2. "FREEZER SET" Button 1) Temperature control of freezer compartment 2) 7 step mode of successive temperature mode. 3) Initial mode by power input : "Medium(-19)" Whenever pressing button, setting is repeated in the order of Medium (-19) Medium Max 1 (-20) Medium Max 2 (-21) Max (-22) Min (-16) Medium Min 2 (-17) Medium Min 2 (-18). Letters are indicated on 88 Display LED Temperature Change Temp indication Min -16 Medium Min 1 -17 Medium Min 2 -18 Medium -19 Medium Max 1 -20 Medium Max 2 -21 Max -22
3. "SUPER FREEZER" Button When this mode is chosen, the icon (FREEZER QUICK) is ON.
12
CONTENTS
4. "REFRIGERATOR SET" button. 1) Temperature control of Refrigerator compartment 2) 5 step mode of successive temperature mode. 3) Initial mode by power input : "Medium (4)" Whenever pressing button, setting is repeated in the order of Medium (4) Medium Max (3) Max (2) Min (6) Medium Min (5). Letters are indicated on 88 Display LED Temperature Change Temp indication Min 6 Medium Min 5 Mid 4 Medium Max 3 Max 2
REMARKS
5. "SUPER REFRIGERATOR" button. When this mode is chosen, the icon (REFRIGERATOR QUICK) is ON. 6. "WATER / ICE" button 1) Select Water / Cubed Ice / Crushed Ice. 2) Icon lights up to show your selection is on. Initial mode by power input : "Water" mode. 3) The mode of Cubed Ice or Crushed Ice continues for 1 hour and then changes to Water. (Water icon turns ON) 7. "ICE MAKER LOCK" button 1) Start by pushing "ICE MAKER LOCK" button "ICE MAKER LOCK" icon is on "WATER" icon is always on 2) Stop by pushing "ICE MAKER LOCK" button again "ICE MAKER LOCK" icon is off "WATER" icon is on 8. "RESET WATER FILTER" button 1) The normal (ICON OFF) is on for 6 month after are first power input. 2) After sic months, icon is ON. 3) How to reset Filter information Push the "RESET WATER FILTER" button for 3 seconds after change. 9. "LOCK" button 1) This button stops operation of different button. "LOCK" icon is on Press this button to lock out this case and to keep temperature and function setting. 2) Push "LOCK" button again for more than a second to stop it. REFERENCE : Please wait for 2-3 seconds in order to take final ice or drops of water when taking out cup from the pressing switches after taking ice or water.
The actual inner temperature varies depending on the food status, as the indicated setting temperature is a target temperature, not actual temperature within refrigerator. Refrigeration function is weak in the initial time. Please adjust temperature as above after using refrigerator for minimum2~3 days.
13
4-2. Defrost Mode
INPUT CONTROL OBJECT 1. Comp 2. F-Fan 3. R-Fan 4. D-Heater CONTENTS
1. Defrost Mode
1. Defrosting Cycle
REMARKS
Pre-Cool
Pre-Cool 1) Time : 50 minutes 2) Comp , F-fan : ON R-fan : Control D-HTR : OFF 3) If F-sensor -27, then Pre-Cool becomes. OFF Heater Defrosting 1) Comp, F-fan, R-fan : OFF D-HTR : ON 2) Time limit 30 seconds : Heater is ON regardless of D-sensor temperature right after defrosting start 30 minutes : in case of D1- Error 80 minutes : in normal control state 3) If D-sensor 13, Heater Defrosting is OFF
Heater Defrosting
Pause
Pause Time : 7 minutes Comp, F-fan, R-fan, Heater etc. : OFF
Fan-Delay
Fan-Delay 1) Time : 5 minutes Comp : ON and F-fan, R-fan, Heater : OFF
2.The defrost mode start with the following conditions 1) Total operation time of comp. becomes : 6,8,10,......... 24 hours. Comp. operating rate : more 85% Total door open time : 2 minutes (Any door, F or R open time is over 2 minutes.) Any error mode : R1, F1, D1, F3, RT/S, Door-switch etc.) 2) Defrosting mode starts unconditionally as long as total comp. work time is 24 hours, even if the above conditions 1) are not satisfied. 3) Defrosting mode starts immediately as long as total time of [comp. ON + comp. OFF] is over 60 hours, even if the above 1) and 2) conditions are not satisfied. 3. In providing initial power (or returning power failure) If D-sensor temp. 3.5, defrosting mode starts .
14
CONTENTS
4. Flow Chart of Defrosting Start Start
REMARKS
Comp. operating time is over 2 hours?
YES
NO
YES
Total time is over 60 hours?
NO
YES
Comp. operating time is over 24 hours?
NO
Comp. operating time is over 6 hours?
YES
NO
YES
Comp. operating rate is more 85%?
NO
YES
Any error ?
NO
YES
Total door open time is over 2 min?
NO
Defrosting start
End
15
4-3. (Forced Defrosting) Mode
INPUT CONTROL OBJECT 1. Comp 2. F-Fan 3. R-Fan 4. D-Heater REMARKS
1. Defrosting Cycle
CONTENTS
1. A/S Defrosting Mode (Heater defrost Pause Fan Delay)
Heater Defrosting
Heater Defrosting 1) Comp, F-fan, R-fan : OFF D-HTR : ON 2) Time limit 30 seconds : Heater is ON regardless of D-sensor temperature right after defrosting start 30 minutes : in case of D1-Error 80 minutes : in normal control state 3) If D-sensor 13, Heater Defrosting is OFF
Pause
Pause Time : 7 minutes Comp, F-fan, R-fan, Heater etc. : OFF
Fan-Delay
Fan-Delay 1) Time : 5 minutes Comp : ON F-fan, R-fan, Heater : OFF
2. How to start 1) Push "REF.TEMP" button 5 times while pushing "FRZ.TEMP" button simultaneously. --------- FRS-U20IA 2) In "LOCK" mode, push "REFRIGERATOR SET" button 5 times while pushing "FREEZER SET" button simultaneously. ------ FRS(N)-U20DA 3. How to proceed 1) Delete Pre-cool mode. (Others are same as normal defrosting) 2) Heater is ON regardless of D-sensor temp. at first 30 seconds. (Check of defrosting current)
4-4. Fan Voltage of Control Mode
INPUT 1. F-Sensor 2. R-Sensor CONTENTS
1. Fan voltage of control mode
CONTROL OBJECT 1. F-FAN, R-FAN, C-FAN REMARKS
FAN Voltage
F-FAN 13 V
R-FAN 13 V
C-FAN 13 V
Refer to the 5-4. (Fan Function ) 16
4-5. Louver Heater Control
INPUT 1. Comp CONTENTS
It is linked with comp.
CONTROL OBJECT Louver Heater REMARKS
4-6. Buzzer or Alarm Control
INPUT 1. Control (Inner or F-PCB) buttons 2. Door Switch 3. Initial Power Input CONTENTS
1. Buzzer sounds if any button of Inner Control is pushed. 2. Buzzer sounds 4 times 3 seconds after initial power input. 3. Buzzer sounds for 3 or 1 times in case of A/S forced defrosting and short (pull down) operation or explanation mode. 4. If door is open, buzzer sounds after every 1 minutes for 5 minutes (Door open alarm)
CONTROL OBJECT Buzzer REMARKS
4-7. Control of Interior Lights (FRS(N)-U20DA)
INPUT 1. Refrigerator door switch 2. Freezer door switch 3. Home bar door switch 4. Dispenser switch CONTENTS
1. Control refrigerator compartment lights R-Lights turn ON/OFF by R-door switch ON/OFF ( For 10 minutes after sensing door open, the lights turn off automatically through door close is not sensed.) 2. Control of freezer compartment lights. F-Light turn ON/OFF by F-door switch ON/OFF ( For 10 minutes after sensing door open, the lights turn off automatically through door close is not sensed.) 3. R-lights ON/OFF by home bar door switch ON/OFF. ( for only model with home bar ) R-lights turn ON for 10 minutes after sensing home bar door switch open. 4. Dispenser lamp control ( for only model with water/ice dispenser ) Dispenser lamp turns ON/OFF by Dispenser switch. Dispenser lamp turns ON for 4 seconds after sensing switch close.
CONTROL OBJECT Lamp
REMARKS
17
4-8. Demonstration
4-8-1. Basic Model
INPUT 1. FRZ. TEMP 2. Door Switch CONTENTS
1. Start Open and close "Freezer door switch" 5 times while pushing "FRZ. TEMP" button simultaneously. 2. Control 1) All other electrical components are OFF except for F-fan / R-fan 2) Fan Control Door open Fan ON / Door close Fan OFF. 3) Display control "FRZ. LED" and "REF. LED" are ON in good order 3. Stop 1) During Demo mode, push "Freezer door switch" open and close 5 times while pushing "FRZ. TEMP" button simultaneously. 2) Power in again
CONTROL OBJECT Comp F/R-Fan Heater REMARKS
4-8-2. Dispenser Model
INPUT 1. "FREEZER SET, WATER/ICE" Button , Door switch CONTENTS
1. Start Push "ICE/WATER" button 5 times while pushing "FREEZER SET" button simultaneously. 2. Control 1) All other electrical components are OFF except for F-fan / R-fan 2) Fan Control Door OPEN Fan ON / Door close Fan OFF. 3. Stop or termination 1) During Demo mode, push "ICE/WATER" button 5 times while pushing "FREEZER SET" button simultaneously. 2) Power in again
CONTROL OBJECT Comp F/R-Fan Heater REMARKS
18
4-9. Compensation of R-sensor ON/OFF Point
INPUT Main PCB CONTENTS CONTROL OBJECT Resistance of R-sensor Mid ON/OFF Point REMARKS
Compensation of R-sensor ON/OFF temp. (down) In case temperature of refrigerator compartment is weak or insufficient, take the following action.
FRS(N)-U20IA
FRS(N)-U20DA
R-SENSOR
R-SENSOR
Refer to the 5-2. (Function of each sensor)
R36
R36
R37
R37
R38
J2
J1
R38
J19
J18
J1 J2
J18,19
R36 : R-SENSOR standard resistance in normal mode (31.4K) R37 : In case of weak ref., cut J1 (or J18) to down the standard resistance by 1.5deg(2K) R38 : In case of weak ref., cut J2 (or J19) to down the standard resistance by 1.5deg(2K) J1 J2 Temperature compensation J18 J19 Temperature compensation 0 0 cut -1.5 cut -1.5 cut cut 3 cut cut 3
FRS(N) -U20IA
FRS(N) -U20DA
19
4-10. Error Display
4-10-1. Basic Model (LED Display of Inner Control)
INPUT Temperature Control Buttons CONTENTS
1. How to start 1) Press "FRZ.TEMP" button 5 times while pressing "REF.TEMP" button at the same time. 2. How to stop 1) Push "FRZ.TEMP" button 1 time. 2) It stops automatically in 4 minutes from the start. 3. All the error codes are reset if they turn to be normal. 4. Error display
CONTROL OBJECT Lamp LED of Inner control REMARKS
CONTENTS F-sensor : open ("Lo"), short ("Hi") R-sensor : open ("Lo"), short ("Hi") RT-sensor : open ("Lo"), short ("Hi") D-sensor : open ("Lo"), short ("Hi") R-Door Switch : defective F-Door Switch : defective Cycle : defective Return after defrosting : defective EEPROM : defective Full Down mode Forced defrost mode for A/S
Display FRZ. LED "5" is on and off FRZ. LED "4" is on and off FRZ. LED "3" is on and off FRZ. LED "2" is on and off FRZ. LED "1" is on and off REF. LED "5" is on and off REF. LED "3" is on and off REF. LED "2" is on and off REF. LED "1" is on and off REF. LED "1" is on REF. LED "1" is on and off (twice)
(Full down mode and forced defrost mode are displayed while pressing "REF.TEMP" button at the error display mode)
20
CONTENTS
5. Control way of Errors (if any) 1) "F-sensor" error Cause : F-sensor open or short Control : Condition of ambient temperature How to reset : If F-sensor is normal, the error is terminal temperature.
REMARKS
RT-S ON/OFF (min)
~ 9 14 / 50
~ 15 16 / 41
~ 21 27 / 45
~ 31 26 / 22
~ 41 35 / 20
Over 41 35 / 20
2) "R-sensor" error Cause : R-sensor open or short Control : Condition of ambient temperature How to reset : If R-sensor is normal, the error is terminal temperature. RT-S ON/OFF (min) ~ 9 OFF ~ 15 3 / 50 ~ 21 2 / 10 ~ 31 3/7 ~ 41 4/6 Over 41 6/4
3) "RT-sensor" error Cause : RT-sensor open or short (full down) Control : Normal operation, deletion of control by RT-sensor If RT-sensor is normal, the error is terminated automatically. 4) "D-sensor" error Cause : D-sensor open or short (full down) Control : Time limit (30 min) of defrosting return If D-sensor is normal, the error is terminated automatically. 5) "Door" error Cause : in case it senses that door is open for more than 1 hour. Control : Deletion of function related door switch sensing If door switch (open & close) is sensed, the error is terminated automatically. 6) "Cycle" error Cause : in case comp. works for over 3 hours when D-sensor temp. is over -5 Control : normal operation When D-sensor temp. is below -5 in comp. off it is terminated. 7) "Return after defrosting" error Cause : in case defrosting return is done by time limit of 80 min Control : Deletion of Pre-cool mode in defrosting mode If defrosting return is done by D-sensor, it is terminated. 8) A/S forced defrosting mode Push "REFRIGERATOR SET" button 5 times while pushing "FREEZER SET" button Simultaneously. Control : A/S forced defrosting control (Pre-cool is deleted) If D-sensor temp. is over 10, the mode is terminated automatically. When all error code is normal, the Refrigerator reset
21
4-10-2. Dispenser Model (CLED Display of Front PCB)
INPUT Temperature Control Buttons CONTENTS
1. How to start 1) Under "LOCK" mode, press "SUPER FREEZER" button 5 times while pressing "FREEZER SET" button at the same time. 2) The front CLED displays as the right diagram shows ( [Ex.] Time Display of 0003 signifies 3 minutes of power on time.) 3) Press "FREEZER SET" button and the following value is displayed successively. Time F-Sensor temperature D-Sensor temperature R-Sensor temperature RT-Sensor temperature P Factor display (Refer to water supply mode of automatic icemaker) Filter remaining time until change (First check ; 4,320Hr) Refer to Filter Information Reset of CLED of front control panel. 4) Error is displayed only if there is any ; it is skipped if no error. 2. How to stop 1) Push "LOCK" button 1 time. 2) It stops automatically in 4 minutes from the start. 3. All the error Codes are reset if they turn to be normal. 4. Error code
CONTROL OBJECT 88 Display CLED REMARKS
ERROR CODE F1 r1 rt d1 dr dF dH EI EF Et Eg ES EA Eu C1 F3 Co D2
CONTENTS F-sensor : disconnection ("Lo"), short ("Hi") R-sensor : disconnection ("Lo"), short ("Hi") RT-sensor : disconnection ("Lo"), short ("Hi") D-sensor : disconnection ("Lo"), short ("Hi") R-Door Switch : defective F-Door Switch : defective Home bar Door Switch : defective I-sensor : disconnection ("Lo"), short ("Hi") Flow sensor : defective Horizontal switch : error Water supply : error Micro switch : error Drop the ice while Et Full ice switch : error Cycle : abnormal or defective Return after defrosting : abnormal or defective Display Full Down mode Display forced defrost mode for A/S
22
CONTENTS
5. Control way of Error (if any) 1) "F1" error Cause : F-sensor disconnection or short Check point : Measure the resistance between both terminals after separating CN8 (or CN15) of the Main PCB. (Refer to the 5-2.) If F-sensor is disconnected or shorted , change the F-sensor in the freezer compartment. How to reset : If F-sensor is normal, the error is terminal temperature. 2) "R1" error Cause : R-sensor disconnection or short Check point : Measure the resistance between both terminals after separating CN7 (or CN14) of the Main PCB. (Refer to the 5-2.) If R-sensor is disconnected or shorted , change the F-sensor in the refrigerator compartment. How to reset : If R-sensor is normal, the error is terminal temperature. 3) "rt" error Cause : RT-sensor disconnection or short (full down) Check point : Measure the voltage of "A" part on the Main PCB. If the voltage is 0.5V~4.5V, it is normal. If the voltage is 0V (short) or 5V (disconnected), change the RT-sensor on the Main PCB How to reset : If RT-sensor is normal, the error is terminated automatically. A A
REMARKS
< Basic Model >
< Dispenser Model >
4) "d1" error Cause : D-sensor disconnection or short (full down) Check point : Measure the resistance between both terminals after separating CN8 (or CN15) of the Main PCB. (Refer to the 5-2.) If D-sensor is disconnected or shorted , change the D-sensor on the evaporator. How to reset : If D-sensor is normal, the error is terminated automatically. 5) Door error ("dF" "dR" "dH" on display) Cause : in case it senses that door is open for more than 1 hour. Check point : F/R door is opened or not. 6) "C1" error Cause : in case comp. works for over 3 hours when D-sensor temp. is over -5 Check point : Refrigerant leakage. 7) "F3" error Cause : in case defrosting return is done by time limit of 80 min Check point : Measure the resistance between both terminals of the defrost heater. (Assembled with evaporator) If the resistance is (disconnected) or 0 (short) change the 8) "d2" mode (A/S forced defrosting mode) Push "REFRIGERATOR SET" button 5 times while pushing "FREEZER SET" button simultaneously. Control : A/S forced defrosting control (Pre-cool is deleted) If D-sensor temp. is over 10, the mode is terminated automatically. Refer to the 4-3. . 23
CONTENTS
REMARKS
9) "EI"ERROR Cause : I-SENSOR disconnection / short Check point : Measure the resistance between both terminals after separating CN11 of the Main PCB. (Refer to the 5-2.) If F-sensor is disconnected or shorted , change the I-sensor in the automatic ice maker. 10) "EF" ERROR Cause : When Flow-sensor ERROR (There is no Pulse during some time) The number of pulse signal is below 10 by 1 sec during water supply. Check point : Water supply line 11) "Eg" ERROR Cause : I-sensor temp (5min after water supply) doesn't go up. Check the I-sensor or water supply line. 12) "ES" error (MICRO switch error) Cause : When it senses 1min continuously Check the MICRO switch of the dispenser.
13) "Ea" error Cause : Malfunction of ice drop motor. Check the motor by pushing test switch. 14) "Eu" error Cause : Switch (which senses if the ice is full or not) is in error. Control : When dropping the ice, the motor just rotates 90 degree. Termination : When the switch is in normal.
15)"EA" ERROR Cause : When sensing Ice dropping by time 3 times in level sensor SW Error. Control : Stop of Ice Maker Termination : With normal level switch. Re-input of power or push if icemaker test switch. 16)"Et" ERROR Cause : Level switch error (No pulse is sensed for some time) Control : By time (Supply mode is skipped) Termination : Normal condition. * When all ERROR CODE is normal, the Refrigerator reset
24
4-11. Summary of Function
4-11-1. Basic Model (Inner Control)
INPUT Each button CONTENTS CONTROL OBJECT Resistance of R-sensor Mid ON/OFF Point REMARKS
Element A/S Function Forced Defrosting Pull Down Demo function Error display "FRZ.TEMP" + "REF.TEMP" 5 times "REF.TEMP"+ "FRZ.DOOR" OPEN/CLOSE 5 times "FRZ.TEMP"+ "FRZ.DOOR" OPEN/CLOSE 5 times "REF.TEMP"+ "FRZ.TEMP" 5 times
4-11-2. Dispenser Model (Front PCB)
INPUT Each button CONTENTS CONTROL OBJECT Resistance of R-sensor Mid ON/OFF Point REMARKS
1. All the modes are started "LOCK" mode (except "FILTER RESET" mode) 2. Element A/S Function Forced Defrosting Reset water filter Demo function Pull Down Error display EEPROM clear Ice maker test "FREEZER SET" + "REFRIGERATOR SET" 5 times Push "RESET WATER FILTER" for 3 seconds "REFRIGERATOR SET" + "WATER/ICE" 5 times "REFRIGERATOR SET"+ "FREEZER SET"+ "WATER/ICE"5 times "FREEZER SET"+ "SUPER FREEZER" 5 times "WATER/ICE"+ "RESET WATER FILTER" 5times "WATER/ICE" + "ICE MAKER LOCK" 5 times
25
4-12. Back up Function (Basic Model)
INPUT None CONTENTS
1. Filter Exchange Information : Record as a real-time from the point of power input 2. P Factor (Information about Ice Maker)
CONTROL OBJECT 1. F-FAN, R-FAN, C-FAN REMARKS
4-13. Automatic Icemaker ( Dispenser Model)
INPUT Full ice sensing switch Ice Maker Lock Sensors CONTENTS
1. Flow of ice making
CONTROL OBJECT
Ice separating motor REMARKS
START
Ice making mode
Ice is being made
(water supply stand by)
Ice separating mode
Ice tray is twisted to separate
ice cubes
Water supply mode
Water is supplied to ice tray
Water supply check mode
Check is water is supplied OK.
RETURN
1) Press TEST switch under the Icemaker for more than 1 second and test starts. * Test mode starts from ice separating mode. * In case test switch has an error of short, test is done only once.
26
CONTENTS
2) With the initial power input, Ice tray turns to be horizontal and ice making mode starts.
REMARKS
3) Control of water hose heater * Heater is always ON if RT-sensor has an error or RT is below 15 degree. * Heater is always ON for 60 minutes (max. Limit time) if Flow-sensor has an error
4) Water supply stand-by Condition : if ice is sensed full Operation : proceeds to Ice making mode (Ice separating and water supply Modes stop)
5) Crusher Function It stops operation when freezer door is open It operates if freezer door is closed.
2 Ice making mode
START
NO
130 min passed?
I-S-9.5
NO
YES
YES
I-S12.5
NO
15 min passed?
NO
YES
YES
Ice saparating mode
1) Ice making stops if ice-sensor is below -12.5 after 130 minutes. 2) Ice making also stops if ice-sensor is below -9.5 for 15 minutes, though ice-sensor is not below -12.5 after 130 minutes. 3) In case of ice sensor, ice making stops after 4.8 hours.
27
CONTENTS
3. Ice separating (drop) mode
REMARKS
status of ice tray Ice separation start level SW MAX1.1sec 8.5~12.2sec 0.2sec
Horizontal position
8~11sec normal level SW motor revolution
CW 10 sec
CCW 11 sec
CW 1.1 sec
STOP
level SW error
1) Time of each zone used to verify level switch error 2) The rotation of motor is sensed at each zone 3) In case of level switch error, ice separation is done by time. 4) If ice separating motor has error, the mode stop. 4. Water supply mode
START
Water supply valve ON
Water flow Pulse Count = 0
1sec passed after water valve ON ? Y
N
N Water flow Pulse > 10
Y
Flow-Sensor Error mode operation
Water flow Pulse spec Pulse spec N N water supply time time spec
Y
Y
water supply valve OFF
END
28
CONTENTS
1) Water supply valve is open when water supply mode starts after separation of ices.
REMARKS
2) Water is supplied by time in case sensor has error. 3) Factor valve is variable which can be useful in AS action Water flow pulse is set to 238 if flow sensor is in normal condition. (If water is supplied by time, maximum water supply time 165 seconds) In case water flow sensor has error, water time is 5.5 seconds.
5. Water supply check mode 5 minutes after water supply the status can be checked by RT-sensor and increase of temp. Ice sensor. RT-S I-S 9 -10 ~15 -9 ~21 -8 ~31 -7 ~41 -6 41 -5
4-14. Dispenser Control Function
INPUT Dispenser switch WATER/ICE Button ICE MAKER LOCK Button Freezer Door Switch CONTENTS
1) Initial mode : water (Mode change : Water Cubed ice Crushed ice) - Selected icon LED turns ON and others are OFF. 2) ICE MAKER LOCK Button Icemaker Lock function and its ICON Turn ON/OFF by pressing the button. 3) Display Water ICON turns ON as default mode The ICON of each mode turns ON by pressing its button. (If display switch makes error during operation of a mode, its ICON turns OFF) When Icemaker Lock ICON turns ON. - ICE MAKER LOCK ICON turns ON - If it is in the mode of Cubed Ice or Crushed Ice, the mode is changed to Water and Water ICON turns ON - If there is no button input for 1 hour after selecting Cubed Ice or Crushed Ice the mode turns to Water (default)
CONTROL OBJECT Dispenser Lamp Crusher Motor Flap Solenoid Crusher Solenoid Dispenser Water Valve REMARKS
29
CONTENTS
4) Control Flow & Timing Chart Crushed Ice
REMARKS
D.P SW
D A A C
D.P Lamp D.P S/V (Flap) Gear Motor
Cubed Ice
D.P SW D.P Lamp Cube S/V D.P S/V (Flap) Gear Motor
A A A B
D
C
Water
D.P SW
D A
D.P Lamp Water S/V
Delay time : A = 500ms, B = 500ms, C = 2.0s, D = 5.0s
30
5. CIRCUIT OPERATION
5-1. Power Circuit Diagram
- Basic Model
A B
D
C
E
- Dispenser Model
A
B
D
C
E
Voltage of every part
Parts Voltage A MC1 230Vdc B CE1 310Vac C CE3 12Vdc D CE4 14.5Vdc E CE6 5Vdc
Caution : Since high voltage (DC310V) is maintained at the power terminal, please take a measure after more than 3minutes have passed after removing power cords in the abnormal operation of a circuit. 31
5-2. Function of Each Sensor
- Dispenser Model
CONTENTS REMARKS
Compensation of R-sensor ON/OFF temp. B
IC1 (MICOM)
C
A
[F-sensor] 1) It senses the temperature of freezer compartment and control Comp., F-fan ON/OFF 2) How it works; Working Point Working Temp. Resistance Sensing Voltage Low ON -11 9.32 3.24V Mid OFF -16 15.19 2.93V High OFF -19 15.58 2.73V
[R-sensor] 1) It senses the temperature of refrigerator compartment and control R-fan ON/OFF 2) How it works; Working Point Working Temp. Resistance Sensing Voltage Low ON 7.7 23.33 2.96V Mid OFF 5.2 24.05 2.83V High OFF 3.2 24.76 2.72V
[D-sensor] 1) It senses return point of defrosting heater. 2) How it works; Working Point Working Temp. Resistance Sensing Voltage Return point of defrosting heater 13 22.56 3.08V
* In case temperature of refrigerator compartment is weak or insufficient though comp. and R-fan operate in normal way; 1) Cut J1 on the M-PCB, then temp. is lowered 1.5 than [Mid OFF point] 2) Cut J1 and J2 on the M-PCB, then the temp, is lowered 3.
32
- Dispenser Model
CONTENTS
REMARKS
Compensation of R-sensor ON/OFF temp. B
IC1 (MICOM)
C
A
D
[F-sensor (A)] 1) It senses the temperature of freezer compartment and control Comp., F-fan ON/OFF 2) How it works; Working Point Working Temp. Resistance Sensing Voltage Low ON -11 9.32 3.24V Mid OFF -16 15.19 2.93V High OFF -19 15.58 2.73V
[R-sensor (B)] 1) It senses the temperature of refrigerator compartment and control R-fan ON/OFF 2) How it works; Working Point Working Temp. Resistance Sensing Voltage Low ON 7.7 23.33 2.96V Mid OFF 5.2 24.05 2.83V High OFF 3.2 24.76 2.72V
[D-sensor (C)] 1) It senses return point of defrosting heater. 2) How it works; Working Point Working Temp. Resistance Sensing Voltage Return point of defrosting heater 13 22.56 3.08V
* In case temperature of refrigerator compartment is weak or insufficient, though comp. and R-fan operate in normal way; 1) Cut J18 on the M-PCB, then temp. is lowered 1.5 than [Mid OFF point] 2) Cut J18 and J19 on the M-PCB, then the temp, is lowered 3
33
5-3. Relay Function
- Basic Model
CONTENTS REMARKS
1. Circuit Diagram
IC1 (MICOM)
Comp
Comp R-Lamp Louver Heater F-Lamp D-Heater
Louver Heater
D-Heater
2. How it works;
Control Mode Method Relay 1 Relay 3 Relay 5 ON Condition MICOM Port #15.0V #35.0V #55.0V IC7 IC ULN2004 Output pin #100.7V #120.7V #140.7V OFF Condition MICOM Port #10V #30V #50V IC7 IC ULN2004 Output pin #1012V #1212V #1412V
Control Comp Louver Heater D-Heater
34
- Dispenser Model
CONTENTS REMARKS
1. Circuit Diagram
IC1 (MICOM)
Comp R-Lamp Louver Heater F-Lamp D-Heater
2. How it works;
Control Comp R-Lamp H/B Heater Dispenser-Lamp Dispenser-Solenoid Water (Ice) Water (Dispenser) Geared-Motor D-Heater F-Lamp Cube-Solenoid Water Pipe Heater Control Mode Method Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Relay 6 Relay 7 Relay 8 Relay 9 Relay 10 Relay 11 Relay 12 ON Condition IC ULN2004 Output pin #100.7V IC7 #110.7V #120.7V #130.7V #140.7V #150.7V #100.7V #110.7V #120.7V #130.7V #140.7V #150.7V OFF Condition IC ULN2004 Output pin #1012V IC7 #1112V #1212V #1312V #1412V #1512V #1012V #1112V #1212V #1312V #1412V #1512V
MICOM Port #15.0V #25.0V #35.0V #45.0V #55.0V #65.0V #75.0V #85.0V #95.0V #105.0V #115.0V #125.0V
MICOM Port #10V #20V #30V #40V #50V #60V #70V #80V #90V #100V #110V #120V
IC8
IC8
35
5-4. Fan Function
1. Circuit Diagram
- Basic Model
- Dispenser Model
2. Explanation for the operation * TA7291P is the drive IC for the only DC motor, and used for control of the fan motor * One input and output is used for the control of the fan motor Input Motor IC No.5 Pin (R:MT2/F:MT3/C:MT1) High Low Output Motor IC No.2 Pin (R:MT2/F:MT3/C:MT1) High Low Remark 13V Stop
- Vref is the reference voltage for the adjustment of the output voltage by the voltage distribution of Vs (Maximum output voltage), and the output voltage applied to the fan is determined by the PWM control using the software. 36
6. DIAGRAM
6-1. Wiring Diagram
- Basic Model
37
- Dispenser Model
38
6-2. Circuit Diagram of Main PCB
- Basic Model
39
40
- Dispenser Model
41
42
7. COMPONENT LOCATE WIEW
7-1. Front View ( Dispenser + Home bar Model )
Front PCB
Home bar Door (Option)
Dispenser Button
7-2. Inner View
Automatic Ice Maker F-Fan Motor Geared Motor
R-Fan Motor
R-Sensor R-Lamp
Inner R-Sensor Controller
F-Door Switch
F-Sensor F-Lamp
R-Door Switch
R-Door Switch
Freezer Compartment (Dispenser Model)
Refrigerator Compartment (Dispenser Model)
Refrigerator Compartment (Basic Model)
43
7-3. Evaporator
Water Pipe
D-Sensor
Temp Fuse Evaporator Defrost Heater
7-4. Machine Compartment
Power cord
Compressor
Condenser
Running Capacitor
OLP & PTC
Dryer
Condenser Fan-Motor
Tray Drip
Water Valve
44
8. HOW TO CHECK EACH PARTS
8-1. Hose Ice Maker Tube Assembly
1) Disassembling Procedure
NO 1 DISASSEMBLING PROCEDURE NO 5 DISASSEMBLING PROCEDURE
Pull forward Ice Storage Case 2 6
Remove 2 screws at the Cove Guide Cab W/Tube A.
Remove 2 screws. 3 7
Disassemble Cover Guide Cab W/Tube A
Pull forward Ice Maker. 4 8
Pull forward Hose Ice Maker Tube As.
Remove Water Hose Heater's 2P housing.
Check Hose Ice Maker Tube As.
2) How to check Hose Ice Maker Tube As.
How to check Measure the resistance of two wire CRITERION Good: 9680(±8%) (8900 ~ 10456) If defective, change
45
8-2. Bracket Geared Motor Assembly
1) Disassembling Procedure
NO 1 DISASSEMBLING PROCEDURE NO 4 DISASSEMBLING PROCEDURE
Remove 2 screws. 2 5
Pull forward Bracket Geared Motor.
Unscrew (4 points). 3 6
Unscrew (red 4 screws). Unscrew (blue 4 screws).
Separate 6 pin housing of Bracket Geared Motor from the top connector.
Check Solenoid Valve and Geared Motor.
2) How to Check Hose Ice Maker Tube Assembly
PARTS SPEC. SPEC. NAME :DAG-6502DEC Geared Motor VOLTAGE :220/240V,50Hz Check resistance value of 2 terminals with a Multi Tester. HOW TO CHECK CRITERION GOOD : 11.3(±10%) (10.8 ~ 12.7) DEFECTIVE ; Change the Geared Motor.
Cube Sol Valve
SPEC. NAME :Cube SN8 VOLTAGE :220/240V,50Hz Check resistance value of 2 terminals with a Multi Tester.
46
GOOD : 145(±8%) (133 ~ 156) DEFECTIVE ; Change the Cube Sol Valve.
8-3. Dispenser Micro Switch
1) Disassembling Procedure
NO 1 DISASSEMBLING PROCEDURE NO 3 DISASSEMBLING PROCEDURE
Insert (-) screw driver into bottom hole of Dispenser Button Guide. Pull up forward to remove the guide. (Be careful not to damage guide surface.) 2 4
Separate wire connectors from Micro Switch.
Remove Micro switch.
Check Micro Switch.
2) How to Check Micro Switch
PARTS HOW TO CHECK GOOD : Tact Switch (Blue Circle) ON (Close) VOLTAGE :125V,3A Check both terminals (red circle) with a Multi Tester (Tester Mode : Resistance (). OFF (Open) Terminals (Red circle) Connected Disconnected Tester Result (Resistance Mode) Some Value No value (0) CRITERION
SPEC. NAME : VP333A-OD-8
DEFECTIVE : Change Micro Switch.
47
8-4. Dispenser Solenoid Valve
1) Disassembling Procedure
NO 1 DISASSEMBLING PROCEDURE NO 4 DISASSEMBLING PROCEDURE
Insert (-) screw driver into bottom left groove of Cover Dispenser Box. Pull forward with a snap.(Be careful not to damage cover and door surface.) 2 5
Separate 2 terminals from Sol Valve and 2P Housings from Cover Ice Flap.
Separate 2 housings of 10P / 7P from Front PCB. (Do not hold only wires to pull out.) 3 6
Unscrew (3 points) to remove Sol Valve.
Unscrew (2 points) to remove Box Dispenser Shut.
Unscrew (1 point) to remove Cover Ice Flap.
2) How to Check Micro Switch
PARTS SPEC. HOW TO CHECK CRITERION
SPEC. NAME :SOL2003-01B Dispenser Sol Valve VOLTAGE :220/240V,50Hz Check resistance value of both terminals with a tester.
Good : 215(±10%) (193 ~ 236) DEFECTIVE : 0 Change Sol Valve.
Flap Heater Assembly
VOLTAGE :DC 12V,1.5W Check resistance value of both terminals with a tester.
48
GOOD : 96(±8%) (88 ~ 104) DEFECTIVE ; Change Flap Heater AS.
8-5. Main PCB
- Basic Model
1 6 3
2 5 4
NO 1 ITEM Compensation of Weak Refrigeration Making R-temp cooler Relay Power Controller Fan Power Controller CHECK POINT REMARK
J1 J2
* Used when making R-temp. down to compensate for weak refrigeration without changing FCP temp. setting. Cutting of J1 ; down by 1.5 Cutting of J1, J2 ; down by 3
2
* To check normal voltage of each electrical devices to & from Mi-com. Check input & output voltage of MICOM and IC7 * To check input & output voltage of Fan #2 : Input
3
F
4 5
R
C
#5 : Output
Electric Current Fuse * To check when each device does not work (250V,3.15A) Time Shortening Switch Regulator IC(5V) * To shorten time in PCB checkup (Pressing 1 time is regarded as 1 minute has passed.) * To check voltage of MICOM and IC Voltage check of IC#6 (Input :12V,Output : 5V)
6
49
- Dispenser Model
1 6 3 5
2
4
NO 1
ITEM Compensation of Weak Refrigeration Making R-temp cooler Relay Power Controller Fan Power Controller
CHECK POINT
REMARK
J18,19
* Used when making R-temp. down to compensate for weak refrigeration without changing FCP temp. setting. Cutting of J18 ; down by 1.5 Cutting of J18, J19 ; down by 3
2
* To check normal voltage of each electrical devices to & from Mi-com. Check input & output voltage of MICOM and IC7, 8. * To check input & output voltage of Fan #2 : Input
3
F
4 5
R
C
#5 : Output
Electric Current Fuse * To check when each device does not work (250V,3.15A) Time Shortening Switch Regurator IC(5V) * To shorten time in PCB checkup (Pressing 1 time is regarded as 1 minute has passed.) * To check voltage of MICOM and IC Voltage check of IC#6 (Input :12V,Output : 5V)
6
50
8-6. Ice Maker
1) Disassembling Procedure
NO 1 DISASSEMBLING PROCEDURE NO 6 DISASSEMBLING PROCEDURE
Remove 2 screws on top front of ice maker. 2 7
Remove full ice sensing switch and level switch.
Pull forward ice maker. 3 8
Unscrew (3 points) Plate Gear Fixture.
Unscrew Fixture of Frame Ice Maker. 4 9
Check if ice dropping motor is normal (OK).
Separate Ice Maker Assembly from Frame Ice Maker. 5 10
Remove 2 pin housing from Plate Gear Fixture.
Separate Cover I/M (A) from Cover I/M (B) with a (-) screw driver. * Follow the reverse order when assembling.
51
Remove I-sensor (ice sensor) from Case Icing As.
2) How to Check Ice Maker
PARTS Ice Dropping Motor HOW TO CHECK CRITERION GOOD : RS-360RH-14250 : 6 ~ 14 DEFECTIVE : Change the motor. Check resistance value of 2 wires with a Multi Tester.
I-Sensor (Ice Sensor)
GOOD : 4.4 ~ 50k (It depends on surround temp.) DEFECTIVE : Change the sensor. Check resistance value of 2 wires with a Multi Tester.
Full Ice Sensing Switch
GOOD : Tact Switch (Blue Circle) ON (Close) OFF (Open) Check resistance value of 2 terminals with a Multi Tester. Terminals (Red circle) Connected Disconnected Tester Result (Resistance Mode) Some Value No value (0)
DEFECTIVE : Change the switch. GOOD : Tact Switch (Blue Circle) ON (Close) OFF (Open) Terminals (Red circle) Connected Disconnected Tester Result (Resistance Mode) Some Value No value (0)
Level Switch
Check resistance value of 2 terminals with a Multi Tester.
DEFECTIVE : Change the switch.
52
9. TROUBLE DIAGNOSIS
9-1. Faulty Start (F/R lights OFF , F-PCB Power OFF)
Start
Power cord or Fuse is disconnected ?
Y
Change the Main Fuse (AC250V 15A)
(In the left side of machine compartment)
N
1'st power of SMPS is on?
N
Check power Cord connection from machine compartment and to CN1 of M-PCB.
Y
Main PCB Fuse is disconnected?
Y
Change the Fuse (AC250V 3.15A) (on the Main PCB)
N
Voltage (DC12V/14.5V/5V) on Main PCB is OK?
N
Refer to the 5-1. (Power circuit diagram)
Y
Wire connection of F-PCB is OK?
Change Main PCB
Y
N
Checkup and connect F-PCB wires. Change F-PCB AS.
How to replace Front PCB
1) Insert a flat tip driver into the left down groove of panel frame and snap it out smoothly. 2) Separate 2 housings of 10P / 7P from Front PCB. (Do not hold only wires to pull out.) 3) Unscrew (7 points) to remove Front PCB. * Follow the reverse order when assembling.
53
9-2. Freezer Compartment
9-2-1. Freezing failure . (Foods are not frozen / cold.) Start
Any Error code on F-PCB?
Y
Refer to error display in operation and function Refer to the 4-10. (Error Display)
N
Does Comp. work?
N
Y
OLP/PTC is OK?
Y
N
Change OLP/PTC
Change the Comp.
F/C-Motor works OK?
N
N
F/C-Motor is OK? Change F/C-Motor
Y
Y
Wiring connection Is OK?
Y
Change M-PCB
N
Check lead wire Temp. Fuse Is OK?
N
Y N
Defrost Heater Is Ok? Defrost Heater : 192W (252 )
Change Fuse. Temp Left-lower side of Evaporator (4th pipe from buttom)
Y
Change the Defrost Heater
Ice formation on Eva. Is OK?
N
Y
54
Check ice formation on Eva. And if refrigerant leak is found, repair it.
Removing and replacing Freezer parts
(1)
1) Remove foods. 2) Remove Ice Bucket, shelves and cases in Freezer compartment.
(2)
* Remove 2 screws of Ice Maker.
(4)
* Remove 4 screws of Geared Motor.
(3)
* Remove the Housing of Ice Maker AS. (Right side)
(5)
* Remove the Housing of Geared Motor AS. (Center)
55
Removing and replacing Freezer parts
(6) * Remove light cover screws. (12) * Remove the screw cap on the F-Louver A with a flat tip driver.
(7) * Pull down smoothly the bottom of light cover to remove.
(13) * Remove 3 screws of F-Louver A.
(8) * Remove the screw of bracket F-Lamp.
(14) * Hold the end of F-Louver A and pull forward slowly.
(9) * Remove the left housing. (15)
* Remove the housing.
(10) (16) * Pull out smoothly the bracket F-Lamp AS. to remove. * Remove the screw of F-Return cover and pull out cover.
(11)
(17
* Hold the end of F-Fan cover and pull forward slowly.
* Hold the end of F-Louver B and pull forward slowly.
56
Removing and replacing Freezer parts
D-Sensor Housing F-Louver B Heater Housing Temp. Fuse Housing 1st : F-Louver B Heater Housing 2nd : None. 3rd : Defrost Heater Housing. Temp. Fuse
Defrost Heater
D-Sensor
Defrost Heater
57
9-2-2. Ice Formation on F-Louver
Start
Dews are formed on the gasket surface inside F compartment ?
Y
Gasket has a gap between cabinet ?
Y
Remove the gap.
N N
Door is hanged down ?
Y
Reassemble the door.
N
Door is open and closed too frequently ?
Y
N
Explain not to open doors too frequently.
Heat appliances are too close to the refrigerator ?
Y
N
Make enough distance between heat appliances and refrigerator.
Watery or hot foods are stored in refrigerator compartment ?
Y
N
Wipe out dews on the louver surface and run the refrigerator again.
Louver heater is disconnected ?
Y
N
Change the louver assembly.
58
9-2-3. Disconnection / breaking of Freezer Lights Wires Start
Freezer light filament is disconnected or breaking ?
Y
N N
Change the light bulb.
Connection of F door switch is OK ? Y Check the F door switch connection and F-light socket.
Repair the F-door switch.
Change of F Lights
Change of F Door Switch
* Remove 2 screws of light cover.
* Insert a flat tip screw driver Into a gap of door switch to pull forward.
* Hold the bottom of light cover and pull forward to remove.
* Disconnect the housing and change the switch for a new one. Be careful when changing the switch. F and R door switch are different in type and shape.
* Change the light bulb. (AC240V 25W)
Follow the reverse order of disassembling after changing the light.
Follow the reverse order of disassembling after changing the switch.
59
9-3. Refrigerator Compartment
9-3-1. Refrigeration failure (Foods does not get cool or cold soon.) Start
Any error mode on F-PCB?
Y
Refer to the 4-10. (Error Display)
N
Solve error code problem, if any.
R-Motor works OK ?
N
R-Motor is OK ?
N
Change the R-Motor.
Y
Y
Wiring connection Is OK ?
Y
Change the Main PCB.
R-Sensor is OK (normal) ?
N
N
Check the wirings.
Y
Freezer compartment Is OK ?
N
Change the R-Sensor and check connector.
Y
Refrigerator gasket have gap ?
Refer to "Freezing does not work."
Y
Gasket have any gap ?
Y
Repair to eliminate the gap of gasket.
N N N Y
Explain not to place foods close to R-sensor or cold air spout. Door is hanged down to make gap between cabinet ?
Y
Reassemble doors.
Foods are placed just close to R-Sensor ?
N
Refrigerator door openings are too often ?
Y
Explain not to open doors unnecessarily or frequently. * Advise to use in "HIGH" mode * Jumper cutting of Main PCB to prevent weak refrigeration ; Option 1 : cut J18 to down 1.5. Option 2 : cut J19 to down 1.5.
N
60
9-3-2. Disconnection / Breaking of Refrigerator Lights Wires Start
Freezer light filament is disconnected or breaking ?
Y
N N
Change the light bulb.
Connection of R door switch is OK ? Y Check the R-door switch connection and R-light socket.
Repair the R-door switch.
Change of R Lights
* Remove screws of light cover.
Change of F Door Switch
* Insert a flat tip screw driver into a gap of door switch to pull forward.
* Hold the bottom of cover and pull forward to remove.
* Disconnect the housing and change the switch for a new one. Be careful when changing the switch. F and R door switch are different in type and shape.
* Change the light bulbs. (AC240V 25W)
Follow the reverse order of disassembling after changing the switch.
Follow the reverse order of disassembling after changing the light.
61
9-3-3. Dews on Refrigerator Compartment
Start
Dews are formed on the gasket inside R-compartment?
Y
Gasket has Any gap ?
Y
Repair to eliminate the gap.
N N
N
Door is hanged down ?
Y
Reassemble the doors.
Y
Door is open too long ? Explain not to open doors too long.
N
Door is open and closed too frequently ?
Y
N
Explain not to open doors unnecessarily.
Heat appliances are used near the refrigerator ?
Y
N
Make enough distance between the appliances and refrigerator.
Watery or hot foods are stored in the R-compartment?
Y
N
Advise to cool down foods, wrap or cover foods with much water before storing in the compartment.
N
R-fan works OK ? Repair and change R-motor.
Y
62
9-3-4. Excessive Refrigeration of Vegetable Case
Start
Refrigerator temp. mode is "HIGH" ? N
Y
Explain the temperature modes. Advise to set the temp. to "Middle" or "LOW" mode.
R-check valve Works OK ? Y
N
Repair and/or Change the R-check valve. Refer to "Repair /Change of Check Valve".
Is there any R-sensor error code ? Y
N R-sensor is OK ?
N
Change the R-sensor.
Y
Check the R-sensor connection. (Check the connector to Main PCB.)
63
Removing of Check Valve
* Remove screws of light cover.
* Hold the bottom and right of damper to pull down to remove.
* Hold the bottom of cover and pull forward to remove.
* Lift up a piece of Check Valve Flap and insert a finger to the valve frame to hold out.
* Disconnect light housing.
* Remove screws with a (+)screw driver.
64
9-4. Operation Noise of Refrigerator
9-4-1. Comp. operation Noise
Start
Refrigerator is leveled ?
N
Y
Level the refrigerator by adjusting wheels. Refer to User's Guide and SVC Manual. Y
Front cover or door gasket is assembled wrong ?
N
Set it right.
Rubber absorber comp is distorted or aged ?
Y
N
Change the Rubber absorber.
Sound from Comp itself or Vibration ?
N
Y
Attach a restrainer on the comp. head to reduce vibration and high frequency noise.
Change the compressor.
Remarks Compressor sound is somewhat normal because it works like a heart to circulate the refrigerant in the pipes during the refrigerator operation. Rattling or metallic touch sound of motor, piston of comp. can be heard when it starts or stops.
65
9-4-2. Refrigerant Flow Sound
Start
Water flowing or hiss sounds from the refrigerator ?
Y
N
Attach an absorber gum on the capillary tube.
Refrigerant sound of hiss or sizzling sound when comp. starts ?
Y
N
Apply a gum on the accumulator.
Refrigerant sound of hiss or sizzling when comp. stops ?
Y
N
Apply a gum on the accumulator.
Any shaking sound from F-compartment when comp. works ? N
Y
Fasten the evaporator in Fcompartment tightly against touching (liner) surfaces.
Explain refrigerator work mechanism and sound to the users or customers.
Remarks Water flowing sound, hiss or sizzling sound can make while refrigerant in the pipes is changing from liquid to gas state when comp. starts or stops. It is normal to the refrigerator.
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Troubleshooting of Evaporator Sound
1. Hiss Sound from Capillary Tube
"I" tube
1
2
1) "I" tube is used to connect the capillary tube and evaporator. (2 welding points : , ) 2) When such a sound is made, attach a absorber on the tube including 2 welding points.
3
2. Sizzling Sound from Accumulator
Attach a absorber on point (accumulator).
3. Shaking or trembling Sound of Evaporator
1) Check whether evaporator is fastened tight with the fasteners of , . 2) Insert a soft spacer (EPS) between left and right wall. Evaporator not to be shaken or trembled during refrigerator operation.
1
2
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9-4-3. Fan Noise
Start
Fan is damaged or transformed ? N
Y
Change the fan.
Fan is touching the surround ?
Y
N
Set it right not to touch.
Fan-motor assembly is moving or shaking ?
Y
N
Set it right not to move.
Motor has its own noise or vibration when working ?
Y
N
Change the motor assembly.
Explain to the customers how fan is working to circulate cold air in the compartments.
Remarks The fan is sending out cold air to circulate it through the compartments. When the air is touching the surface of louver or liner wall, such sound can make.
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Troubleshooting of Fan Noise
1. Fixing or Fastening of Fan Motor
1) Check if fan motor frame of the assembly is fastened tightly with screws to the liner wall. Unless it is tight, vibration of shaking can make.
2) Check if fan motor and fan are hanged down. Fan working sound can be louder if they are not set right.
2. Any Touch Sound from Fan
1) Check if sealing sponge on the insulator touches the fan. If so, set it again not to touch it. 2) If any damage on the insulator around the fan rotation is found, set the fan motor assembly right not to touch it.
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9-4-4. Pipe Noise
Start
Pipes are touching in the machine compartment ?
Y
N
Separate the touching pipes, if any.
Tray drip makes noise by Condenser shaking ?
Y
N
Apply cushion material between Comp. base and Tray drip.
Pipe itself is shaking much ?
Y
N
Move or change the points of vibration absorber rubbers on the pipes to reduce the shaking. Y
Compressor itself is shaking much ?
N
Attach a absorber on the comp. head.
Explanation to the users.
Remarks Refrigerant is erupting rapidly from the compressor to circulate pipes, so pipe shaking noise can make to some degree. In case compressor vibration is sent to a pipe directly, apply vibration absorber rubbers to welding points of the pipe and comp. or to a much bent point on the pipe.
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9-5. Door
9-5-1. Door Opening Alarm Continues though the door is closed.
Start
Door switch is pushed well ?
N
Check if interior light is ON.
Y
Attach a thin pad on the door liner or change the door assembly.
Door switch is soaked with water or there is water in the switch ? N
Y
Change the door switch.
PCB input is OK ?
Y
N
Check #5,6 of CN8 (F-Door) and #4,6 of CN7 (F-Door). Open : 5V, Close : 0V
Repair any disconnection of wires and defective Door switch.
Connector insertion to Main PCB is OK ?
Y
N
Repair the defective connection.
Door switch itself is OK ?
Y
N
Change the switch.
Check it up.
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10. COOLING CYCLE HEAVY REPAIR
10-1. Summary of Heavy Repair Process Remove refrigerant Residuals Contents * Cut charging pipe ends (Comp. & Dryer) and discharge refrigerant from drier and compressor. Tools * Nipper, side cutters
Parts replacement and welding
* Confirm refrigerant (R-134a or R-600a) and oil for compressor and drier. * Confirm N2 sealing and packing conditions before use. Use good one for welding and assembly. * Weld under nitrogen gas atmosphere. * Repair in a clean and dry place.
* Pipe Cutter, Gas welder, N2 gas
Vacuum
* Evacuate for more than forty minutes after connecting manifold gauge hose and vacuum pump to high (drier) and low (compressor) pressure sides.
* Vacuum pump , Manifold gauge.
Refrigerant charging and charging inlet welding
* Weigh and control the bombe in a vacuum conditions with electronic scales and charge through compressor inlet (Process tube). * Charge while refrigerator operates). * Weld carefully after inlet pinching.
* Bombe (mass cylinder), refrigerant manifold gauge, electronic scales, punching off flier, gas welding machine
* Check leak at weld joints. Note :Do not use soapy water for check. Check * Check cooling capacity refrigerant leak Check condenser manually to see if warm. and cooling Check hot pipe manually to see if warm. capacity Check frost formation on the whole surface of the evaporator.
* Electronic Leak Detector, Driver.
Compressor compartment and tools arrangement
* Remove flux from the silver weld joints with soft brusher wet rag. (Flux may be the cause of corrosion and leaks.) *Clean tools and store them in a clean tool box or in their place.
* Copper brush, Rag, Tool box
Transportation and installation
* Installation should be conducted in accordance with the standard installation procedure. (Leave space of more than 5 cm from the wall for compressor compartment cooling fan mounted model.)
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10-2. Precautions During Heavy Repair Items Use of tools. Precautions 1) Use special parts and tools for R-134a or R-600a
Removal of retained refrigerant.
1) Remove retained refrigerant more than 5 minutes after turning off a refrigerator. (If not, oil will leak inside.) 2) Remove retained refrigerant by cutting first high pressure side (drier part) with a nipper and then cut low pressure side. (If the order is not observed, oil leak will happen.)
Low pressure side Evaporator
Suction tube
Compressor
Hot Pipe
Dryer Process tube Discharge tube Condenser High Pressure side
Replacement of drier.
1) Be sure to replace drier when repairing pipes and injecting refrigerant. 1) Weld under nitrogen atmosphere in order to prevent oxidation inside a pipe. (Nitrogen pressure : 0.1~0.2 kg/cm2.)
Nitrogen blowing welding.
Others.
1) Nitrogen only should be used when cleaning inside of cycle pipes inside and sealing. 2) Check leakage with an electronic leakage tester. 3) Be sure to use a pipe cutter when cutting pipes. 4) Be careful not the water let intrude into the inside of the cycle.
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10-3. Practical Work for Heavy Repair
Items 1. Removal of residual refrigerant.
Precautions
1) Remove residual refrigerant more than 5 minutes later after turning off the refrigerator. ( If not, compressor oil may leak inside.) 2) Remove retained refrigerant slowly by cutting first high pressure side (drier part) with a nipper and then cut low pressure side.
Suction tube Low pressure side Evaporator
Compressor
Hot Pipe
Dryer Process tube Discharge tube Condenser High Pressure side
2. Nitrogen blowing welding.
Compressor
Low pressure side
Evaporator
Hot Pipe
Dryer Process tube
Condenser
High Pressure side
* When replacing a drier: Weld and parts by blowing nitrogen (0.1~0.2kg/cm2) to high pressure side after assembling a drier. * When replacing a compressor: Weld and parts by blowing nitrogen to the low pressure side. Note) For other parts, nitrogen blowing is not necessary because it does not produce oxidized scales inside pipe because of its short welding time. KEYPOINTING Welding without nitrogen blowing produces oxidized scales inside a pipe, Which affect on performance and reliability of a product.
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Items
Precautions * Pipe Connection Connect a red hose to the high pressure side and a blue hose to the low pressure side. * Vacuum Sequence Open , valves and evacuate for 40 minutes. Close valve . Evaporator
3.Vacuum degassing.
Compressor
Hot Pipe
Condenser
Dryer
Low Pressure Vaccum Pump Blue Yellow
High Pressure
Red
KEYPOINTING 1) If power is applied during vacuum degassing, vacuum degassing shall be more effective. 2) Operate compressor while charging refrigerant. (It is easier and more certain to do like this.) * Charging sequence 1) Check the amount of refrigerant supplied to each model after completing vacuum degassing. 2) Evacuate bombe with a vacuum pump. 3) Measure the amount of refrigerant charged. - Measure the weight of an evacuated bombe with an electronic scale. - Charge refrigerant into a bombe and measure the weight. Calculate the weight of refrigerant charged into the bombe by subtracting the weight of an evacuated bombe. Indicate the weight of an evacuated bombe KEYPOINTING 1) Be sure to charge the refrigerant at around 25°C. 2) Be sure to keep -5g in the winter and +5g in summer.
4.Refrigerant charging.
Calculation of amount of refrigerant charged the amount of refrigerant charged = a weight after charging - a weight before charging (a weight of an evacuated cylinder)
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Items 4.Refrigerant charging.
Precautions 4) Refrigerant Charging Charge refrigerant while operating a compressor as shown above. 5) Pinch a charging pipe with a pinch-off plier after completion of charging. 6) Braze the end of a pinched charging pipe with copper brazer and take a gas leakage test on the welded parts. Compressor Evaporator
Hot Pipe
Bombe Condenser 5. Gas-leakage test 6. Pipe arrangement in each cycle Dryer
* Take a leakage test on the welded or suspicious area with an electronic leakage tester. * Check each pipe is placed in its original place before closing a cover back-M/C after completion of work.
10-4. Standard Regulations for Heavy Repair
1) Observe the safety precautions for gas handling. 2) Use JIG (or wet towel) in order to prevent electric wires from burning during welding. (In order to prevent insulation break and accident.) 3) The inner case shall be melted and insulation material (polyurethane) shall be burnt if not cared during welding inner case parts. 4) The copper pipe shall be oxidized by overheating if not cared during welding. 5) Not allow the aluminum pipes to contact to copper pipes. (In order to prevent corrosion.) 6) Make sure that the inner diameter should not be distorted while cutting a capillary tube. 7) Be sure that a suction pipe and a filling tube should not be substituted each other during welding. ( High efficiency pump.)
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10-5. Brazing Reference Drawings. Accumulator Hot Pipe I-Pipe
Suction Pipe F Evaporator R
Pipe Suc Conn Condenser Dryer Pipe Conn B Capi-Tube Welding Point Compressor
Copper Welding (Ag 5%) Silver Welding (Ag 35%)
7 Points 3 Points
Flow of Refrigeration Cycle Wire-Con. Pipe Capillary Tube Pipe Conn. B Hot Pipe
Dryer
High
Compressor
Low
Accumulator Suction Pipe Evaporator
Pipe Suction Conn
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11. INSTALLATION GUIDE
11-1. Installation Preparation
Check if the refrigerator can pass a doorway or enter a door first.
Dimensions( including Door Handles) (Width*Depth*Height)
903mm X 734.5mm X 1790mm
Find a suitable place to install
Sufficient space from refrigerator back to the wall for free air ventilation
Avoid direct sunlight.
Once the installation place is ready follow the installation instructions. If surround temperature of refrigerator is low (below 10)), foods can be frozen or the refrigerator can work in abnormal way.
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11-2. If the refrigerator can not enter the door
Removing Freezer Door
Remove front bottom cover first, if it is attached.
1
Remove front bottom cover first, Pull out the left collar of the coupling first, then hold the coupling and pull out the left water tube.
2
Unscrew top hinge cover with a screw driver. Remove the hinge cover.
3
Turn top hinge bolt counterclockwise . Disconnect the harness wires.
4
Lift up the front of hinge to remove. ( After the hinge is removed the door can fall down forward. Be careful !)
5
Be careful not to damage the water line when removing the door.
Removing Refrigerator Door
1
Unscrew top hinge cover with a screw driver. Remove the hinge cove