samsung refrigerator training 2003 trainmnls

SAMSUNG REFRIGERATOR TRAINING 2003

Based on model RS2577

Table of Contents The Samsung Difference Page 3 Installation Cautions Page 4 Refrigerator/Freezer Gasket to Cabinet Seal Test Page 5 Sealed System Page 6 Operation Functions Page 7

Power Freeze Function Page 7 Power Cool Function Page 7 Child Lock Function Page 7 Exhibition Function Page 7

Self- Diagnostic Function Page 8 Self-Diagnostics during Initial Power ON Page 8 Self-Diagnostics during normal operation Page 8 Load Operation Check Function Page 9 Set Point Shift Function Page 10 Defrost Function Page 12 Forced Operation Function (Pull-Down / R-Defrost / R.F- Defrost) Page 12 Circuit Operations Page 13

Condenser Fan Delay Page 13 Main PCB Power Supply Page 13 Main PCB Main Micro Voltages Page 14 Main PCB Lamp Circuits Page 14 Main PCB Temperature Sensing Circuits Page 15 Main PCB Display and Key Matrix Page 17 CoolSelect Zone Circuit Page 18 Damper Drive Circuit Page 18 Main PCB Fan Motor Circuitry Page 19 Main PCB Relay Control Page 20

Ice Maker Circuitry Page 21 Drinking Water Circuit Page 23 Refrigerator Disassembly/Assembly Page 24 Door Page 24 Water Filter Page 28 Evaporator Fan Page 29 Evaporator Page 29 Freezer Disassembly/Assembly Page 30 Door Page 30 Control Panel Page 33 Door Gasket Page 33 Icemaker Page 34 Auger Motor Case Page 35 Evaporator Fan Page 37 Evaporator Page 37 Machine Compartment Disassembly/Assembly Page 38 Main PCB Page 38 Water Solenoids Page 39 Condenser Fan Page 39 Sub Condenser Page 39 Troubleshooting Tips and Bulletins Page 40 TV Noise Page 40 Exhibition Mode Page 41 Filter Assembly Part Number Page 41 Water Leakage from the Filter Page 42 One Cycling Page 42 Slow or no ice production Page 43

Figure 1

The Samsung Difference 1. Twin Cooling System

a. In this system, the refrigerator and the freezer have two separate evaporators. The freezer and the refrigerator are cooled individually and are therefore, more efficient. Food odor from the refrigerator does not affect food in the freezer due to separate airflow circulation.

b. Each evaporator has its own fan, both of these fans circulate cold air in their respective compartments.

2. Multi-Flow System

a. Within this system, cool air circulates through multiple vents on every shelf level in both compartments. This provides even distribution of cooling inside cabinets to keep food fresh longer. (See figure 1)

Figure 2

Figure 3

Figure 4

Figure 5

Installation Cautions 1. To protect refrigerator when moving

Use a padded hand truck to avoid damage to unit. If entrance width is less than 39”, remove doors prior to installation and reattach doors by following the procedure below.

Removing Doors a. Open the freezer and refrigerator

doors, then take off the front leg cover assembly by turning the three screws counter-clockwise. Remove the screw from the clamp holding the water tube. Disconnect the water tube by pressing the coupler in, and pulling the water tube out. (See Figure 2)

b. With the door closed, remove the upper hinge cover using a screwdriver, and then disconnect the wires hidden underneath it. Remove the hinge screws and the ground screw by turning counter-clockwise, and take off the upper hinge. (See Figure 3) Take care removing the door to ensure that it does not fall on you.

c. Remove the door from the lower hinge by carefully lifting the door so as not to

damage the water tube. Remove the lower hinge from the lower hinge bracket by lifting the lower hinge (See Figure 3)

d. Refer to Disassembly/Assembly instructions starting on page 24 of this Training Guide for more door removal procedures.

Attaching Doors

a. Insert the lower hinge in the bracket lower hinge. (See Figure 4) Attach the freezer door by inserting the hose in the lower side of the door into the hole in the lower hinge and pulling the hose down.

b. Insert the upper hinge shaft into the hole while leveling the upper hinge and cabinet holes. Reattach the hinge screws and screw them in. Connect the wire harnesses. Put the front part of the upper hinge cover on the front part of the upper hinge and reattach. (See Figure 5)

c. Refer to Disassembly/Assembly instructions starting on page 24 of this Training Guide for more door attaching procedures.

Refrigerator/Freezer Gasket to Cabinet Seal Test

In the event that a customer complains about cold air leakage from the Refrigerator/Freezer in the area where the gasket seals up against the cabinet, perform the following test. This test should also be performed anytime a door or gasket is replaced.

1. Tear a piece of paper two to three inches wide by eight inches long. (A standard note pad page, cut to size, is sufficient. DO NOT fold the paper to size.) NOTE: The paper should be no smaller than two inches in width.

2. Open the Refrigerator/Freezer door.

3. Place the paper between the Refrigerator/Freezer cabinet and door in a way that it will be "sandwiched" between the gasket and cabinet.

4. Close the door with approximately a quarter of the page protruding out from the door. This will facilitate pulling the paper.

5. Pull gently on the paper. A small resistance to the pull should be felt when applying a gentle pull on the paper with two fingers. This is normal and sufficient to confirm that the gasket is sufficiently seated against the cabinet.

6. Perform the pull test around the perimeter the Refrigerator/Freezer door to confirm that all locations are sealing properly.

In the event that the paper pulls freely with no effort, the gasket is not sealing properly and it is recommended that the gasket and/or door assembly be replaced.

2. Remove all protective tape and padding in refrigerator

Connect water lines and power cords. Make sure to adjust the clearance between the doors.

3. Set the temperature control to the desired temperature and wait for an hour

The refrigerator should get slightly chilled and the motor will run smoothly.

4. Once the refrigerator temperature is sufficiently low You can now store food in the refrigerator. After starting the refrigerator, it takes a few hours to reach the appropriate temperature. When the system’s power is initially engaged, the default set temperatures are –4 degrees for the freezer and 38 degrees for the refrigerator, respectively.

Sealed System This system is in charge of the refrigeration cycle and the cool air circulation route. The responsibility for each of the major components is as follows:

1. Compressor - When the compressor is on, it forces the gas through the system. 2. Sub Condenser - Used to cool down the system. 3. Side Cluster Pipe - Used to cool down the system. 4. Hot pipe - Designed to prevent condensation. 5. Dryer - Used to control condensation. 6. Capillary Tube - Controls the pressure and flow of the refrigerant as it enters the

evaporator. 7. Freezer and Refrigerator Evaporators - Causes a pressure drop, this drop turns

the refrigerant to gas. 8. Suction Pipe - Attached to the compressor, used to transport the gas.

Figure 6

Operation Functions 1. Power Freeze (Quick ice) Function

When the Power Freeze (Quick ice) button is pressed the LED indicator will immediately light up. Please allow 10 seconds lag time to begin the actual operation. When this button is pressed again, the power freeze (Quick ice) function stops and the indicator will turn off. If you select Power Freeze (Quick ice), the interior temperature of the freezer will be set to -14 degrees Fahrenheit, until the ice bucket is filled up with ice cubes. When the ice bucket is filled up, the freezer will return to it’s original set temperature. Also, whenever the ice bucket full lever bar is released from being filled with ice cubes, the freezer will return to the Power Freezer (Quick ice) function as long as the function is selected. Press the Power Freeze (Quick ice) button twice to cancel. If you use this function, energy consumption will increase. Please turn off when not using this function. Note: When the Power Freeze (Quick ice) is selected, it enables maximum ice making output. The ice-making interval is reduced from 130 minutes per tray to 92~105 minutes. (Ice making times and quantities for 24 hours will increase to approx. 15 trays/156 cubes)

2. Power Cool Function

Power Cool operation and the indicator work similarly to the Power Freeze (Quick ice) function. When power cool is selected, the Compressor and the Refrigerator-Fan operate continuously until the refrigerator reaches 25 degrees Fahrenheit. This function will be terminated after running for 2 ½ hours.

3. Child Lock Function When the child lock button is pressed for 3 seconds, the child lock indicator will come on with an audible tone. When the lock function is initialized, no function commands except the ice type button will be accepted, this function will prevent accidental setting that may be caused by children or pets. To unlock the setting function, press this button for 3 seconds again.

4. Exhibition Function

This function is for display purposes on the floor of a showroom or store. For the exhibition mode, press Power Freeze (Quick ice) and Freezer Temp. buttons simultaneously for 8 seconds until “ding dong” sounds. In this mode, most of the unit will function normally, all except the compressor and the sealed system, which will not operate. Also, there is no defrost cycle in this mode. Press Power Freeze (Quick ice) and Freezer Temp. buttons again for 8 seconds to cancel this mode. You will hear a “ding dong” sound.

Self- Diagnostic Function 1. Self-Diagnostics in the Initial Power ON

The control board performs a self- diagnostics test within one second of applying power to the unit and checks out the temperature sensors and fans. If a sensor or fan failure occurs, a corresponding LED segment will blink. When a LED

segment blinks, only the cancellation function (Press Power Freeze and Power Cool buttons simultaneously for 8 seconds) is acceptable. After replacing a bad sensor, fan or a cancellation of this function, the self-diagnostic will end.

2. Self-Diagnostics in the normal operation To select this function, press the Power Freeze and Power Cool buttons simultaneously for 8 seconds. In the self-diagnostic mode, only corresponding LED segments in the chart of figure 7 will be illuminated if a problem is detected. After a 30 second illumination of an error signal, the system will return to normal operation.

3. Additional Self-Diagnostics applied Since June 2003 (No.7 and 13 of figure 7) 1) Refrigerator compartment defrost error If defrost heating does not stop within 80 minutes after start, display will indicate error. This means there is a problem with the thermal fuse, sensor or heater. For service method of each part, refer to service manual. 2) Freezer defrost error If defrost heating does not stop within 70 minutes after start, display will indicate error. This means there is a problem with the thermal fuse, sensor or heater. For service method of each part, refer to service manual. Caution: If the unit is powered off, this function cannot be used.

Figure 8

Load Operation Check Function

Use this procedure as way to check component or mode status while the unit is operating. Procedure: In normal operation, press the Power Freeze and Power Cool buttons simultaneously for 6 seconds, the display panel will blink for 2 seconds. At this time, press the Fridge Temp. Button to get into the check mode with an audible tone. Each illuminating LED segment stands for the component, which has an output signal from the control board. Refer to figure 9 and to the chart in figure 8. This mode will terminate automatically after 30 seconds

• For the R-FAN, only one rpm is applied for the current models, so that #1 and #2 show R-FAN operation only.

• The F-FAN and C-FAN are operated at high/low rpm’s automatically depending on the operational conditions of the unit.

• #4, #5 and #6 only display the system operation state according to the ambient condition.

Figure 9

Refrigerator Temp Sensor Shift

Set Point Shift Function

This function is used to set the measurement reference points of certain temperature sensors and the water fill time of the icemaker. There are five different Point Shift Function adjustments. Freezer Temp Sensor, Fridge Temp Sensor, Icemaker Water Supply Time, Icemaker Temperature Sensor, and Cool Select Zone Temperature Sensor can be adjusted with this function Procedure: 1. Press Freezer Temp. and Power Cool buttons simultaneously for 12 seconds to get

into this mode. Note: The Reference Value or Point Shift Mode will appear in the Fridge Temp LED. The Code or Value will appear in the Freezer Temp LED. Initially, all Point Shift Modes will be set to Code, “0”. This is factory default.

2. To change the Shift Point Mode for adjustment press the Fridge Temp or Power Cool buttons. (“0” – “1” – “3” – “4” – “20”)

3. To make the actual adjustment, press the Freezer Temp button to increase the Code value. Press the Power Freeze button to decrease the Code value.

4. 20 seconds after making the adjustment, a new setting will be stored into the EEPROM and the unit will return to normal operation.

5. See reference charts below for actual data.

Freezer Temp Sensor Shift

Water Supply Time Shift

Cool Select Zone Temp Shift

Icemaker Temp Sensor Shift

Note: Setting the differential temperature on the Icemaker too high could cause the following:

1. Not fully frozen Ice. 2. Ice cubes sticking together.

Defrost Function

A defrost cycle is determined based on the accumulated compressor on time. When the power is engaged for the first time, the defrost cycle for the freezer and the refrigerator will begin after 4 hours of accumulated on-time of the compressor. A defrost interval depends on the ambient temperature, the number of door openings, and the door open time. A minimum interval is 6 hours and a maximum is 8 hours for the refrigerator, and 12 hours to 16 hours for the freezer respectively. The defrost heater on-time is determined by the defrost sensors.

Forced Operation Function (Pull-Down / R-Defrost / R-F- Defrost)

Quick check of main components of the sealed system. This Function enables a pull-down mode (Compressor Check), a defrost mode for the refrigerator only, a defrost mode for the freezer and the refrigerator at the same time. Also a cancellation is available. Entry Procedure: 1. Press and hold the Power Freeze and Fridge Temp. Buttons for 8 seconds

simultaneously to get into ready mode for forced operation. Beeping tones should sound and the display will go blank. The display panel will return to normal after 20 seconds in the ready mode if no other functions are entered.

2. At the ready mode, press any button (except Ice Type and Child Lock) once to start the pull-down operation cycle. Press any of the appropriate buttons again to start the defrost cycle of the refrigerator. Wait approximately 5 seconds between button presses or until the extended beep ends to change modes. Press one of the buttons a third time for the defrost cycle of both the refrigerator and freezer to begin. Finally, to cancel this mode hit one of the buttons for the forth time to cancel this function all together. Another way to cancel this function is to unplug the power cord and then plug it back in at any time.

Pull-Down Operation: In this pull-down mode, the compressor will start immediately (No 5 minute delay) and if the system is in the defrost cycle; it will be cancelled right away. Note: if this pull-down begins right after the compressor was off, the compressor may not start to run due to an overload condition. In this mode, the Compressor and Freezer Fan will operate continuously for 24 hours and the Refrigerator Fan will be on and off according to the set temperature (34 degrees F). After 24 hours of operation, the system will be cycled at –14 degrees Fahrenheit for the freezer and 34 degrees Fahrenheit for the refrigerator in the ready mode. Defrost Operations: In this mode, operation of the Defrost Heaters are tested. First the Refrigerator Heater is tested on its own. The second test is done in both compartments at the same time. The amount of time these modes will operate is variable (see Defrost Function above for approximations). For confirmation of heater activation from the Main PCB, check connector CN70 across the appropriate pins for AC Line Voltage to appear when activating the Defrost Operation mode. Cancellation: 1. At the R, F-Defrost mode, press any of the appropriate buttons again to return to

normal operation. The display will remain blank for approx. 8 seconds before normal operation resumes.

2. Simply unplug the power cord, and then plug it in again to return to normal operation.

Figure 11

Figure 10

Figure 12

Circuit Operations Condenser Fan Delay

Depending on the ambient room temperature, the condenser fan will operate in different modes. See figure 10 for the location view of the Condenser Fan. See figure 11 below for the operation table.

Main PCB Power Supply

The SMPS (Switch Mode Power Supply) converts the AC input voltage (115V, 60Hz) to a high DC voltage (170V) on the primary side of the Transformer. This converted DC power will be sensed in all of the windings of the Switching Transformer and will generate a constant waveform on the transformer using the high speed (100KHz) switching motion of TOP223Y (FET). The diode D104 will rectify the generated voltage into a steady 12Vdc, which is the source power used for the digital display panel and relays. The regulator (KA7805) down converts the 12Vdc into the 5Vdc source for the control board and sensor’s circuits. The Photo-Coupler PC817 is used as a feedback regulator in conjunction with the voltage divider (R102 / R103) and ZD2 to ensure that the 12Vdc line maintains the proper level.

Figure 13

Figure 14

Main PCB Main Micro Voltages VDD is located at pin 64 of the Micro. The voltage at this pin should be a steady 5Vdc. The Crystal Oscillator is located between pins 30 and 31 of the IC. The Crystal generates a sine wave voltage of approximately 3.3Vp-p. The Micro Reset is applied to pin 29. This is a low level reset so this pin will normally read 5Vdc. The Ground pin of the Micro is pin 14.

Main PCB Lamp Circuits

Figure 14 above shows the Ref and Freezer Lamp circuits. The state of the circuit pictured here is with both doors closed and the lamps off. Lamp Activation occurs when a door is opened and the switch changes contacts to allow current flow through the lamp. When a door is opened and the appropriate switch changes state, the Micro senses this as a high being applied to either pin 43 or pin 44. The Micro will detect how long the door was opened when the switch changes state again and pins 43 and 44 return low. Door openings are calculated to determine the time the Compressor will be on and how long it takes to make a tray of ice.

Figure 15

Main PCB Temperature Sensing Circuits

All six Thermistors are negative temperature coefficient (NTC) type sensors. This means that their resistance value will decrease when there is an increase in the temperature level around them. The resistance value of the thermistor will increase when the temperature decreases. There are four Thermistors in the Freezer, and two in the Refrigerator section. The Freezer Sensor is used during the cooling cycle to ensure that the proper cabin temperature is maintained in the freezer. A voltage divider is set up between the Thermistor and R303. The input voltage into pin 56 of the MICRO, is calculated by the following formula: (Rth x Vcc)/(R303+Rth) Where Rth is a corresponding resistance to the thermistors output. See Appendix 1. So, when the proper voltage level is applied to pin 56 of the Micro, the Freezer Fan will turn off. When that voltage level decreases due to a temperature increase in the freezer side the fan will turn back on during the cooling and defrost cycles. The Freezer-Defrost Sensor is connected with a Bimetal in parallel. In the normal cooling operation of the system, the bimetal is on and a voltage level of 0V (Ground) is input into the microprocessor. The Bimetal be closed when the temperature is 23º F or lower. Pin 57 is ignored during the cooling cycle. The Bimetal is the principle sensing element for the thermistor, during the defrost cycle the Bimetal will open above 54º F, and a divided voltage with the Thermistor and R304 will be sent to the microprocessor to keep sensing the freezer temperature. (The Bimetal is not applied for the products produced after the first of June) The Refrigerator Sensor operates in a similar fashion to the Freezer Sensor, so the voltage level detected at pin 59 of the Micro controls the Refrigerator Fan. The Refrigerator Defrost Sensor has no Bimetal, so pin 60 of the Micro monitors a true voltage divider during the defrost cycle to turn the Refrigerator Fan on and off to maintain the proper cabin temperature of the refrigerator. The Ambient Sensor is located on the outside of the unit on top of the Freezer section and is a part of a similar voltage divider circuit like that of the Freezer Sensor. This sensor is needed to determine fan speed as compared to the surrounding temperature of the unit. The Ice Maker Sensor (not shown in Figure 15) is used to alert the Micro of the temperature level inside the Ice Maker compartment. This is important since the Temp level is part of the calculation for determining the amount of time it will take to dump a tray of ice. The Ice Maker Sensor is a standard voltage divider circuit just like the F & R Sensor circuits.

For troubleshooting, see figure15 for Sensor test point and use Appendix 1 for the proper resistance measurements. Remember these resistance measurements should be taken when the main power is disconnected from the appliance. Also the connector to the Main PCB should be disconnected to achieve reliable readings of the sensors. THERMISTOR SPEC CHART

Temp (ºF) Res (KΩ ) Volt (V) Temp (ºF) Res (KΩ ) Volt (V) Temp (ºF) Res (KΩ ) Volt (V) -43.6 98.870 4.541 12.2 21.410 3.408 68.0 6.013 1.878 -41.8 93.700 4.518 14.0 20.480 3.360 69.8 5.792 1.834 -40.0 88.850 4.494 15.8 19.580 3.310 71.6 5.581 1.791 -38.2 84.150 4.469 17.6 18.730 3.260 73.4 5.379 1.749 -36.4 79.800 4.443 19.4 17.920 3.209 75.2 5.185 1.707 -34.6 75.670 4.416 21.2 17.160 3.159 77.0 5.000 1.667 -32.8 71.800 4.389 23.0 16.430 3.108 78.8 4.821 1.626 -31.0 68.150 4.360 24.8 15.740 3.057 80.6 4.650 1.587 -29.2 64.710 4.331 26.6 15.080 3.006 82.4 4.487 1.549 -27.4 61.480 4.301 28.4 14.450 2.955 84.2 4.329 1.511 -25.6 58.430 4.269 30.2 13.860 2.904 86.0 4.179 1.474 -23.8 55.550 4.237 32.0 13.290 2.853 87.8 4.033 1.437 -22.0 52.840 4.204 33.8 12.740 2.801 89.6 3.894 1.401 -20.2 50.230 4.170 35.6 12.220 2.750 91.4 3.760 1.366 -18.4 47.770 4.134 37.4 11.720 2.698 93.2 3.631 1.332 -16.6 45.450 4.098 39.2 11.250 2.647 95.0 3.508 1.298 -14.8 43.260 4.061 41.0 10.800 2.596 96.8 3.390 1.266 -13.0 41.190 4.023 42.8 10.370 2.545 98.6 3.276 1.234 -11.2 39.240 3.985 44.6 9.959 2.495 100.4 3.167 1.203 -9.4 37.390 3.945 46.4 9.569 2.445 102.2 3.062 1.172 -7.6 35.650 3.905 48.2 9.195 2.395 104.0 2.962 1.143 -5.8 33.990 3.863 50.0 8.839 2.346 105.8 2.864 1.113 -4.0 32.430 3.822 51.8 8.494 2.296 107.6 2.770 1.085 -2.2 30.920 3.778 53.6 8.166 2.248 109.4 2.680 1.057 -0.4 29.500 3.734 55.4 7.852 2.199 111.2 2.593 1.030 1.4 28.140 3.689 57.2 7.552 2.151 113.0 2.510 1.003 3.2 26.870 3.644 59.0 7.266 2.104 114.8 2.429 0.977 5.0 25.650 3.597 60.8 6.992 2.057 116.6 2.352 0.952 6.8 24.510 3.551 62.6 6.731 2.012 118.4 2.278 0.928 8.6 23.420 3.504 64.4 6.481 1.966 120.2 2.206 0.904 10.4 22.390 3.456 66.2 6.242 1.922

Appendix 1

Figure 15

Main PCB Display and Key Matrix

Display Operation

This model uses a decoder IC that has 4 inputs and 9 outputs. If the IC 9 decoder receives signals from Micro pins (3-6), this data will be out the Decoder in a sequence to the freezer door display. Pins 9, 14 and 15 are used for the CoolSelect Zone display.

Key Scan Function

IC9 is a Decoder IC that outputs pulse signals to the six scan lines of the key matrix. When a button is pressed, the corresponding signal will be sent to the Micro at pin 34, and the function will be executed by the Micro.

Figure 16

CoolSelect Zone Circuit

The CoolSelect Zone is a storage drawer used to implement the following functions: “Quick Cool”, “Thaw”, and “Temp. Selection” (Soft Freeze, Chill, and Cool). The CoolSelect Zone has its own additional display panel located inside the refrigerator compartment. The panel LED’s are off while the door is closed. When the refrigerator door is open, the microprocessor will sense this from the status of the door switch, and the LEDs will function. The additional sensor used in this circuit is interfaced using a three pin connector CON3. This sensor is used to measures the temperature of the CoolSelect Zone compartment only. Pin 58 of the micro is the input for sensing this Thermistor. This sensor enables the microprocessor to control the temperature of the CoolSelect Zone.

Main PCB Fan Motor Circuitry This refrigerator adopts BLDC (Brushless Direct Current) motors to reduce energy consumption. Under certain conditions, the fans will operate in 2 modes (High) or (Low) speed. Generally, the fans operate in the High mode during the day and in the Low mode at night. This function is controlled partially by how many times the doors are opened and closed during operation and the condition of the Ambient Sensor. The chart listed below gives the voltages for test points of the motors at high and low speeds. See figure 17 above for the specific test points.

Voltage of Motor Remark Test Point b

(F-Fan) Test Point c

(R-Fan) Test Point d

(C-Fan) High 11.1V 10V 10V Low 10V 10V 8.3V

Fan operation would be detected at pins 40, 41 & 42 of the Micro. (Freq (Hz) x 12 = motor rpm)

Troubleshooting:

Fan resistance measurements checking via connector CN72. All measurements are referenced from pin 7 (Com) of connector CN72 (disconnected).

CN72 Resistance CN72 Resistance Pin 6 2K Pin 3 17.7K Pin 5 1.6K Pin 2 18.2K Pin 4 1.2K Pin 1 7.6K

Figure 17

Figure 18

Main PCB Relay Control

Compressor Control The Compressor is controlled by pin 18 of the Micro. RY73 is the Relay used to complete the electrical circuit when the switch is in the bottom position. Defrost Heaters Control The Freezer Defrost Heater is controlled by pin 16 of the Micro via Relay RY71. Pin 17 of the Micro is used to control the Refrigerator Heater via RY72. Both Heaters use pin 11 of connector CN70 as a hot connection and pin 3 as a common. Each Heater has a Thermal Fuse connected in series with it. Thermal Fuse Troubleshooting: Freezer Thermal Fuse = 49.3 Ohms (Normally) Refrigerator Thermal Fuse = 94.3 Ohms (Normally) Sub Heaters Control The Home Bar, Dispenser and Water Tank Heaters are all controlled by pin 19 of the Micro through RY74.

Ice Maker Circuitry Cover Ice Solenoid The Cover Ice Solenoid, which is located in the Freezer door, is controlled by pin 27 of the Micro. Q701 and SSR71 are the interface to the solenoid. Ice Solenoid Valve The Ice Solenoid Valve is controlled by pin 20 of the Micro via RY75. The valve controls the flow of fresh water to the ice tray after the Refrigerator has dumped ice. Auger Motor / Cube Solenoid Valve The Auger Motor is controlled by pin 22 of the Micro through Relay RY76. This motor will be activated when the Ice Switch on the Freezer door is depressed. The Cube Solenoid Valve is controlled by pin 25 of the Micro via Relay RY77. This valve is activated depending on the type of ice programmed by the customer. This valve also requires Relay RY76 to be in the on position for it to operate. Ice Maker Control

Figure 19 above shown the Ice-Maker control circuitry. The Ice Maker Sensor is used as part of a voltage divider. This thermistor has a negative temperature coefficient (NTC). This means that its resistance value will decrease when there is an increase in the temperature level around it, and the resistance value of the thermistor will increase when the temperature decreases. This voltage divided level is monitored at pin 61 of the Micro and is one of the sources to determine the amount of time to dump a tray of ice. Pins 7 and 8 of the Micro are used to activate the Ejecting Motor during an ice cube dump. Pin 8 is the source to turn the motor in the Counter Clockwise direction to dump the ice, and pin 8 turns the motor back in the opposite direction to level the ice tray out. IC4 and IC5 are the Drivers Amps used to apply enough torque to the motor. The Test SW is the black button located on the Ice Maker Assy. Press this button to simulate an ice dump to ensure proper operation of the Assy. When this button is

Figure 19

Figure 20

pressed, the motor will be activated to turn (twist) the ice tray into the position where the ice would be dumped out of it. During this time, the Level SW will be closed. This applies a low to the Micro pin 51 to inform it that the ice tray is not in the normal (Flat) position. The motor will then be commanded to reverse rotation so that the tray returns to the normal position and the Level SW opens. Once this is detected by the Micro, the Ice Solenoid Valve will be turned on via RY75 to supply water to the ice tray for the next cycle to begin. The Ice Full SW is connected to the big Guide Ice Lever that runs parallel to the ice tray. When the amount of ice in the bucket pushes the level up far enough, this switch will close and the Ice Maker will stop producing ice. When the amount of ice in the bucket reduces to a low enough level so the Level SW opens, the Ice Maker will start producing ice again.

Drinking Water Circuit

Figure 21 above shows the water flow lines throughout the unit. The main components involved here are the Filter (Shared), the Valve (Separation), Water Tank (Water Option Only) and the Ice Maker (Ice Option Only). The Water Filter is located in the upper right corner of the Refrigerator cabinet. The Valve is located in the rear mechanical compartment on the lower right side looking at the unit from the back. When the Water SW is depressed on the freezer door, power will be applied to the water line side of the valve, and water will flow into the Water Tank. This will continue on past the Check Valve and out the water hose on the front. The Check Valve is used to eliminate any dripping from the water hose when the Water SW re-opens. When the ice tray returns to the level position after dumping the ice, RY75 on the Main PCB will activate and apply power to the ice portion of the valve. Water will then flow for a set duration to re-fill the tray.

Figure 21

Figure 22

Figure 23

(Refrigerator) Disassembly/Assembly Refrigerator Door Removing the Front Leg Cover

Open the freezer and refrigerator doors, and then take off the front leg cover assembly by turning the three screws counter-clockwise. See figure 22. Separating the Water Supply Line from the Refrigerator

Remove the screw from clamp (a).

Remove the water tube by pressing the coupler (2) and pulling the water tube (1) away. See figure 23.

Figure 24

Figure 25

Figure 26

Figure 27

Disassembly

With the door closed, remove the upper hinge cover (1) using a screwdriver, and then disconnect the wires (2). See figure 24.

Remove bolts (3) and ground screw (4). Then take off the upper hinge (5) in the direction of the arrow (6). Take care when removing the door to ensure that it does not fall on you.

Remove the door from the lower hinge (7) by lifting the door (8) in the direction of the arrow. See figure 26.

Remove the lower hinge (9) from the bracket lower hinge (10) by lifting the lower hinge (9) in the direction of the arrow. See figure 27.

Figure 28

Figure 30

Figure 31

Figure 29

Assembly Insert the lower hinge (1) in the lower bracket (2). See figure 28.

Place the hole in the refrigerator door (3) over the lower hinge (4). See figure 29.

Insert the upper hinge shaft (5) into the hole (6). After leveling between the upper hinge hole (7) and the hole of the cabinet (8). Reattach bolt (9) and screw (10). See figure 30.

Connect the wires from the door to the cabinet. See figure 31.

Figure 33

Figure 34

Figure 32

Put the upper hinge cover (11) on the front part the hinge (12). Reattach the front part of the cover first. See figure 32.

Reattaching the Water Tube

While pressing the front face of coupler (2), insert the water tube (1) in the coupler. Then tighten the screw on the clamp (a).

Reattaching the Front Leg Cover

Reattach the front leg cover and tighten the three screws down, as shown in figure 34.

Figure 35

Figure 36

Water Filter The water filter is located in the rear upper right-hand corner of the refrigerator. The water filter is used to filter the water for both the icemaker and the water dispenser. Removal: Turn the water filter ½ turn counterclockwise and pull it down. Installation: Align the filter with the indication mark (unlock position) and push it up while turning ½ turn clockwise until the lock position is aligned. Do not over-tighten. Filter Indicator: The indicator initially lights green. The light color will change to orange after five months of operation then to red on the 6th month. The EEPROM in the control board counts a period of time regardless of a power failure. To reset the counter and the light color, press and hold the ICE TYPE and CHILD LOCK buttons for 3 seconds simultaneously. If these two buttons are pressed simultaneously for 5 seconds, this function will cease. To restore this function, press these buttons again for 3 seconds.

Evaporator Cover In The Refrigerator

1. Pull out the screw cap and remove the screw. 2. Remove the lamp cover by unlocking the tabs and pulling the cover down. 3. Remove the water tank from the evaporator cover by unscrewing the 2 screws at the bottom of figure 36. 4. Remove the 6 screws of the evaporator cover and the 2 fixed screws of the wire connector cover. 5. Take off motor and lamp wire connector located on the upper liner. 6. Remove the ductwork of the evaporator fan.

Figure 37

Figure 38

Figure 39

Upper Ductwork 1. Remove the screw caps (2) and screws (5). 2. Slide the upper fan ductwork out while disconnecting the wire connector(lamp and thermistor) as shown in figure 37. Refrigerator Evaporator Fan Motor The evaporator fan is located in the middle rear of the refrigerator compartment. This fan circulates cold air in the refrigerator section when activated. 1. Remove the 4 screws located at

the corners of the fan bracket.

2. Take the fan assembly off the cover.

Evaporator in Refrigerator

Evaporator is located in the bottom back of the refrigerator compartment. 1. Take off the ductwork in refrigerator. 2. Disconnect the wire connector. (Heater and Thermistor) 3. Desolder the capillary tube and the suction line from the evaporator. 4. Remove the evaporator. 5. With a file, score the capillary tube just upstream of the soldered point. Break off the soldered section to help prevent solder from plugging the tube during soldering. 6. Insert a new evaporator and braze the suction and capillary tube to the evaporator using silver solder. 7. Install a replacement dryer. Note: Evacuate and recharge the system using normally approved procedures.

Figure 40

Figure 42

Figure 41

Figure 43

(Freezer) Disassembly/Assembly Freezer Door Removing the Freezer Door

Disassembly With the door closed, remove the upper hinge cover (1) using a screwdriver, and then disconnect the wires (2). See figure 40.

Remove bolts (3) and ground screw (4), and take off the upper hinge (5) in the direction of the arrow (6). Take care when removing the door to ensure that it does not fall on you. See figure 41.

Remove the door from the lower hinge (7) by lifting the door (8) in the direction of the arrow. See figure 42.

NOTE: Lift the door straight up to prevent damage to the bottom hinge. Be careful not to pinch the water tubing and wire harness on the door. Place doors on a protected surface.

Remove the lower hinge (9) from the bracket lower hinge (10) by lifting the lower hinge (9) in the direction of the arrow. See figure 43.

Figure 44

Figure 45

Figure 46

Assembly

Insert the lower hinge (1) in the lower bracket (2).

Reattach the freezer door by inserting the hose (3) from the lower side of the door into the hole of the lower hinge (4), and pull the hose down.

Insert the upper hinge shaft (5) of the cabinet into the door’s hole. After adjusting the level between the upper hinge hole (7) and the hole of the cabinet (8), reattach the three bolts (9) and screw (10).

Figure 47

Figure 48

Connect the wires as shown in figure 47.

Put the front part of the upper hinge cover (11) on the front part of the upper hinge (12) and reattach from the front part of the upper hinge cover first. See figure 48.

Figure 49

Figure 50

Disassembly/Assembly Control Panel Disassembly: Insert a flat-head screwdriver in the slots located on the bottom of the control panel and unlock the tabs. After removing the panel, disconnect the wire connector from the PCB. Assembly: Connect the wire connector back to the PCB. Line up the panel and snap the locking tabs back into place.

.

Door Gasket, The door gasket is a molded into a channel located in the door liner. 1. Open the door. 2. Grasp the gasket and pull in an outward motion until the molded gasket separates from the door liner.

Note: Reference Gasket Seal Test procedures on page 5 of this manual.

Figure 51

Figure 52

Figure 53

Ice Dispenser And Ice Maker The ice dispenser is located in the upper left hand portion of the freezer. This assembly is used to store ice made by the icemaker and dispense the ice. Lift the ice bucket up ① and slide out the ice

dispenser assembly ②.

The icemaker is located inside of the ice dispenser assembly.

Removal 1. Remove the 2 icemaker support screws and slide out the assembly. 2. Disconnect the icemaker wire connector. 3. Unlock the locking tabs to separate the icemaker kit.

Assembly 1. Assemble together the geared motor shaft and the front of ice tray. 2. Lift the front locking tab and assemble the icemaker kit. 3. Connect the icemaker wire connector. 4. Match the tab holes and 2 tabs located on the top of the liner, and slide the icemaker into position. 5. Tighten the 2 screws to the icemaker support.

Figure 54

Auger Motor Case

This shelf is designed to support the icemaker / ice dispensed and the Xtra-Space area. 1. Remove the Xtra-Space cover by pushing it down and pulling it forward. 2. Slide the partition out. 3. Remove the 2 screws on the bottom front of the case. See figure 54. 4. Slide out the case while disconnecting the wire harness behind it.

Figure 55

Figure 56

Evaporator Cover in Freezer

1. Pull out the screw caps and remove 6 screws. 2. Remove the ductwork of the evaporator fan in the direction of the arrow as shown. 3. Disconnect the wire connector in the rear of the cover as shown in figure 55.

Upper Ductwork

1. Remove the screw cap and screw. 2. Slide the upper fan ductwork out while disconnecting the wire connector (Lamp and Thermistor) as show in figure 56.

Figure 57

Figure 58

Freezer Evaporator Fan Motor

The evaporator fan is located in the mid-section of the freezer compartment. This fan circulates very cold air in the freezer when activated. 1. Remove 4 screws located at the corners of the fan bracket. See figure 57. 2. Take the fan motor assembly off.

Evaporator in Freezer

The Evaporator is located in the lower to middle section of the freezer compartment. 1. Take off the ductwork in Freezer. 2. Disconnect the wire connector (Heater, Bimetal, and Thermistor). 3. Desolder the inlet and outlet tubes. 4. Remove and replace the evaporator. 5. Take the same steps to seal the system as mentioned in the refrigerator evaporator removal procedures on page 29 of this Training Manual.

Figure 59

Figure 60

Figure 61

Machine Compartment Disassembly/Assembly Machine Compartment and Electric Box

1. Disconnect the power cord of the refrigerator. 2. Remove 6 fixed screws of the compressor cover.

3. Slide up and take off the compressor cover to see the machine compartment.

Main PCB

1. Remove 2 screws to remove the Electric Box from the machine compartment. 2. Pull the box out of the compartment so that it is hanging on the floor. 3. Press the tab in electric box cover with a flat head screwdriver to separate the top cover from the bottom and expose the main PCB.

Figure 62

Figure 63

Figure 64

Water Solenoids

There are two solenoids in one package. One is for the water dispenser, the other supplies water to the icemaker. Both are controlled by the Micro located on the Main PCB. 1. Remove 1 bracket screw on electric box. 2. Take the solenoids assembly out of the machine compartment. 3. Disconnect the 3 water tubes.

Condenser Fan

The condenser Fan is located in the middle of machine compartment. It blows out the hot air in the machine compartment created by the Sub Condenser and the Compressor. 1. Disconnect the condenser fan wire. 2. Remove 1 screw on the drain water tray. 3. Take the condenser fan assembly out.

Sub Condenser The sub-condenser is located in the machine compartment. The heat is extracted by condenser fan. 1. Desolder the compressor discharge and the sub-condenser outlet. 2. Take out the sub-condenser.

Troubleshooting Tips and Bulletins SUBJECT: Dealer showroom “Exhibition Mode”. SYMPTOM: The complaint will be no cooling in either the Freezer or Refrigerator compartments. The Compressor is not activating. However, the button and indicators on the front display operate normally and the internal lights turn on when the doors are opened. REPAIR: The unit might be in the “Exhibition Mode”. This is a normal function of the refrigerator for display on the Dealer show floor. Use the following procedure to exit the “Exhibition Mode”:

Hold down the POWER FREEZE and FREEZER TEMP buttons simultaneously for eight seconds until the unit makes an audible tone.

SUBJECT: Part number missing in service manual. SYMPTOM: Missing part number for the water filter receptacle assy. REMARKS: Part Number (DA97-00725B)

Note: Water filter receptacle assy.

SUBJECT: Water leaking at the filter. SYMPTOM: Water leaking at the filter. REMARKS: If the filter is installed incorrectly, it will leak water. REPAIR: Please make sure you line up the filter correctly to avoid water

leak. INTSRUCTIONS: 1. Turn the water filter 1/2 turn counterclockwise and pull it down. 2. To install the filter, align the indication mark (unlock position)

and push it up while turning ½ turn clockwise until the lock position is aligned. Do not over-tighten.

.

Note: If the filter is removed, you will still get water to the icemaker and water dispenser. SYMPTOM: The Unit is only cycling once and will not cool after that, usually on the Freezer side. However, if you unplug then plug the unit back in it will work again for one cycle. REPAIR: Check Ohm readings on thermal fuse. When fuse is open the Defrost cycle will be inhibited and the unit will not cool again until reset.

Product: Refrigerator SBS Bulletin No.: Model: RS2533SW, RS2555SW(SL), Bulletin Date: 02/18/03 RS2577SW, RS2577SL

Subject: Slow or no ice production. Background: Proper way to test for problem. Solution: Initially, have customer run the following test to determine whether problem is operational or if unit needs service.

A. Start with empty ice bin and run for 24 hours at the default settings.

B. 12 Trays or 120 cubes should be made during this time. If so unit is OK.

C. If 50 to 80 cubes are produced during this time frame, instruct to try the

test again using a lower temperature or the Power Freeze function. If OK, then problem is the environment and these settings should compensate.

D. If less than 50 cubes are produced during the initial 24 hour test, then

service call is required. Service technician should run self-diagnostic procedures starting on page 31 of the service manual. Replace listed parts that come up as errors.

E. If self-diagnostic yields no clear indication, use the Set Point Shift

Function starting on page 34. Lower option 4 on page 36 of service manual icemaker temperature sensor.

This bulletin is for the production date before June2003.The serial no is xxxx43CT6xxxxxx~ xxxx43CW5xxxxxx. From June products to be used Quick ice function.For RS2533SW,2555SW/SL. But not for 2577)

To speed up the ice making for a old model (before June 2003), please Replace main PCB with yellow label. (RS2533SW:DA41-00134D/ RS2555SW/SL:DA41-00104E). HomePAD is not ready. The Power Freeze (Quick ice) function refer to owner’s manual and Training manual page 7.

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