R-122 SERVICE MANUAL MATRIX 18.2 CU FT TOP MOUNT REFRIGERATOR WRT138FZDB**, WRT138FZDM**, WRT138FZDW** *All Engineering Versions W10881764
FORWARD This Whirlpool Service Manual, (Part No. W10881764), provides the In-Home Service Professional with service information for the 18.2 CU FT TOP MOUNT REFRIGERATOR. The Wiring Diagrams used in this Service Manual are typical and should be used for training purposes only. Always use the Wiring Diagram supplied with the product tech sheet when servicing the refrigerator. For specific operating and installation information on the model being serviced, refer to the Use and Care Guide or Installation Instructions provided with the refrigerator. GOALS AND OBJECTIVES The goal of this Service Manual is to provide information that will enable the In-Home Service Professional to properly diagnose malfunctions and repair the 18.2 CU FT TOP MOUNT REFRIGERATOR. The objectives of this Service Manual are to: Understand and follow proper safety precautions. Successfully troubleshoot and diagnose malfunctions. Successfully perform necessary repairs. Successfully return the refrigerator to its proper operational status. WHIRLPOOL CORPORATION assumes no responsibility for any repairs made on our products by anyone other than authorized In-Home Service Professionals. ii 18.2 Cu Ft Top Mount Refrigerator Copyright 2016, Whirlpool Corporation, Benton Harbor, MI 49022
18.2 Cu Ft Top Mount Refrigerator SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS REFRIGERATOR SAFETY...1-2 MODEL & SERIAL NUMBER LABEL LOCATION...1-3 TECH SHEET LOCATION...1-3 NOTES...1-4 SECTION 2 THEORY OF OPERATION DIAGNOSTICS & TROUBLESHOOTING: SAFETY INFORMATION...2-2 POWER DISTRIBUTION...2-3 REFRIGERATION SYSTEM...2-4 WATER & ICE SYSTEM...2-5 DEFROST SYSTEM...2-5 LIGHTING SYSTEM...2-5 NOTES...2-6 SECTION 3 DIAGNOSTICS & COMPONENT ACCESS DIAGNOSTICS...3-2 COMPONENT ACCESS...3-3 18.2 Cu Ft Top Mount Refrigerator iii
PRODUCT SPECIFICATIONS & WARRANTY INFORMATION SOURCES (inside back cover) iv 18.2 Cu Ft Top Mount Refrigerator
GENERAL INFORMATION Section 1: General Information This section provides general safety, parts, and information for the 18.2 Cubic Foot Top Mount Refrigerator Refrigerator Safety Model & Serial Number Location Tech Sheet Location 18.2 Cu Ft Top Mount Refrigerator 1-1
GENERAL INFORMATION Refrigerator Safety Your safety and the safety of others are very important. We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word DANGER or WARNING. These words mean: DANGER You can be killed or seriously injured if you don't immediately follow instructions. WARNING You can be killed or seriously injured if you don't instructions. follow All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed. 1-2 18.2 Cu Ft Top Mount Refrigerator
GENERAL INFORMATION Model & Serial Number Location The Model & Serial Number tag is located in the Refrigerated Compartment on the left side liner near the top (Figure 1). FIGURE 1: Model & Serial Number location Tech Sheet Location The Tech Sheet is located on the bottom rail of the machine compartment in the rear of the unit (Figure 2). FIGURE 2: Tech Sheet Location 18.2 Cu Ft Top Mount Refrigerator n 1-3
GENERAL INFORMATION Notes 1-4 18.2 Cu Ft Top Mount Refrigerator
THEORY OF OPERATION Section 2: THEORY OF OPERATION This section provides information on Theory of Operation for the 18.2 Cu Ft Top Mount Refrigerator. Power Distribution Refrigeration System Defrost System Lighting System Component Access Diagnostic & Troubleshooting 18.2 Cu Ft Top Mount Refrigerator 2-1
THEORY OF OPERATION For Service Technician Use Only DANGER WARNING Electrical Shock Hazard Only authorized technicians should perform diagnostic voltage measurements. After performing voltage measurements, disconnect power before servicing. Failure to follow these instructions can result in death or electrical shock. Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. Voltage Measurement Safety Information When performing live voltage measurements, you must do the following: Verify the controls are in the off position so that the appliance does not start when energized. Allow enough space to perform the voltage measurements without obstructions. Keep other people a safe distance away from the appliance to prevent potential injury. Always use the proper testing equipment. After voltage measurements, always disconnect power before servicing. IMPORTANT: Electrostatic Discharge (ESD) Sensitive Electronics ESD problems are present everywhere. Most people begin to feel an ESD discharge at approximately 3000V. It takes as little as 10V to destroy, damage, or weaken the main control assembly. The new main control assembly may appear to work well after repair is finished, but a malfunction may occur at a later date due to ESD stress. Use an anti-static wrist strap. Connect wrist strap to green ground connection point or unpainted metal in the appliance -OR- Touch your finger repeatedly to a green ground connection point or unpainted metal in the appliance. Before removing the part from its package, touch the anti-static bag to a green ground connection point or unpainted metal in the appliance. Avoid touching electronic parts or terminal contacts; handle electronic control assembly by edges only. When repackaging main control assembly in anti-static bag, observe above instructions. IMPORTANT SAFETY NOTICE For Technicians only This service data sheet is intended for use by persons having electrical, electronic, and mechanical experience and knowledge at a level generally considered acceptable in the appliance repair trade. Any attempt to repair a major appliance may result in personal injury and property damage. The manufacturer or seller cannot be responsible, nor assume any liability for injury or damage of any kind arising from the use of this data sheet. 2-2 18.2 Cu Ft Top Mount Refrigerator
POWER DISTRIBUTION The refrigerator components operate at 120 VAC and 5 VDC. This section describes how power is supplied to the refrigerator and distributed to the control board(s). The control board(s) provide power output to individual components. POWER SUPPLY 120 VAC Power is supplied to the refrigerator at the Machine Compartment by a plug. From the Machine Compartment, 120 VAC Power is routed to the Refrigerator Compartment (RC), and the Freezer Compartment (FC). The 120 VAC routed to the FC terminates at the liner side connector for the optional Ice Maker. The 120 VAC routed to the RC is factory spliced and routed to the RC Light, Hercules Control Board at CN2-4, and on some models, to the FC Light. For Service Technician Use Only THEORY OF OPERATION 5 VDC Supply The CB generates 5 VDC power from the 120 VAC power supply. The 5 VDC power is used to power loads. 5 VDC Load(s) The CB supplies 5 VDC power to the following loads: RC Thermistor FC Thermistor Evaporator/Defrost Thermistor HERCULES CONTROL BOX The Hercules Control Box (CB) (Figure 1) is located in the RC, in the housing for the User Interface (UI). FIGURE 1: Hercules Control Box 120 VAC Supply 120 VAC power from the power cord is supplied to the CB at CN2-4. 120 VAC Load(s) The CB supplies 120 VAC power to the following loads: Compressor Condenser Fan Evaporator Fan, and Defrost Heater 18.2 Cu Ft Top Mount Refrigerator 2-3
THEORY OF OPERATION REFRIGERATION SYSTEM OPERATION The refrigeration system compares actual Refrigerator Compartment (RC) temperature to the set-point temperature. If the temperature is too warm, the sealed system operates to cool the RC and Freezer Compartment (FC). For Service Technician Use Only Evaporator TEMPERATURE SET-POINTS The refrigerator maintains the RC temperature at the designated set-point. The temperature set-points for the RC is set using the Control Box/User Interface (UI)in the RC. The UI has three pre-determined set-points. UV Dye Drier TEMPERATURE SENSING The refrigerator compares the actual RC temperature to the RC temperature zone set-point to determine when cooling is necessary. Actual temperature of the RC is detected by a thermistor located in the RC Air Diffuser. Freezer Compartment Temperature Control The Sealed System operates to cool the RC and FC simultaneously in response to input received from the RC thermistor. The FC temperature is derived by an air damper controlling air flow to the RC. Temperature Control Theory The evaporator is located in the FC behind the rear wall. The FC evaporator fan is mounted in front of the evaporator and draws a suction on both the RC and FC. The evaporator and fan are enclosed in a styrofoam air plenum containing an air duct which directs a portion of the air down and into the RC through an air damper located in the plenum. The remaining portion of the air is directed into the FC. The air damper is controlled by the Freezer Temperature Selector Switch. This switch has three positions, the position of the switch determines the volume of air flowing to the RC. As the air damper is moved towards the MIN FC position, the damper restricts air flow to the RC, and increases air flow to the FC and cooling time required to satisfy the RC temperature setpoint. In this manner, the RC temperature remains near the UI setpoint temperature, while the FC temperature changes according to the position of the FC Temperature Selector Switch. SEALED SYSTEM The sealed system uses a standard compressor to drive the refrigeration cycle (FIGURE 2). Refrigerant is pumped through the condenser and a UV Dye Drier to the Evaporator in the FC. The compressor takes a suction on the outlet of the evaporator. Compressor Condenser AIR FLOW Air flow in the temperature controlled compartments is provided by the single evaporator fan located in the FC evaporator area. Proper air flow allows efficient removal of heat and uniform temperature distribution in each zone. The air flow system uses a condenser fan to provide air flow in the machine compartment, cooling equipment and removing waste heat from the condenser. REFRIGERATOR COMPARTMENT AIRFLOW Airflow is driven by the FC evaporator fan. Air flow is directed through the styrofoam plenum and FC damper to the RC. FREEZER COMPARTMENT AIRFLOW Airflow is driven by the FC evaporator fan. Air flow is directed through the styrofoam plenum into the FC. The FC Evaporator Fan is a single speed fan. It is powered by 120 VAC from Control Board connector CN1-3. It is wired in parallel with and operates together with the compressor and Condenser Fan. MACHINE COMPARTMENT AIRFLOW The Machine Compartment is cooled by the Condenser Fan. The Condenser Fan is a single speed fan. It is powered by 120 VAC from Control Board connector CN1-3. It is wired in parallel with and operates together with the compressor and Evaporator Fan. 2-4 18.2 Cu Ft Top Mount Refrigerator
Water & Ice System Select models of the refrigerator come equipped with a optional Modular Ice Maker and Water Valve. Models with the water valve may also have the Modular Ice Maker added at a later time. Water Supply Water is supplied to the Modular Ice Maker through the Water Valve. The Water Valve is powered by 120 VAC. Power to the Water Valve is supplied by timing circuitry internal to the Modular Ice Maker. For Service Technician Use Only THEORY OF OPERATION LIGHTING SYSTEM The Lighting System provides light for the Refrigerator Compartment (RC), and on some models, the Freezer Compartment (FC). RC Lighting The RC has a socket for a single standard incandescent type bulb. The bulb is supplied with a constant 120 VAC and is in series with a normally open switch. When the RC door is opened, the door switch closes, turning on the light. Modular Ice Maker The Modular Ice Maker is powered by 120 VAC. The power is supplied directly from the power cord, via a splice in the transition grommet in the Machine Compartment. The Modular Ice Maker contains a timer which controls operation of the Ice Maker Fill, Timing, and Harvest cycles. See the Tech Sheet included with the Ice Maker for further information. FC Lighting Select models contain an FC light which operates identically to the RC lighting described previously. DEFROST SYSTEM The defrost system is designed to remove ice build-up from the Freezer Compartment (FC) evaporator. FC defrost is accomplished using an 120 VAC Heater An Adaptive Defrost Control (ADC) routine determines when a defrost cycle is needed. ADC monitors Compressor operation, and door openings as the primary inputs. Normal Operation During defrost, 120 VAC power is applied to the heater from Control Board connector CN1-5. The FC Evaporator Thermistor monitors the temperature during defrost. When the FC Evaporator Thermistor reads 41 F (5 C), or after 25 minutes, whichever comes first. Defrost is ended by removing the 120 VAC power from Control Board connector CN1-5. Backup Operation There is a thermal fuses wired in series with the defrost heater. The thermal fuse is designed to interrupt the defrost cycle if the normal method does not function properly. The thermal fuses open at 183 F (84 C), interrupting power to the heater. 18.2 Cu Ft Top Mount Refrigerator 2-5
THEORY OF OPERATION NOTES 2-6 18.2 Cu Ft Top Mount Refrigerator
DIAGNOSTICS & COMPONENT ACCESS Diagnostics & Component Access This section provides instruction on Diagostics and Component Access for the 18.2 Cu Ft Top Mount Refrigerator. Diagnostics Component Access 18.2 Cu Ft Top Mount Refrigerator 3-1
DIAGNOSTICS & COMPONENT ACCESS For Service Technicians Use Only REFRIGERATION SYSTEM DIAGNOSTICS & TROUBLESHOOTING Overview Diagnostics contains Service Tests to troubleshoot and identify the cause of most system problems. Use of the on-board diagnostic routine will increase the speed and accuracy of troubleshooting. Always use the tech sheet provided with the refrigerator when running diagnostics. To Access diagnostics: ¾ Press SW1 until LED1 is lit (Figure 1). ¾ Press and Hold the Refrigerator Door Switch ¾ Press and Hold SW1 for 5 Seconds (Figure 1) ¾ Release both switches when all LED s turn on. LED s will go out after 10 seconds. To Navigate Diagnostics: ¾ Use the tech sheet provided with the product, or found on Service Matters to navigate diagnostics. ¾ Advance through the Seven Diagnostic Steps sequentially by pressing SW1 (Figure 2). ¾ Table 1 on the Tech Sheet lists the components tested during each Step. The LED Display pattern can be used to determine the current Step number if you lose track. To Exit Diagnostics: Service Diagnostics will Exit: ¾ After 20 minutes, Or Or ¾ After Cycling Power to the Refrigerator, ¾ After advancing to Step 7. NOTE After advancing to Step 7, the refrigerator will resume normal operation if no errors were detected in Step 5 or Step 6. NOTE After advancing to Step 7, all 3 LED s will flash if a failed component was detected in Step 5 or Step 6 3-2 18.2 Cu Ft Top Mount Refrigerator
Component Access For Service Technicians Use Only WARNING DIAGNOSTICS & COMPONENT ACCESS 5. Remove the six (6) plastic Hole Plugs from the back of the freezer liner. 6. Remove the six (6) ¼ screws from the back of the freezer liner. 7. Remove the Ice Maker Fill Tube Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 8. Depress the two clips on Ice Maker wiring connected and push the connector through the back wall. 9. Pull at the top corners of the evaporator cover to remove. (It is helpful to use a small 1/8 Allen wrench to pull at the top right corner). Electronic Control Board 1. Remove the two (2) ¼ screws attaching the control box to the top of the refrigerator liner. 2. Use a small flat blade screwdriver to release the wiring connector at the top of the refrigerator liner. 3. Remove the two wiring connectors from the electronic control board. 4. Slide the electronic control board upwards to remove it from the track on the control box. Refrigerator Thermistor 1. Use a small flat blade screwdriver to release the two clips at the top left and right of the air diffuser cup and remove. Condenser Fan 1. Remove the ¼ hex head screw at the top of the fan bracket. 2. Remove the ¼ hex head screw at the bottom of the fan bracket. NOTE: Due to clearance restrictions, it may be easier to use a ¼ crescent wrench to remove the screw. 3. Slide the fan out approximately 1, then tilt the top of the fan assembly back and to the left to clear the plastic molding in the drip tray. 4. Disconnect the wiring harness and remove the fan. 2. Remove the two (2) ¼ screws from the air diffuser cover. 3. Disconnect the thermistor wire connector and remove from the thermistor from the clip inside the air diffuser cover. Evaporator Cover 1. Remove the freezer shelf. 2. Remove the three (3) Philips head screws for the Ice Maker. 3. Disconnect the Ice Maker wiring connector. 4. Place the freezer temperature damper to the Min position. 18.2 Cu Ft Top Mount Refrigerator 3-3
DIAGNOSTICS & COMPONENT ACCESS Notes 3-4 18.2 Cu Ft Top Mount Refrigerator
PRODUCT SPECIFICATIONS & WARRANTY INFORMATION SOURCES IN THE UNITED STATES: FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL: FOR WHIRLPOOL PRODUCTS: 1-800-253-1301 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER S HOME CALL: THE TECHNICAL ASSISTANCE LINE: 1-800-832-7174 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED IN-HOME SERVICE PROFESSIONAL FOR LITERATURE ORDERS (CUSTOMER EXPERIENCE CENTER): PHONE: 1-800-851-4605 FOR TECHNICAL INFORMATION AND SERVICE POINTERS: www.servicematters.com IN CANADA: FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL PHONE: 1-800-461-5681 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER S HOME CALL: THE TECHNICAL ASSISTANCE LINE: 1-800-488-4791 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED IN-HOME SERVICE PROFESSIONAL
18.2 CU FT TOP MOUNT REFRIGERATOR W10881764