2018 REFRIGERATION TRAINING

Top Freezer Refrigerators

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Connect water line if unit has an icemaker. Check for leaks.

Icemaker information:
How to cycle Icemaker.
Freezer must be at a minimum of 15 degrees for icemaker to make ice.

Level Refrigerator --- Level refrigerator side to side but tilt to the
rear just enough so that the Fresh Food door closes by itself from a
45 degree opening.

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Installation

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 Installation Don’ts

Not enough air space

around refrigerator South facing window

Near heat register

Range too close

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Installation

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Installation

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Installation

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Installation

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 Not Cooling or Not Cooling Properly
• Check power cord/outlet – 120VAC
• Check the temperature control
• Check door gaskets – no gaps/damage
• Check door light switches – light has to go off – open freezer door & peel back fresh
food door gasket
• Check for clean condenser
• Check freezer & condenser fan for operation
• Check for thick accumulation of frost on the rear freezer wall which indicates a defrost
system fault
• Check defrost control operation – manually turn defrost timer – also check defrost
thermostat & heater
• Check compressor operation – electrical components (relay, overload, & wires – use
Ohmmeter)

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 Door Gasket Replacement
➢ To remove the gasket, grasp at one
corner & pull it from the retainer.
➢ To replace the gasket start at one
corner & press the rib firmly into the
retainer.

Note: gaskets may come shipped in packaging

that renders them slightly twisted and out of shape.
Soaking a new gasket in warm soapy water is
recommended to make them more pliable for
installation.

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 Air Flow
The freezer fan moves the warm air
from the interior through the cold
evaporator coil in the freezer.

The cold air is circulated through the

freezer removing heat from the from
the air and the contents

The freezer fan also circulates some

air into the fresh food section through
the control housing

Warm air is returned into the freezer

by the air return duct

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 Air Flow

Air Supply Duct From

Freezer

Air Return Duct to Freezer

Defrost Drain Tub

Inside the Liner

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The Main Operational Components of a
Refrigerator
Temperature Control

Defrost Timer
Defrost Thermostat Defrost System
Defrost Heater

Evaporator Fan
Condenser Fan Air Flow

Compressor
Overload Compressor Assembly
Relay
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 Test Equipment
WX5X603
A MultiMeter is necessary to check AC voltage,
resistance or ohms Ω and high temperature.

Selections:
• AC Voltage
• Ohms Ω
• Temperature

Leads:
o
• 90 Leads with sharp tips insulated to the tip
• Hi Temp Lead

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Not Cooling or Not Cooling Properly
Check for power at outlet – 120VAC and the polarity is correct

Neutral L1

Ground

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 Not Cooling or Not Cooling Properly
Temperature Control Setting
Check control setting for usage – ‘Colder’ which is recommended– if you change settings
must wait 24 hrs. to let refrigerator stabilize

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 Not Cooling or Not Cooling Properly
Temperature Control

With the control in any on position read

across the terminals and it should read
‘0’ ohms with warm temperatures

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 Not Cooling or Not Cooling Properly
Check door light switches – press with thumb to see if light goes out & check
to make sure light goes out with door closed – open freezer door & peel back
top of fresh food door gasket

L1 N

Place meter leads here or here

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 Not Cooling or Not Cooling Properly
Clean Condenser

Clean the condenser regularly with a brush, vacuum

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Not Cooling or Not Cooling Properly

16
8Ω

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Not Cooling or Not Cooling Properly

S
pr
in
g
cli
p

D
e
pt
h
1/
1
6
”
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 Not Cooling or Not Cooling Properly

Remove icemaker and shelf.

Place small flat blade screwdriver in The Air Tower

slot and gently push up

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Not Cooling or Not Cooling Properly
Gently push in on either side and lift up, swing bottom outward and
slightly pull down for Air Tower tabs to clear evaporator cover.

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 Not Cooling or Not Cooling Properly
• Remove air baffle from air duct

• Remove two 1/4” hex head screws.

• From the fan orifice, pull evaporator cover outward

to remove.

• Make sure the foam baffle is reinstalled or it will

not cool properly.

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 DEFROST SYSTEM
ELECTROMECHANICAL
DEFROST
TIMER
Normal Frost Pattern On Evaporator
Not Cooling from No Defrost

What do you do???

There Are 4 Possibilities

 Defrost System – Defrost Control

1.

Defrost Control
 Defrost System – Defrost Heater

2.

Defrost Heater
Defrost System – Defrost Termination Thermostat

3.

Defrost Termination Thermostat

 Defrost System – Defrost Wiring Harness

4.
Defrost wiring harness is all the wires and
connectors connecting the defrost control,
heater and termination thermostat together.
 Defrost System
Defrost Control aka Defrost Timer
•The defrost control used on most models is a electro-mechanical timer.
• It consists of a clock motor, attached to an insulated housing that contains a cam, and a single pole, double throw switch.
• The terminals are clustered together at one end of the control housing.

2 3 4 1
 Defrost System
Defrost Timer aka Defrost Control
• The purpose of the defrost control is to regulate the frequency & duration of the defrost cycles
• This is accomplished by energizing the clock motor to drive a set of gears that, in turn, rotates the cam which operates
the switch.
• The timer can be manually advanced by turning the shaft clockwise with your finger or a flat bladed
screwdriver until a loud click is heard.
• This will advance the defrost timer into defrost or out of defrost depending where the switch contacts are located on
the cam.
 Defrost System – Control Contacts
Run Cycle
• One complete rotation of the defrost control
consists of the run cycle and the defrost cycle.
• The purpose of the defrost control is to regulate
the frequency and duration of the defrost and
run cycles
234 1
• This is accomplished by the temperature
control energizing the control’s clock motor to
drive a set of gears that, in turn, rotate the cam 4

which operates the switch.

2
• At the beginning and ending of the defrost cycle
3 1
an audible "SNAP" can be heard each time a
switch blade drops off the edge of the cam. DEFROST
CONTROL
 Defrost System – Control Contacts
Run Cycle Before Defrost
• Just before defrost cycle begins the cam has rotated to the
position where a mark on the cam aligns with a mark on the
control housing.

Contacts 2 – 3 Open 2 1 4 3
Blue
2
4
Aqua 3
2
4
Black
3 1

DEFROST
Contacts 3 – 4 Closed CONTROL
 Defrost System – Control Contacts
Defrost Cycle
• At this position, terminal 4 switch blade drops off the edge of the cam
starting the Defrost Cycle.
• This opens contacts 3 to 4 and closes contacts 3 to 2.

Contacts 2 – 3 closed 234 1

Blue
2
4
Aqua
3
2
Black 4
3 1
DEFROST
Contacts 3 – 4 Open CONTROL
 Defrost System – Control Contacts
Run Cycle After Defrost
• As the cam continues to rotate, terminal 3 switch blade will drop off the edge of the cam.
• This opens contacts 3 to 2 and closes the first set of contacts 3 to 4, ending the defrost
cycle and starting the run cycle.

234 1
Contacts 2 – 3 Open
Blue
2
Aqua 4
3

Black
4 2

3 1

Contacts 3 – 4 Closed DEFROST

CONTROL
 Defrost System
Defrost Control aka Defrost Timer
• The controls can be found in the control panel inside the fresh food compartment mounted to the control console.
• Refer to the service guide or mini manual for the model being serviced for exact information.

CORRECT TIMERS MUST BE USED WHEN BEING REPLACED

 Control Console
The defrost timer is located on the fresh food control console mounted to the FF ceiling.
Defrost System Defrost Termination T’stat
 Defrost System
Defrost Termination Thermostat
• The purpose of the defrost thermostat (Bi-metal), located on the evaporator, is to de-energize the
heater, during the defrost cycle, when the frost has melted from the evaporator.
• After all frost has been completely removed from the evaporator, the temperature of the evaporator
begins to rise.
• When the limit temperature of the thermostat is sensed, the bimetal disc warps and pushes the transfer
pin against a switch blade which opens the switch contacts.
• When the temperature of the evaporator has cooled sufficiently, the bimetal disc warps in the opposite
direction.
• Then, the spring-loaded switch blade pushes the transfer pin out of the way and closes the contacts.
 Defrost System
• Defrost thermostats are rated with respect to the specified limit temperature -- the temperature at
which the thermostat is designed to open.
• This thermostat opens at 64oF, as indicated with the first number. The differential being 41, so
64 – 41 = 23; this thermostat will close again at 23oF.
• Temperature limit specifications are stated in the Mini-Manual for each respective model.
 Wire Splicing
WR97X163 Silicone grease
WR01X10466 Small Bell Connector
WR2X4330 Large Bell Connector

When replacing a defrost thermostat use large WR2X4330D bell connectors

 Defrost System
Defrost Heater
• Defrost Heaters can be of the Calrod® type above, or radiant style, below (coiled heater in a glass tube).
• Both heaters will be attached to the lower portion of the evaporator.

Glass Tube Radiant Heater

Calrod® Type Heater

Click below to play video
 Electromechanical Defrost
Diagnostics
Test points in the compressor harness connector
Machine Cabinet
4 1 Orange 1 4
2 White 2
5 5
Black
6 Brown 6
3 3
Pink
Blue

3 1
DEFROST
CONTROL
Electromechanical Defrost Schematic
 Defrost Termination Thermostat Testing
Alternative test of Defrost Thermostat:
Cut and strip
• Leave the thermostat attached to the lead wires
cold evaporator.
• Disconnect power to the refrigerator.
• Cut and strip lead wires going to the
defrost thermostat.
• Using your ohm meter check for
continuity across both lead wires.
•If shows continuity it will have to be
spliced back into the harness
DEFROST SYSTEM
ELECTRONIC
DEFROST
CONTROL
Abnormal frost on evaporator from defrost system failure

What do you do???

 Adaptive Defrost Control
• On some models the conventional defrost timer has been replaced by an electronic defrost control board.
• These refrigerators use less electricity by more precisely controlling the defrost cycle.
• Adaptive defrost interval is set from 8 to 80 hours depending on compressor run time and door openings.
• These models still incorporate a conventional cold control for compressor operation.
 Adaptive Defrost Control
• Once you have removed the control housing from the ceiling of the refrigerator; you
will see the control box that houses the defrost control board.
• To open the cover, remove the push pin.
 Adaptive Defrost Control
• The defrost control board is also held in place by a plastic push pin.

Top Freezer Model Control Housing Shown

 Adaptive Defrost Control Pin Location
FF Fresh Food Light Input Neutral Input

DT Defrost Heater Time Input

FZ Freezer Light Input

L1 Line Power Input

DF Defrost Heater Output

CC Cold Control Output

CR Compressor Input
Compressor Output

Note: Some models use door switch inputs others do not. Always check the wiring diagram.
 Adaptive Defrost Control
Defrost System Test

Iniate Defrost

• Press the fresh food door switch three (3) times within five (5) seconds when the control is not
already in defrost.

• After this defrost is initiated, the normal defrost sequence will follow and the normal rules will
determine the start of the next defrost.

Terminate Defrost

Press the fresh food door switch three (3) times within five (5) seconds when the control is in defrost.

Pressing this switch in this way will terminate the defrost and initiate a refrigeration state.
 Adaptive Defrost Control
• Some models do not have door switch inputs to adjust adaptive defrost time.
• These units will use compressor 8 hour run time only for the defrost timing.
• You will not be able to force a diagnostic defrost on this type unit.
• On these units you can check resistance of
the defrost circuit on a control console
harness connector.
 Adaptive Defrost Control Diagram
The defrost heater can easily be
checked from the board harness
by isolating the circuit.
Measure between the pink and
blue wires, you should read 36Ω
on your meter
 Adaptive Defrost Control Diagram
Note that there 2
The defrost thermostats can be of the same rating
checked from the board harness is series for safety
by isolating the circuit and
measuring between the pink
and orange wires.
When both defrost thermostats
are closed the reading on your
meter will be ‘0’
 Adaptive Defrost Control Diagram
The defrost thermostats can be Note that there 2
checked from the board harness of the same rating
is series for safety
Isolate the circuit and measure
between the pink and orange wires
in the wiring harness
When the evaporator is warm or
one t’stat has failed the open
circuit will read ‘O.L’
COMPRESSOR
Compressor
Compressor Windings

S R

Compressor Terminal
Configurations

S R
 Compressor Windings
• Set multimeter on the ohm ‘Ω’ scale
• Place meter leads on Start ‘S’ – Common ‘C’
• In this example the multimeter reads 6.0Ω
 Compressor Windings
• Set multimeter on the ohm ‘Ω’ scale
• Place meter leads on Run ‘R’ – Common ‘C’
• In this example the multimeter reads 4.0Ω
 Compressor Windings
• Set multimeter on the ohm ‘Ω’ scale
• Place meter leads on Run ‘R’ – Common ‘C’
• In this example the multimeter reads 4.0Ω
 Compressor Windings
• Set multimeter on the ohm ‘Ω’ scale
• Place meter leads on Run ‘R’ – Start ‘S’
• In this example the multimeter reads 10.0Ω
Compressor Windings

Continuity at room temp.

Compressor Relay (Potential Relay)

Closed
Contacts
Open
Position
Contacts
Position
 Compressor Relay (PTC Relay)

Positive Temperature Coefficient

This means when the temperature increases

the resistance increases
Electromechanical
Icemaker
 Icemaker

WR30X10093

Icemaker is replaced as a complete assembly

 Icemaker
• 7 cube mold
• 2 lbs ice production per 24 hours (approximately 70 –
100 cubes in 24 hrs.)
• Normal cube height is ¾” at the midpoint
• Normal water fill is 95 cc’s per cycle (approximately 3
oz.)
• Normal fill time is 5.1 seconds
• Normal cycle time is approximately 3 min.
• On/Off is a slide lever that holds the feeler arm in the
full bucket position
• Thermostat in the icemaker closes at 15º F and
opens at 48º F
Icemaker - Schematic
 Icemaker – Operation
Freeze
• After the water freezes solid in the mold the thermostat closes at 15º F.
• The thermostat contact from black to orange closes, which starts the operation of the motor and
mold heater
• The slide switch must be in the ON position to start

ICE
WATER

Home Position
 Icemaker – Operation
Release
• After the rake rotates a few degrees the HOLD switch changes position.

ICE
 Icemaker – Operation
Release
• The motor drives the rake throughout the rotation

ICE
 Icemaker – Operation
Release

• After the rake rotates a little more than halfway it stalls against the ice in the mold

ICE
 Icemaker – Operation
Release

• The heater remains on warming the mold releasing the ice and the rake starts to move again

ICE
 Icemaker – Operation
Ejection

• After the ice is released the rake rotates pushing the ice out of the mold
 Icemaker – Operation
Ejection

• The rake continues to rotate through the mold pushing the ice cubes
 Icemaker – Operation
Ejection
• As the rake approaches the Home Position the water fill contact will close but does not fill
because the water valve coil is bypassed by the closed thermostat. (path of least resistance)
 Icemaker – Operation
Ejection
• When home position is reached the motor continues to run because the mold is still below
48°F keeping the thermostat closed.
 Icemaker – Operation
Ejection
• The mold is still below 48º F so the motor and heater remain on for a second rotation of the
rake pushing the ice cubes onto the stripper then slide off into the bucket below
 Icemaker – Operation
Ejection
• With no ice in the mold, the heater now warms the mold above 48º F opening the thermostat
 Icemaker – Operation
Ejection
• The rake continues to turn through the empty mold
 Icemaker – Operation
Ejection

• Just before the rake returns to the home position the Water fill contact closes for 5.1 sec.

WATER

Fill Position
 Icemaker – Operation
Freeze
• The rake completes the rotation to the home position
• With water in the mold the freeze cycle begins

WATER

Home Position
 Icemaker – Operation
OFF Position
• When the ice bucket is full or the ON-OFF slide is in the OFF position the Feeler arm is held in preventing
the motor or heater to start when the thermostat closes.

WATER

Home Position

95
 Icemaker – Operation
Diagnostics
• When the icemaker is in the home position the rake is
pointed horizontally toward the mold mounting brackets
• To manually start the icemaker pull the rake toward the front
of the icemaker from the home position (note the rake is
ratcheted so it will move easily)
• The more the rake is rotated the less time it takes to return to
the home position
• Just before the rake returns to the home position the
icemaker fills with water if the mold temperature is above 50
degrees F
• The rake will only make one revolution when the thermostat
is open
 Icemaker
Depending on the original configuration, some of the components shown above may need to
be transferred from the original icemaker to the replacement.

Fill Cup IM Insert

Stripper
Cover

Feeler Arm
APPENDIX

98
 Icemaker – Operation
Ejection
• After the ice is released the rake rotates pushing the ice out of the mold
WATER

WATER

100
Contacts 3 – 4 Closed
Contacts 2 – 3 Open

2 1 4 3

2
3
4
 Contacts 2 – 3 Open
Blue
2
Aqua 3

Black
4

Contacts 3 – 4 Closed
 Icemaker – Operation
Release
• After the rake rotates a few degrees HOLD switch changes position.
• This keeps the motor running through out the rotation of the rake
• After the rake rotates a little more than halfway it stalls against the ice in the mold
• The heater remains on warming the mold releasing the ice and the rake starts to move again

ICE ICE

ICE ICE
 Icemaker – Operation
Release
• After the rake rotates a few degrees HOLD switch changes position.
• This keeps the motor running through out the rotation of the rake
• After the rake rotates a little more than halfway it stalls against the ice in the mold
• The heater remains on warming the mold releasing the ice and the rake starts to move again

ICE
ICE
ICE
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