REFRIGERATOR SERVICE MANUAL
Contents
1. 06 C0M2 051 13 TC4 PWM 1 PDO CLZ1 2 L101 P40 15 OR7 3 MIN SCK 390 L102 16 4 MID 390 L103 Li R9 5 MAX 390 V 0101 18 L _SW101 P43 2 6 238 R10 REF TEMP gt 10K ORRI gt 26 1KF 7 e AIN0 3K SF 5 5 223 ORDI 77 E 26 1KF 61 9 AAD 2K D SENSOR 223 10 77 777 ORI4 10K 62 6 AIN2 ORCRI 09615 10 4 7K TEST PIN 8 fal P64 6 4 AIN4 7 9 12 19 22 25 26 34 7 EXPLODED VIEW V The parts of refrigerator and the shape of each part are subject to change in different localities optional parts 35 optional parts 2 25 33 E N 557 AN NM N WO E 37 207 8 P No 3828JD8462B SEP 2003 Printed in Korea2. 0 228M50C6XXL 11213121516 PWB ASSY MAIN HEATER CORD L HEATER PLATE FAN MOTOR FUSE M 72 C sman 3854JD1044A THE PLUG TYPE CAPACITOR PART COMPRESSOR EARTH PART ON CIRCUIT DIAGRAM ARE SUBJECTED TO CHANGE IN DIFFERENT LOCALITIES AND ACCORDANCE WITH MODEL TYPE WHEN STARTING CAPACITOR IS NOT USED NO 3 4 OF PTC START ARE CONNECTED INTERNALLY BK BLACK BN BROWN RD RED BO BRIGHT ORANGE YL YELLOW GN GREEN BL BLUE PR PURPLE GY GREY SB SKY BLUE WH WHITE PK PINK NOTE 1 This is a basic diagram and specifications vary in different localities 11 6 TROUBLESHOOTING 6 1 COMPRESSOR AND ELECTRIC COMPONENTS Power Remove the PTC Source Starter from the Compressor and measure the voltage between Terminal C of Compressor and Terminals 5 or 6 of PTC Rating Voltage 10 OLP disconnected No Voltage Replace OLP Check connection condition Advise the customer to use a regular Trans Applied voltage isn t in the range of Rating Voltage 10 gt Check the Check the resistance YES 3 resistance of among M C S C and gt Reconnect Motor M S in Motor Replace Compressor Compressor Compressor YES
3. REMARK 1 6870JB2062 PWB MAIN FR 1 DS 1107A D00 SAN t 1 6 6170JB2014 220V 0 15V SUNG 2 TRANS PCB TRANS 3 6630JB8001W 202 11 047P 2 46 EUN 4 WAFER 5 6630JB8007J 917788 1 10P amp C0M2 6 7 022820046 7 409 TOSHIBA IC1 0 77 82004L 8 _ KE7812008 aToRIKIAZ8S12P 1 2 9 0M6780500 KIA78SOSP KEC 5 704200 7042 4 10 RESET IC ze 11 0 0010100 BMR 01010 12 6920820054 JWiaFHN NAIS RYI RELAY 13 6920 82003 G5N 1A OMRON RY2 14 570 00012A CSTS4 00MGW MURATA 05 1 15 6212JB8001B 16 61024880018 VARISTOR INR14D621 IL JIN V 1 17 000400409 DIODE 1M4004 ypas 2 DELTA 18 0DD414800AA SMTCHING DIODE 1M4148 D 2 19 Joce1081H618 1000 25V CE1 ELE CAPACITOR SAM HWA 20 0CE227AH638 105 220uF 25V CE2 21 0 2271 638 220uF 16V 22 ocki040H908 104 50V CC1 2 3 4 CER CAPACITOR TAE YANG 23 JOCK2230H908 223 50V CC6 7 24 ock1020H908 102 50V CC5 25 oRD3900F609 3909 1 6W R7 8 26 08039000609 3909 1 4W R9 27 0802001 609 2KJ 1 6W R12 28 08020010609 2KJ 1 4W R11 1 CHO YANG 29 J0RD27016609 2 74 1 4W inen R2 4 30 0804701 609 FILM 4 7 1 6W 815 31 0RD47016609 4 7KJ 1 4W asu XI 61 32 oRD1002F609 10KJ 1 6W R14 33 08010020609 1 4W
4. L CORD PLATE HEATER OUT CASE Coated Steel Sheet INNER CASE ABS INSULATION Polyurethane Foam OPTION 2 PARTS IDENTIFICATION FREEZER COMPARTMENT Twisting Ice Service Optional or General Type Ice Making Freezer Shelf Freezer Temperature Control Knob REFRIGERATOR COMPARTMENT Chilled Compartment Refrigerator Temperature Control Micom Shelves Lamp Deodorizer Optional Vegetable Drawer Used to keep fruits and vegetables etc fresh and crisp Cover Lower Optional Freezer Door Rack Egg Storage Rack Refrigerator Door Rack Optional Refrigerator Door Rack Leveling Screws NOTE This is a basic model The shape of refrigerator is subject to change 3 DISASSEMBLY 3 1 DOOR e Freezer Door 1 Remove the hinge cover by pulling it upwards 2 Loosen hexagonal bolts fixing the upper hinge to the body and lift the freezer door BOLT Qu HINGE COVER HINGE Figure 6 3 Pull out the door gasket to remove from the door foam Ass y GASKET Figure 7 e Refrigerator Door 1 Loosen hexagonal bolts fixing the lower hinge to the body to remove the refrigerator door only LOWER HINGE Figure 8 2 Pull out the door ga
5. TO THE REFRIGERATION SYSTEM 3 TO THE CHARGE CYLINDER VALVE TO BE CLOSED AFTER VACUUM TO THE VACUUM Figure 5 PUMP In addition check the graduated scale on the cylinder for the quantity of R 134a to be added for example if we have 750 grams of Freon in the cylinder and must add 165 grams to the group this amount will be reached when R 134a has dropped to 585 grams remembering that the indicator shows a lower limit of meniscus Do this after choosing the scale corresponding to the gas pressure different scales reported as the same gas pressure indicated by the pressure gauge on the top of the column To make R 134a flow into the system open the valve placed at the base of the cylinder and connected to the filling tube The amount of Freon cannot be added to the system all at once because it may cause a blocking of motor compressor Therefore proceed by adding original quantity of about 20 30 grams and close the valve immediately The pressure rises and the motor compressor must start sucking the gas and making the pressure go down again Regulate the valve again maintaining the same manner until reaching to the quantity of R 134a established for the system being charged When the system is running the suction pressure must be stabilized between 0 30 to 0 6 atmosphere 1 SPECIFICATIONS 1 1 GR 262 ITEMS SPECIFICATIONS ITEMS SPECIFICATIONS F
6. At the temperature of 72 C it stops the emission of TEMP from the Defrost Heater 1 Pull out the shroud F after removing the Grille Fan Figure 13 2 Separate the connectors connected with the Def Control ASM and replace the Def Control ASM after cutting the Tie Wrap Figure 14 SHROUD F DEF CONTROL ASM Figure 13 Figure 14 3 6 REFRIGERATOR ROOM LAMP 1 Remove the cover lamp R by pulling with a type driver 2 Remove the lamp R by turning REFRIGERATOR ROOM LAMP Figure 17 3 7 CONTROL BOX R 1 Remove the Cover Lamp R CONTROL BOX R COVER LAMP Figure 18 2 Loosen 2 screws 3 Full the Control Box R 4 Separate the lead wire Housing 3 8 REPLACEMENT OF DOOR OPENING TYPE e Precaution Before replacing the door opening type first of all should take out foodstuffs and accessories like shelves or trays and so on which are not fixed in the refrigerator Use the Driver Bolt Driver Torque Wrench or Spanner to fix or remove the bolt Be careful not to fall down the refrigerator in disassembling or assembling the Hinge Lower and the Adjustable Screw Asm Don t lay the refrigerator down in working with it it will cause to get out of order Be careful not to drop the door in disassembling
7. Check the Check the resistance of 4 resistance of two terminals in PTC Replace PTC Starter Starter PTC Starter 5 YES E YES Check if applying OLP works within 22 Check OLP a tegula OLP gt 30 sec in forcible 2 OLP operation by Replace OLP turning instant power on and off Check Measure minimum Components start in starting state starting voltage after 5 the voltage of Rating Voltage 10 below min for balancing cycle pressure and cooling the PTC 12 6 2 PTC AND OLP Normal operation of Separate the PTC Starter Observation value is Check another Compressor is from Compressor and gt 220V 50Hz 220 33096 electric impossible or poor measure the resistance 115V 60Hz 6 80 30 components between No 5 and 6 only 240V S0Hz 330 330 RSIR type No 4 and 5 of 2220 PTC Starter with a Tester or DE Whistone Bridge Figure 37 Replace The resi i The resistance value is 0 PTC Starter or serveral hundreds value is Separate the OLP from the YES Check another Compressor and check the electric components _ resistance value between two terminals of OLP with a Tester Figure 38 NO Replace OLP Figure 37 Figure 38 13 6 3 ANOTHER ELECTRIC COMPONENTS Y Cooling is impossi
8. If the temp of the defrosting sensor is below 25 C After a power failure or SVC POWER in 0 5 sec COMP amp COOLING FAN ON ON POWER in 0 5 sec DEFROSTING intl0osec DEFROSTING ON HEATER ON HEATER OFF in0 5sec COMP amp COOLING FAN U ON 19 7 1 4 ERROR DIAGNOSTIC MODE 1 The error diagnostic mode allows the SVC when a fault that may affect the performance of the product occurs while operating the product 2 Even II the function control button is pushed when an error occurs the function will not be performed 3 When the error is cleared while the error code is displayed due to a fault the appliance returns to the normal condition Reset 4 The error code is displayed by the refrigerator temp indication LED on the display of the refrigerator while the remaining LEDS are off R1 R2 R3 Ref Temp Control BLINK 1sec on 1sec off OFF NORMAL Error Code Display State of Operation with Error NO Error Cause R1 R2 R3 Comp Cooling fan Defrosting heater Faulty refrigerator R Cut or short circuited wire of 15 min ON 1 sensor on the control lt gt lt gt e refrigerator sensor 15 min OFF O box of the refrigerator 2 de rosting sensor 0 Cut or short circuited wire of No defrosting defrosting sensor Cut or disconnected wire of 3 Defrosting failure gt defrosting heater or temperature 6 6 fuse i
9. gt Low gt Medium Low gt Medium in order 2 When the power is initially applied or restored after a power failure it is automatically set to Medium Medium Medium Temp Control ROOM Ref Temp Control 18 7 1 2 DEFROSTING 1 The defrosting is performed each time when the total running time of the compressor reaches 7 hours 2 After the power is turned on or restored after a power failure the defrosting starts when the total running time of the compressor reaches 4 hours 3 When the temperature of the defrosting sensor reaches 13 or above the defrosting stops If the temperature does not reach 13 C in 2 hours after the defrosting starts the defrosting error code is displayed Refer to 7 1 4 Error Diagnostic Mode 4 With the defective defrosting sensor cut or short circuited wire the defrosting will not be performed 7 1 3 SEQUENTIAL OPERATION OF ELECTRIC COMPONENTS The electric components such as the comp defrosting heater and cooling fan start sequentially to avoid the noise and damage to the part which may result from the simultaneous start of various components on turning the power on or after the completion of a test Condition of Operation Operating Sequence uo VI 1 si ay If the temp of the defrosting sensor is 25 C or above For the initial use after the purchase or grounding
10. PARTIAL Freeze room and Flowing sound of Refrigerant A little high Normal discharging of o CLOG Refrigerator is heard and frost forms more than refrigerant 2 don t get cold in inlet only ambient e The capillary tube is faulty m normally temperature lt WHOLE Freezer room and Flowing sound of Refrigerant Equal to ambient Normal discharging of 2 CLOG Refrigerator is not heard and frost isn t temperature Refrigerant M dont get cold formed MOISTURE Cooling operation Flowing sound of Refrigerant Low than Cooling operation restarts CLOG stops periodically is not heard and frost melts ambient when heating the inlet of temperature capillary tube 8 5 Freezer Low flowing sound A little high e The pressure of high zm RESSION Refrigerator Refrigerant is heard and than ambient pressure part in Dm don t get cold frost forms in inlet only temperature compressor is low m NO COMP No compressing Flowing sound of Refrigerant Equal to ambient No pressure of high pressure 9 I RESSION operation is not heard and no frost temperature part in compressor V Leakage Detection e Observe discharging point of refrigerant which may be in oil discharging part in compressor and hole of evaporator Whether Compressor YES Whether frost gt forms or not in runs or not Evaporator Frost formed normally Whether oil No frost or forms in inlet
11. or assembling the freezer or the refrigerator door This refrigerator according to the install position or user s liking can be used as the type of opening from the right or the left ll HOW REPLACE THE DOOR OPENING TYPE Converting Door is Optional 1 Separate the Cap and Hinge Upper 6 2 Separating the Freezer Door Separating the Hinge C 0 and the Refrigerator 4 Separating the Hinge Lower 9 Door 5 Move the Position of Adjustable Screw 6 Assemble the Hinge Lower 9 Assembly Move the Cap 6 Bracket of the Refrigerator Move the Cap and Assemble the Hinge C 0 Door After removing the washer Assembe the Door Stopper F for Right 1 0 Move the Cap and Assemble the Freezer Opening Type Door 4 ADJUSTMENT 4 1 COMPRESSOR 4 1 1 Role The compressor inhales low temperature and low pressure gas evaporated from Evaporator of the Refrigerator and condenses this gas to high temperature and high pressure gas and then plays delivering role to Condenser 4 1 2 Composition The Compressor is Composed of Compressor Apparatus compressing gas Compressor Motor moving Compressor Apparatus and Case protecting Compressor Apparatus and Motor There are PTC Starter and Over Load Protector OLP in the Compressor outside On the other hand because the Compressor consists of 1 1000mm processing precision components and is sealed after producing with
12. 1007 AWG24 VSF 0 18 12 0 3MM 9 l LEAD WIRE UL1007 AWG24 VSF 0 18 12 0 3MM 14 HOUSING 316092 1 AMP 8P 15 TAP 917764 1 AMP 16 DOUBLE LOCK PLATE 917704 1 8P 17 HOUSING 35022 0006 MOLEX WHITE 18 CONTACT 35021 1101 PBT MOLEX 19 TAPE VINYL W19xL60MM 1 22 6500JB1001S SENSOR TEMPERATURE K43 PVC R SENSOR 200 26 49111001 SOLDER SOLDERING ALMIT KR 19RMA HEESUNG 27 49111004 SOLDER LEAD BAR 5635 20 DAE IM SOLD 28 59333105 FLUX JS71 KOKI 7 5 PWB DIAGRAM 33 bi RS qug IC2 IC3 e 78512 178505 28 VDD Voref VAL 1 at E CI E cc pie 3 Tar T nu 80 25V 25V 0V lU U e M Mod 77 3 TEST 4 IC4 4 7K Ran KIA7042P RESET n 2 9 717104 717104 RY1 gt 77 77 JWloFHN 29 COMP 0o E P i 14 55 F F MOTOR a A106 oo C F MOTOR C 24 P15 AS FUSE M 03 106 xL 1 XOUT CST4 00MGW 4505C01L 8 2 77 II HH XIN TOSHIBA TMP87C409N IC1 CIRCUIT DIAGRAM
13. 22 ___ 11 332322222 222 2 _ _ _ _ 12 17 COMPRESSOR AND ELECTRIC 0 12 AND OLR cos sisi hea eer Ae u S uu 13 ANOTHER ELECTRIC 00 kaisa aE 14 SERVICE DIAGNOSIS CHART etate ette etate ne ide Det ede dlc 15 REFRIGERATING CYCLE n eet tu si uu e te t dete 16 17 DESCRIPTION OF FUNCTION amp CIRCUIT OF s 18 34 EXPLODED VIEW z si 35 37 REPLACEMENT 157 inanan nn 38 SAFETY PRECAUTIONS Please read the followings before servicing your refrigerator 1 Check if an electric leakage occurs in the set 7 When you stand up during observing the lower part 2 To prevent electric shock unplug prior to servicing with the upper door open move with care to prevent head wound which may happen by hitting the upper 3 In case of testing with power on wear rubber gloves to prevent electric shock 4 If you use any appliances check regular current voltage and capacity 5 Don t touch metal products in cold freezer with wet hand It may cause frostbite 6 Prevent water flowing to electric elements in mechanical parts door 8 When sloping the set remove any materials on the set especially thin plate type ex glass shelf or books 9 When servicing evapor
14. R10 34 0RD27026609 27KJ 1 4W R3 5 ORD1803F609 180KJ 1 6W 08056027609 56KJ 1 6W ORD3302F609 33KJ 1 6W ORD1802F609 18KJ 1 6W 08012027609 12KJ 1 6W 35 0801002 609 10KJ 1 6W RCR1 08082017609 8 2KJ 1 6W 08056017609 5 6KJ 1 6W ORD3301F609 3 3KJ 1 6W 08020017609 2KJ 1 6W ORD4700F609 470J 1 6W 36 08010046609 1MJ 1 4W R6 37 ORN2612F409 26 1KF 1 6W RR1 ORN2612F409 RESISTOR FIXED 38 METAL FILM 26 1KF 1 6w RD1 39 0RN26126409 26 1KF 1 4W 40 08516220409 16 2 1 4W 41 42 OTRI06009AC KRA1O6MIKEC 01 3 6 43 OTR319809CA KIC3198 P 02 4 0 6 7 5 J195 7 CC8 44 43607015 JUMP WRE mn 45 0 6 10mm J8 9 TEST 46 47 49111001SOLDER KR 19RMA 48 49111004 SOLDER LEAD BAR H63A HEE SUNG DAE JIN SOLD 49 59333105 FLUX AUTO JS71 KOKI 50 31 7 4 3 PWB ASS Y DISPLAY AND PARTS LIST 101 5101 1 32 Description Spec Maker Bigo 1 6870JB2061A PWB PCB DISPLAY R B29 HM PJT DOO SAN 2 6600JB8005A SWITCH KPT 1105A KYUNG IN SW101 3 ODL500329AA LED SV50 R032BF569GG SEOUL SEMI L101 L103 4 000414809 DIODE SWITCHING 1N4148 26MM 5 LEAD WIRE UL1007 AWG24 VSF 0 18 12 0 3MM 6 LEAD WIRE UL1007 AWG24 VSF 0 18 12 0 3MM 7 LEAD WIRE UL1007 AWG24 VSF 0 18 12 0 3MM 8 l LEAD WIRE UL
15. REEZER 61 FREEZER 1 EA SHELF NET CAPACITY REFRIGERATOR 158 REFRIGERATOR 2 1 TOTAL 219 VEGETABLE TRAY Drawer Type GR 262S V Q 540 W x610 D x1510 H EGG TRAY 1 Piece DIMENSIONS mm GR 262Q V C 540 W x628 D x1510 H ICE TRAY 1 Piece 2 NET WEIGHT kg 46 ICE BANK 1 Piece COOLING SYSTEM Fan Cooling COMPRESSOR P T C Starting Type TEMPERATURE FREEZER Knob Shutter EVAPORATOR Fin Tube Type CONTROL REFRIERATOR Micom Control CONDENSER Pipe On Sheet Type Full Automatic REFRIGERANT R134a 1209 DEFROSTING SYSTEM Heater Defrost LUBRICATING OIL FREOL a 22G 210cc OUT CASE Coated Steel Sheet DEFROSTING DEVICE L CORD PLATE HEATER INNER CASE ABS OPTION INSULATION Polyurethane Foam 1 2 GR 292 ITEMS SPECIFICATIONS ITEMS SPECIFICATIONS FREEZER 61 FREEZER 1EA SHELF NET CAPACITY REFRIGERATOR 176 REFRIGERATOR 2EA 1 TOTAL 237 VEGETABLE Drawer Type GR 292S V Q 540 W x610 D x1600 H EGG TRAY 1 Piece DIMENSIONS mm C 292CIVIC 540 W x628 D x1600 H ICE TRAY 1 Piece 2 NET WEIGHT kg 49 ICE BANK 1 Piece COOLING SYSTEM Fan Cooling COMPRESSOR P T C Starting Type TEMPERATURE FREEZER Knob Shutter EVAPORATOR Fin Tube Type CONTROL REFRIERATOR Micom Control CONDENSER Pipe On Sheet Type Full Automatic REFRIGERANT R134a 120g DEFROSTING SYSTEM Heater Defrost LUBRICATING OIL FREOL a 22G 210cc DEFROSTING DEVICE
16. REFRIGERATOR CAUTION BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL MODEL GR 262SQ COLOR SUPER WHITE GR 292SQ CONTENTS SAFETY PRECAUTIONS lt lt _ 222 2 _ lt 333 ___ _ _ __ 2 Ei __ _ _ _ 33 _____ _ _ 3 _ _ _ 33 _ __ ____ __ __ 3 6 6 6 6 6 6 6 6660 9 __ _ __ 4 _ 5 _ _ __ _____ __ 3 3 lt 3 lt _ _ _____3 _______ _ _ _ _ _ __ 6 7 6 DOOR SWITGH ntm ebd ien dp D arret 6 t Rein tabo vn ip et are MEI 6 DEF CONTROE ASM z zie DECRE EC UR IRE CO ERE RUE UNS 7 REFRIGERATOR ROOM LAMP 7 CONTROLBOX AS MR IE SE RB EE ER 7 REPLACEMENT OF DOOR OPENING 8 9 _ 2 2 2 2 2 10 11 COMPRESSOR rd RE t UR th e EHE RR es a RU 10 PTC STARTER CAREER REOR aa E 10 OVER LOAD PROTEGTOR ERR M 586 11 CIRCUIT DIAGRAM 3 3 lt 322 22 22
17. SENSOR CHECK POINT NORMAL 30 C 50 C SHORT CIRCUITED OPEN Refrigerator Sensor Defrosting Sensor POINT A Voltage POINT Voltage 05 45 OV 5V 24 7 2 6 TEMPERATURE COMPENSATION OVERCOOLING UNDERCOOLING COMPENSATION CIRCUIT 1 Refrigerator Temperature Compensation pa R14 IC p62 9 a 7 E Refrigerator Resistance Temperature Remark RCR1 Compensation 180 5 0 Compensation by aoe 33 3 0 18 2 0 12 1 0T 10 KQ 0 Standard Temperature 8 2 KQ 1 0 Compensation by sera gt 3 3 3 0 2KQ 4 0 4700 5 0 b Table of Temperature Compensation by adjusting the resistance Difference with the current temperature E g If the refrigerator compensation resistance RCR1 is changed from 10K the current resistance to 18K the adjustment resistance the temperature of the refrigerator rises 2 C 25 7 2 7 KEY BUTTON INPUT amp DISPLAY LIGHT ON CIRCUIT MM 7 51 13 Q6 CON2 TC4 PWM AA IA106 i 00 021 IC1 2 MIC0M gt pao 19 7 3 MIN pom 390 L102 16 R8 4 MID 390 L103 p42 17 R9 5 225 V D101 1 p43 18 i 6 st swo 005 REF TEMP 102 10K 77 b The circuit
18. ator part wear cotton gloves without fail It is to prevent wound by sharp fin of evaporator 10 Leave a breakage of refrigerating cycle to a heavy service center The gas in cycle inside may soil ambient air SERVICING PRECAUTIONS Air Recharging in Compressor Test the refrigeration by connecting it electrically before refilling operation It is necessary to ascertain the function of the motor compressor and identify the defects immediately If the defects have been found empty the old system of eventual R 134a residue by breaking off the end of the extension piece at its narrow point Figure 1 Replace the filter and any damaged components Unsolder and pull off the piece remaining inside the service tube and then attach an extension completely with male Hansen and last solder it to the same tube again Figure 2 CHARGE TUBE FEMALE POINT TO BE BROKEN EXTENSION HANSEN gt SERVICE TUBE EXTENSION SOLDERING POINT Figure 1 Figure 2 It is necessary to execute the soldering operation with valve open so that the fumes caused by oil residue can come out freely without blowholes between two tubes during heating the point to be soldered The extension fitted with the male Hansen is connected to the female fitting of the vacuum pump tube Figure 3 TO THE VACUUM PUMP PRESSURE GAUGE Figure 3 Air evacuating from the system begins so soon as the pump starts The refrigeration system must
19. be kept under vacuum until the reading on the low pressure gauge indicates vacuum 0 absolute 1 atm 760 mm hg in any case it is advisable to keep the pump running for about 30 minutes Figure 3 In case that a considerable leakage occurs and to stop the vacuum pump will be necessary and add a small quantity of Freon to the system if vacuum should not be obtained pressure gauge can t fall to 1 atmosphere start the refrigeration unit and find the leakage with the special leak finder When the defective soldering point is visible re do it after opening the extension tube valve and reestablishing the normal outside pressure inside the group Because the melted alloy is sucked into the tubes and block them the pressure must be rebalanced when vacuum is in the system in soldering As soon as the vacuum operation is over add the quantity in grams of R 134a to the refrigerant system Remember that every system has an exact quantity of R 134a with a tolerance of 5 grams that can be added Figure 4 TO THE R 134a CYLINDER TO THE REFRIGERATION SYSTEM Figure 4 Before performing this operation if the vacuum pump and refilling cylinder are connected make sure that the valve placed between the vacuum pump and refilling tube are closed to keep the Freon for adding to the system Figure 5 FILLING OR VALVE TO BE OPENED CHARGE TUBE WHEN REFILLING Q
20. ble Compressor doesnt run E Check if current flows to the following Cause components a Thermistor b Starting devices 3 Shorted or broken gt Poor contacting Poor contacting c OLP or shorted d Compressor coil n Coil shorted e Circuit Parts Poor contacting or shorted o gt Replace each component Running state of Compressor is poor heck i 600048 staring gt Low voltage gt Raise the voltage voltage Check if current flows Poor contacting Replace to starting devices broken gt each component Check current flowing in sub coil of gt Shorted Compressor Check capacity of OLP Lack of capacity GA The items described above are normal Y Cooling ability is poor Fan motor doesn t run Y Check current flowing in door S W gt Check current flowing in the Fan Motor Much frost are sticked to the EVAPORATOR Check current flowing of the following components e Def Sensor FUSE M Check current flowing of the following components e L Cord e Plate Heater gt Coil of motor Compressor Replace the compress
21. charging M C vacuum Perform vacuum operation until a proper degree is within 1 Torr vacuum degree is built up 2 If the vacuum degree of the cycle inside is If a proper vacuum degree isn t built up 10 Torr below for low pressure and 20 Torr check the leakage from 4 for high pressure it says no vacuum the Cycle Pipe line part and leakage state Quick Coupler Connecting part 8 Vacuum degree of vacuum pump must be 0 05 Torr below after 5 min 4 Vacuum degree must be same to the value described item 2 above for more than 20 min DRY AND 1 The pressure of dry air must be more AIR than 12 16Kg cm 5 NITROGEN 2 Temperature must be more than GAS 20 70 C 3 Keep the pressure to 12 6Kg cm also when substituting dry air for Nitrogen Gas NIPPLE 1 Check if gas leaks with soapy water Check if gas leaks from connecting part of 6 AND 2 Replace Quick Coupler in case of leakage Coupler COUPLER PIPE Put all Joint Pipe in a clean box and 7 cover tightly with the lid so that dust or humidity is not inserted 17 7 DESCRIPTION OF FUNCTION amp CIRCUIT OF MICOM The following description is basically for GR 262 GR 292 For the other models refer to the diagram of the entire PCB circuit 7 1 FUNCTION 7 1 1 FUNCTION 1 When the appliance is plugged in it is set to Medium Each time the button is pushed it is set to Medium gt Medium High gt High
22. eplace FAN MOTOR Passage of cool air blocking Remove impurities supplied into REFRIGERATOR EVA frozen See DEFROSTING is poor DEFROSTING is NO DEFROSTING 1 HEATER emit heat Check the MAIN PCB HEATER disconnection Replace HEATER poor TEMPERATURE FUSE disconnection Replace TEMPERATURE FUSE Connection is poor Certify EVA connection and wire of MAIN PWB CONNECTOR CON1 DEF SENSOR is poor Replace DEF SENSOR HEATER RELAY is poor Replace RY2 of MAIN PWB 2 DRAIN PIPE blocking Certify DRAIN PIPE DRAIN PIPE blocking Remove ice and impurities 3 Remain ice at DEFROSTING Certify HEATER PLATE resistance Certify the attaching Attaching is poor Reassemble DEF SENSOR of DEF SENSOR Certify the attaching DOOR sticking is poor Reassemble DOOR state gap of FREEZER Replace GASKET REFRIGERATOR DOOR 29 7 4 MAIN PWB ASSY AND PARTSLIST 7 4 1 MAIN PWB ASS Y 89 d J08 30 7 4 2 REPLACEMENT PARTS LIST gu oH 2444 2 wo DWG DESCRIPTION _
23. is used as a starting device of motor 10 4 2 3 PTC Applied Circuit Diagram e According to Starting Method of Motor OVERLOAD PROTECTOR COMPRESSOR MOTOR HERMETIC TERMINAL PTC STARTER RSIR 4 2 4 Motor Restarting and PTC Cooling 1 For restarting after power off during normal Compressor Motor operation plug the power cord after 5 min for pressure balance of Refrigerating Cycle and PTC cooling 2 During normal operation of Compressor Motor PTC elements generate heat continuously Therefore if PTC isn t cooled for a while after power off Motor can t operate again 4 2 5 Relation of PTC Starter and OLP 1 If power off during operation of Compressor and power on before is cooled instant shut off within 2 min or reconnect a power plug due to misconnecting isn t cooled and a resistance value grows As result current can t flow to the sub coil and Motor can t operate and OLP operates by flowing over current in only main coil 2 While the OLP repeats on and off operation about 3 5 times PTC is cooled and Compressor Motor performs normal operation If OLP doesn t operate when is not cooled Compressor Motor is worn away and causes circuit short and fire Therefore use a proper fixed OLP without fail 4 2 6 Note to Use PTC Starter 1 Be careful not to allow over voltage and over current 2 No Strike Don t apply a forcible power or strike 3 Keep apart f
24. mes dirty Did you keep smelly foods without wraping e It smells plastic Clean the inside of the set Wrap smelly foods The new products smell plastic but it is removed after 1 2 weeks e In addition to the items described left refer to the followings to solve the complaint poor 15 Replace the Check if dew forms Defrosting 6 ied gt the Freezer iS poor 908006050 defrosting circuit Check Refrigerating The cycle Repair the cycle Cycle gt is faulty The operation of Check the the Thermistor is gt Replace Bie Thermistor Thermistor 6 5 REFRIGERATING CYCLE V Troubleshooting Chart GSE STATE OF STATE OF THE TEMPER TORE RENE THE SET EVAPORATOR SUE COMPRESSOR PARTIAL Freezer room and Low flowing sound of A little high e A little Refrigerant LEAKAGE Refrigerator Refrigerant is heard and more than discharges don t get cold frost forms in inlet only ambient Normal cooling is possible m normally temperature when injecting Refrigerant gt of regular amount gt WHOLE Freezer room and Flowing sound of Refrigerant Equal to ambient No discharging of Refrigerant LEAKAGE Refrigerator is not heard and frost isn t temperature Normal cooling is possible don t get cold formed when injecting Refrigerant normally of regular amount o
25. ndicated at least 2 hours later after the error occurs 20 7 2 PCB FUNCTION 7 2 1 POWER CIRCUIT CON1 TR Iz S zu 01 04 1N4004 4 oss 2 VDD VAI 140621 CEI Mr 220uF 25V 25V Varef Vss L Vass TEST IC1 MICOM The secondary part of the TRANS is composed of the power supply for the display and relay drive 12Vdc and that for the MICOM ana IC 5V The voltage for each part is as follows PART VA 1 CE2 CE3 VOLTAGE 220 Vac 1 2 5 1 is part preventing the over and noise When 385V higher power is applied the inside elements short circuited and broken resulting in the blowout of the fuse in order to protect the elements of the secondary part of the TRANS 21 7 2 2 OSCILLATION CIRCUIT CST4 00MGW 05 1 LI LIII This circuit is to generate the base clock for calculating time and the synchro clock for transmitting data from and to the inside logic elements of the IC1 MICOM Be sure to use the authentic parts since the calculating time by the IC1 may be changed or it will not work if the OSC1 SPEC is changed 7 2 3 RESET CIRCUIT a IC4 l kiA7042P 27 CV 2 I MIC0M L 104
26. only gt leaks or not Observe the discharging Normal amount amount of Refrigerant No or much amount YES Faulty Inject Refrigerant to Compressor 905065801 Compressor and check cooling operation Check Compressor Clogged dust Gas leakage Normal frost formed in 16 Evaporator Check the leakage point V General Control of Refrigerating Cycle NO ITEMS CONTENTS AND SPECIFICATIONS REMARKS WELDING 1 H 30 ROD Chemical Ingredients Recommend H34 containing 34 Ag in the Ag 3096 Cu 2796 Zn 2396 Cd 2096 Service Center Brazing Temperature 710 840 C 1 2 Bcup 2 Chemical Ingredients Cu About 93 P 6 8 7 5 The rest within 0 296 Brazing Temperature 735 840 C FLUX Ingredients and how to make Make amount for only a day Borax 30 Holding period 1 day Borax 3596 Close the cover of container to prevent dust 2 Fluoridation kalium 3596 putting in the FLUX Water 4 Keep it in a stainless steel container Mix the above ingredients and boil until they are transformed into liquid DRIER 1 Assemble the drier within 30min Don t keep the drier in a outdoor because ASM after unpacking humidity damages to it 2 Keep the unpacked drier at the temperature of 80 100 C VACUUM 1 When measuring with pirant Vacuum Apply M C Vacuum Gauge without fail gauge of
27. oor NO COOLING COMPRESSOR operates Check the MAIN PCB COMPRESSOR lock or Replace COMPRESSOR blocked OLP PTC is poor Replace OLP PTC COMPRESSOR RELAY is Replace MAIN PWB RY1 poor THE CONNECTING WIRE Certify the black wire of MAIN iS poor PWB CONNECTOR CON1 Whether refrigerant leaks or Measure the amount of frost Refrigerant leakage Remedy the leaking part leaks or not sticking on EVA and the and reaching Refrigerant surface temperature of condenser pipe FREEZER Whether FAN MOTOR Check the MAIN PCB FAN MOTOR is poor Replace FAN MOTOR TEMPERATURE is poor operates or not DOOR LINE contact Replace DOOR LINER CONETTING WIRE is poor Certify MOTOR and the connection of the black wire of MAIN PWB CONNECTOR CON1 DEFROSTING normal Certify the amount of frost sticking on EVA DEFROSTING is poor See the DEFROSTING trouble SENSOR normal Check resistance the SENSOR in the Refrigerator SENSOR RESISTANCE is poor Replace SENSOR 28 CLASSIFICATION STATE OF TROUBLE POINT BE CHECKED CHECKING METHOD CONTENT REMEDY COOLING is poor REFRIGERATOR TEMPERATURE is poor 1 FREEZER TEMPERATURE is normal See FREEZER TEMPERATURE is poor Certify the attaching state of DOOR 2 Cool air of FAN MOTOR is is sufficient Certify the amount of cool air and its speed touching check FAN MOTOR is poor R
28. or F Poor contacting gt Coil is shorted Replace each component m Shorted Replace each component 14 Replace each component 6 4 SERVICE DIAGNOSIS CHART COMPLAINT POINTS TO BE CHECKED REMEDY Cooling is Is the power cord unplugged from the outlet e Plug to the outlet impossible Check if the power S W is set to OFF Set the switch to ON Check if the fuse of power S W is shorted Replace a regular fuse Measure the voltage of power outlet If voltage is low wire newly Cooling ability Check if the set is placed close to wall Place the set with the space of about 10cm is poor Check if the set is placed close to stove gas Place the set apart from these heat cooker and direct rays appliances s the ambient temperature high or Make the ambient temperature below the room door closed Check if putting in hot foods Put in foods after they get cold Did you open the door of the set too often Don t open the door too often and close or check if the door is closed up it firmly Check if the Control is set to Min Set the control to mid position Foods in the Are foods placed in cooling air outlet Place foods in high temperature section Refrigerator Front Part are frozen Check if the Display LED is set to Max Set the Display LED to Mid Is the ambient tem
29. out dust or humidity deal and repair with care 4 1 3 Note to Use 1 Be careful not to allow over voltage and over current 2 No Strike If applying forcible power or strike dropping or careless dealing poor operation and noise may occur 3 Use proper electric components appropriate to the Compressor 4 Note to Keep Compressor If Compressor gets wet in the rain and rust in the pin of Hermetic Terminal poor operation and poor contact may cause 5 Be careful that dust humidity and flux due to welding don t inflow in Compressor inside in replacing Compressor Dust humidity and flux due to welding which inflows to Cylinder may cause lock and noise 4 2 PTC STARTER 4 2 1 Composition of PTC Starter 1 PTC Positive Temperature Coefficient is no contact semiconductor starting device which uses ceramic material and the material consists of 2 The higher the temperature is the higher resistance value becomes These features are used as starting device of Motor 4 2 2 Role of PTC Starter 1 PTC is attached to Hermetic Compressor used for Refrigerator Show Case and starts Motor 2 Compressor for household refrigerator applies single phase induction Motor For normal operation of single phase induction motor in the starting operation flows in both main coil and sub coil After the starting is over the current is cut off in subcoil The proper features of PTC play the above all roles So PTC
30. perature below 5 C Set the Display LED to Min Dew or ice Is watery foods kept Seal up watery foods with wrap forms in the Check if putting in hot foods e Put in foods after they get cold chamber of Did you open the door of the set too Don t open the door too often and close the set often or check if the door is closed up it firmly Dew forms Check if ambient temperature and humidity Wipe dew with a dry cloth This happening in the Out Case of surroumcling air are high Is the gap in the door packed is solved in low temperature and humidity naturally Fill up the gap Abnormal noise generates Is the set positioned in a firm and even place Does any unnecessary objects exist in the back side of the set Check if the Drip Tray is not firmly fixed Check if the cover of mechanical room in below and front side is taken out Adjust the Adjust Screw and position in the firm place Remove the objects Fix it firmly on an original position Place the cover at an original position To close the door is not hangy Check if the door packing becomes dirty by filth such as juice e Is the set positioned in a firm and even place Is too much food putted in the set Clean the door packing Position in the firm place and adjust the Adjust Screw Keep foods not to reach the door Ice and foods smell unpleasant Check if the inside of the set beco
31. rm The RESET circuit is for allowing all the functions to start at the initial conditions by initializing various parts including the RAM inside the MICOM IC1 when the power is initially supplied or the power supply to the MICOM is restored after a momentary power failure For the initial 10ms of power supply LOW voltage is applied to the MICOM RESET terminal During a normal operation 5V is applied to the RESET terminal If a trouble occurs in the RESET IC the MICOM will not work 22 7 2 4 LOAD DRIVE CIRCUIT 1 Load Drive Condition Check CON1 7 e 5 POWER 07 JW1aFHN COMP rr Event d 3 L al R2 25 14 02 F F MOTOR j II m Y ul MICOM G5N 1 C F MOTOR a 6 42 Ez I a de P15 FUSE M DEF HEATER Q3 A106 Load Type a p Motor Defrosting Heater Measurement Location A gt ON 1V or below ondition OFF 12V 23 7 2 5 TEMPERATURE SENSOR CIRCUIT 26 1KF P60 R11 IC1 IM0 _ gt 2K 7 MICOM T 223 B RD 8 R12 26 1KF gl AIN1 223 10 777 R SENSOR D SENSOR The upper CIRCUIT reads REFRIGERATOR temperature and DEF SENSOR temperature for defrosting into MICOM OPENING or SHORT state of each TEMPERATURE SENSOR are as follows
32. rom any liquid If liquid such as oil or water inflows into PTC PTC materials it may break due to insulation breakdown of material itself 4 Don t change at your convenience Don t disassemble PTC and mold If damaging to outside of PTC starter resistance value alters and poor starting of compressor motor may cause b Use a properly fixed PTC 4 3 OLP OVER LOAD PROTECTOR CONTACTING 4 3 1 Definition of OLP POINT 1 OLP OVER LOAD PROTECTOR is attached to Hermetic Compressor and protects Motor by cutting off current in Compressor Motor by Bimetal in the OLP in COVER BIMETAL case of over rising temperature 7 2 When over voltage flows to Compressor motor Cane CONTACTING works by heating the heater inside OLP nd u POINT OLP protects Motor by cutting off current which HEATER flows to Compressor Motor 4 3 2 Role of OLP 1 OLP is attached to Hermetic Compressor used to V TERMINALS Refrigerator and Show Case and prevents Motor Coil BIMETAL from being started in the Compressor ADJUST 2 Do not turn the Adjust Screw of OLP in any way for SCREW normal operation of OLP Composition and connection Diagram of OLP Figure 21 HEATER 5 CIRCUIT DIAGRAM CIRCUIT DIAGRAM PWB ASSY DISPLAY 112131415 ex fepe vv Ltt R SENSOR mi DEF SENSOR
33. shown above is to determine whether a function control key on the operation display is pushed and to turn on the corresponding function indication LED The drive type is the scan type 26 7 3 RESISTANCE SPECIFICATION OF SENSOR TEMPERATURE SENSOR RESISTANCE OF REFRIGERATOR DEFROST SENSOR 20 C 77 15 60 KQ 10 47 3 5 38 4 0 C 30 KO 5 C 24 1 10 C 19 5 15 C 15 9 20 13 KQ 25 C 11 KQ 30 8 9 40 6 2 50 4 3 e resistance SENSOR has 5 difference Measure the resistance of SENSOR after leaving it over 3 minutes in measuring temperature This postponing is necessary because of perceiving speed 27 7 4 TROUBLE SHOOTING Replace PCB when no trouble after checking the contents of trouble CLASSIFICATION STATE OF TROUBLE POINT BE CHECKED CHECKING METHOD CONTENT REMEDY POWER SOURCE 1 All the DISPLAY FREEZER FREEZER REFRIGERATOR POWER SOURCE is poor Certify Fuse is poor LED OFF REFRIGERATOR DOOR OPEN Certify outlet Voltage 2 DISPLAY LED LAMP is dim CHECK with the naked Applied voltage mistake Use boosting TRANS represents abnormal The connection of Certify connection of CONNECTOR connection Reconnect CONNECTOR operation CONNECTOR of MAIN PWB CONNECTOR is poor TRANS FUSE open Replace TRANS COOLING is p
34. sket to remove from the door foam Ass y 3 2 DOOR SWITCH 1 To remove the door switch pull out it with a type driver as shown in figure 9 2 Disconnect the lead wire from the switch Figure 9 3 3 THERMISTOR 1 Remove the Cover Lamp R by the use of type driver inserting in the low holes of the cover Loose 2 screw Pull the Control Box R Disconnect the Housing of lead wire Separate the INSU Multi Duct and Control Box R Separate the Thermistor and Control Box R Separate the Thermistor and Display PCB NOOR WP INSU MULTI DUCT DISPLAY PCB THERMISTOR CONT BOX R COVER LAMP R Figure 10 3 4 FAN AND FAN MOTOR 1 Remove the freezer shelf 2 Separate the twist by pulling right 3 Loose 1 screw 4 Pull out the Grille Fan and Shroud F SCREW Figure 11 5 Disconnect the housing of lead wire 6 Separate the Fan Assy 7 Loose 2 screw fixed to the Bracket 8 Pull out Shroud F remove the Fan Motor Assy 9 Separate the Motor Bracket and Rubber FAN MOTOR SHROUD F GRILLE FAN Figure 12 3 5 DEF CONTROL ASM Def control ASM consists of Defrost Sensor and FUSE M Defrost Sensor functions to defrost automatically and it is attached to the Evaporator and the metal side of the case senses Temp Fuse M is a kind of safety device for preventing over heating of the Heater when defrosting
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