Service
Service Manual for
Amana
®
This manual is to be used by qualified appliance
technicians only. Amana does not assume any
responsibility for property damage or personal
injury for improper service procedures done by an
unqualified person.
Bottom Mount Refrigerators
Refer to “Technical Sheet”, part #12074201
for values and wiring schematics.
Raytheon
Appliances
RS1200001
Revision 0
November 1996
Base manual covers 84” tall
bottom mount refrigerators.
RS1200001 2 November 1996
Safety Symbols, Words, and Labels
DANGER
Immediate hazards which will result in
severe personal injury or death.
WARNING
Hazards or unsafe practices which could
result in severe personal injury or death.
Caution
Hazards or unsafe practices which could
result in minor personal injury or product or
property damage.
Amana Refrigeration, Inc. is not responsible for
personal injury or property damage resulting from
improper service. Review all service information
before beginning repairs.
Warranty service must be performed by an
authorized Amana
®
technician. Amana Refrigeration,
Inc. also recommends contacting an authorized
Amana
®
technician if service is required after
warranty expires. Contact (319) 622-5511 for further
assistance.
Electrical Requirements
WARNING
Electrical Grounding Instructions -- This
refrigerator is equipped with a three-prong
(grounding) plug for protection against
possible shock hazards. If a two-prong wall
receptacle is encountered, contact a qualified
electrician and have the two-prong wall
receptacle replaced with a properly grounded
three-prong wall receptacle in accordance
with the National Electrical Code.
Refrigerator is designed to operate on a
separate 103 to 126 volt, 15 amp., 60 cycle
line.
Do not under any circumstances cut or
remove the round grounding prong from
the plug. Refrigerator must be grounded
at all times. Do not remove warning tag
from power cord.
WARNING
Do not use a 2 prong adapter.
Do not use an extension cord.
Safety and Electrical Information
Grounding Information
Standard color for ground wires is green or green with
yellow striping. Ground wires are not to be used as
conductors carrying current. Compressor, condenser
fan motor, evaporator fan motor, defrost timer,
temperature control, and ice maker are grounded
through an individual wire attached to electrical
component and another part of refrigerator. Ground
wires should not be removed from individual
components while servicing unless component is
removed and replaced. It is extremely important to
replace all grounds prior to completing service. When
nib-headed screw is used to complete grounding
circuit, replace screw with a like screw.
November 1996 3 RS1200001
Contents
Safety and Electrical Information
Safety Symbols, Words, and Labels ....................... 2
Electrical Requirements .......................................... 2
Grounding Information............................................. 2
Installation Instructions ............................................... 5
Sound Information ...................................................... 9
System Diagnosis
Pressure and Relationship Chart........................... 10
Refrigerant Overcharge Symptoms .......................11
Refrigerant Shortage Symptoms............................11
Restriction Symptoms ............................................11
Air in System Symptoms....................................... 12
Low or High Ambient Temperature Installation .........
Symptoms.............................................................. 12
Heat Load Symptoms............................................ 12
HFC134a Service Information
Health, Safety, and Handling................................. 13
Comparison of CFC12 and HFC134a Properties.. 13
Service Equipment ................................................ 14
Drier Replacement ................................................ 14
Replacement Service Compressor ....................... 15
Refrigerant Charge ................................................ 15
Leak Testing........................................................... 15
Evacuation and Charging ...................................... 15
Refrigerant Flow ....................................................... 17
Air Flow ..................................................................... 18
Machine Compartment Assembly ............................ 19
Component Function and Testing............................. 20
Electronic Functional Description ............................. 25
Electronic Testing Mode ........................................ 26
Forced Defrost Activation .................................. 26
Forced Compressor Activation........................... 26
Open Thermistor Detect..................................... 26
Key Board Functions ............................................. 26
Display On Pad .................................................. 26
Warmer Pad ....................................................... 26
Colder Pad ......................................................... 26
Freezer Temp Pad.............................................. 27
Ref Temp Pad .................................................... 27
Vacation Pad ...................................................... 27
Max Ref Pad ...................................................... 27
Max Frz Pad....................................................... 27
Alarm Off Pad .................................................... 27
Display Off Pad .................................................. 27
Door Open Alarm ............................................... 27
High Temp .......................................................... 27
Temperature Control Operation............................. 27
Adaptive Defrost Operation................................... 28
Power Up Condition............................................... 28
EEPROM Update in Control Memory ................... 28
Accessing Program Mode .................................. 28
Operation............................................................ 29
Mode A Functions .............................................. 29
Mode B Functions .............................................. 29
Exiting Program Mode ....................................... 30
Refrigeration and Defrost Component Checks .........
Made at High Voltage Board ................................. 32
Circuitry ................................................................. 33
Freezer Compartment Refrigeration ......................
Cycle Circuitry .................................................... 33
Fresh Food Compartment Refrigeration ................
Cycle Circuitry .................................................... 33
Fresh Food and Freezer Compartment .................
Refrigeration Cycle Circuity ............................... 33
Adaptive Defrost Circuitry .................................. 33
Door Disassembly Procedures
Air Discharge Grille ............................................... 34
Refrigerator Door................................................... 34
Freezer Drawer and Basket................................... 34
Door Stops............................................................. 34
Door Handles......................................................... 34
Door Gaskets......................................................... 34
Inner Door Liners and Outer Door Shells .............. 34
Refrigerator Door Switch ....................................... 34
Cabinet Components Disassembly Procedures
Refrigerator Fan .................................................... 35
Refrigerator Light Switch ....................................... 35
Refrigerator Light Socket....................................... 35
Center Mullion ....................................................... 35
Freezer Switches and Thermistor Panel ............... 35
Freezer Evaporator Cover..................................... 35
Defrost Thermostat................................................ 35
Evaporator Defrost Heater .................................... 35
Evaporator ............................................................. 35
Evaporator Fan Blade ........................................... 35
Evaporator Fan Motor ........................................... 35
Front and Rear Roller Assembly ........................... 35
Water Valve ........................................................... 35
Condensate Drain Pan .......................................... 36
Shelf Support Ladders........................................... 36
Chef's Pantry Assembly ........................................ 36
Refrigerator Thermistor ......................................... 36
Machine Compartment Disassembly Procedures
Machine Compartment Access ............................. 37
Low and High Voltage Board and Showroom Switch
Access ................................................................... 37
Low Voltage Board................................................. 37
High Voltage Board................................................ 37
Compressor, Condenser, and Condenser .................
Fan Access ............................................................ 37
Capacitor ............................................................... 37
Overload and Relay............................................... 37
Condenser Fan Blade............................................ 37
Condenser Fan Motor............................................ 37
Precondenser Pan Loop ........................................ 37
Compressor ........................................................... 37
Condensate Drain Pan .......................................... 38
Condenser ............................................................. 38
Power Disconnect Switch ...................................... 38
Showroom Switch.................................................. 38
Typical External Sweat Pattern ................................ 39
Troubleshooting Guide.............................................. 40
RS1200001 4 November 1996
Ice Maker
Operation ............................................................... 42
Specifications ........................................................ 42
Testing Procedures ................................................ 42
Disassembly Procedures ....................................... 43
Cover.................................................................. 43
Module, Motor, and Support Assembly .............. 43
Shut-off Arm ....................................................... 43
Module and Heater Assembly ............................ 43
Fill Cup ............................................................... 43
Ejector Blades or Stripper .................................. 44
Accessing Control Box ....................................... 44
Water Fill Adjustment............................................ 44
Water Problems..................................................... 45
Temperature Problems .......................................... 45
Thermostat ............................................................ 45
Wiring Harness ...................................................... 45
Water Valve ........................................................... 46
Wiring Harness ...................................................... 46
Ice Maker Troubleshooting Chart ............................. 47
Ice Maker Wiring Diagram and Parts Layout ........... 50
Trim Kit Installation Instructions
B136CKR1 and B136CKL1 Custom Handle Kit.... 51
B136SPK1 1/4” Facia Front Enclosure Kit............ 58
B136SPK2 3/4” Side Panel Kit.............................. 65
Contents
November 1996 5 RS1200001
Installation Instructions
Securing
WARNING
To avoid severe personal injury or property
damage from refrigerator tipping over, do not
open more than one door at a time, until
refrigerator has been secured to the structure.
Secure refrigerator to structure using lag bolts
located in the refrigerator's machine
compartment.
1. Locate and mark 2 wall studs to mount 2x4. See
"Installation Specifications". Do not cover electrical
outlet with 2x4.
Locate and predrill 1/4" holes in 2x4. Countersink
2x4 for bolt heads using a wood bit. See "Installation
Specifications".
2. Remove 2x4 mounting board from top rear of
refrigerator. Bolt 2x4 securely to wall studs with
supplied bolts. If application does not have studs
such as a framed wall mount to wall, not surface,
using a minimum 1/4" diameter fasteners (not
supplied). If cabinets are deeper than 24" mounting
board must be shimmed and structurally secured to
the 2 x 4 board. Longer bolts are required to shim
mounting board.
3. To avoid water line damage, verify water line is
secure so refrigerator does not run over water line.
See "Installation Specifications" for water line
location.
4. Repair any loose flooring in cutout.
5. Tape door and drawer shut with masking tape.
Before moving the refrigerator in place, confirm the
finished dimensions, electrical and plumbing locations,
and minimum door and drawer clearances are accurate.
6. Position refrigerator in front of cutout.
7. Remove air grille assembly by lifting center blade.
Uncrating
WARNING
To avoid severe personal injury or property
damage from refrigerator tipping over, 2 or
more people are required to install
refrigerator. Take caution when removing
refrigerator from skid. Do not drop refrigerator.
Do not open more than one door at a time,
until refrigerator has been secured to
structure. Refrigerator is top heavy and easily
tips.
Caution
To avoid personal injury, wear gloves
when performing any installation procedure.
The 2 x 4 mounting board, for securing refrigerator to
wall, is attached to top rear of refrigerator. Save
cardboard to protect walls when installing refrigerator.
1. Remove top and bottom strap.
2. Remove top cap.
3. Cut along dashes on carton rear with a utility knife
extended 1/4".
4. Remove carton, exterior packaging, and tape from
lag screws. Do not remove nylon cord from power
cord.
5. Remove shipping brackets from skid by removing 4
bolts with a 7/16" socket head screwdriver.
6. Strap refrigerator on cart. To prevent doors from
opening, tilt refrigerator to handle side. Remove
refrigerator from skid.
7. To avoid floor damage, use protective material.
Caution
To avoid property damage, protect soft vinyl
or other flooring with protective material when
moving refrigerator. Verify wheels are clean
before placing refrigerator on flooring.
Center air
grille blade
Air grille
RS1200001 6 November 1996
Installation Instructions
8. Remove (4) 1/4" screws with a magnetic extended
screw driver.
9. Pull air grille assembly forward.
10. Verify operation by plugging in power cord. Power
switch will be shipped in the on position and the
showroom switch will be shipped in the off position.
Display should flash. Press any key. There is a 6
minute delay before refrigerator starts. Verify
position of each switch if there is no power to
refrigerator.
11. Pull end of nylon cord around refrigerator side (side
without 1/4" panel installed, if any) level with top of
refrigerator door. Tape cord in place.
WARNING
To avoid electrical shock which can cause
severe personal injury or death, disconnect
power to refrigerator using power switch
before performing any installation procedure.
After performing installation procedure,
connect power using power switch.
Air grille
assembly
1/4" screws
Showroom
switch
Power
switch
12. Roll refrigerator into cutout to within 3" of being
flush with kitchen cabinets. To avoid kitchen cabinet
damage, place cardboard between kitchen cabinets
and refrigerator. Push cardboard back with
refrigerator and remove cardboard when refrigerator
is in place. Remove power cord slack by pulling
nylon cord straight out while pushing refrigerator
completely into place. Power and nylon cord will
rest along refrigerator side.
13. Level refrigerator by turning front and rear leveling
wheel bolts clockwise to raise refrigerator and
counterclockwise to lower refrigerator. Rotate
stabilizing legs until firmly in place against floor.
14. Align refrigerator with sides of kitchen cabinets
using leveling bolts.
15. Secure lag bolts by removing center air grille blade.
Screw lag bolts securely into 2x4 mounting board
using a magnetic 6" extension socket. See
"Installation Specifications".
16. Push extra nylon cord back in along side of
refrigerator out of sight or cord can be flush with
refrigerator.
Pull nylon
cord straight
out
Lag bolts
Power cord
must rest
as shown
November 1996 7 RS1200001
Installation Instructions
Door Panel Installation
Panels must not weigh more than 50 pounds per door.
Refrigerator Door 3/4" Raised Panel
1. Slide out handle screw insert and remove handle
by removing screws with a Phillips
screwdriver.
2. Align panel brackets (supplied) with center edge
of panel. Install brackets using 1/4" screws
(supplied).
3. If base panel is less than 1/4" use plastic
shims (supplied). Shims go between bracket and
wood to space panels to desired depth.
4. Drive low profile screws (supplied) with
Phillips screwdriver.
• Panel brackets must be exactly flush to 1/16"
inboard of panel edge.
• For ease of panel installation 2 people are
required to lift and guide panel into trim.
• Install 1 panel at a time.
5. Align panel in trim and push evenly. For
smoother installation apply bar soap on door
trim and refrigerator trim. If panel binds loosen
top or side door trim. Adjust panel and retighten.
6. Install handle with screws. Install screw strip
(supplied) by starting in one corner and pushing
the length of the strip down.
Handle
Refrigerator Door
Water Connection
The garden hose fitting, compression nut, and sleeve
are located in the literature packet. Amana
®
Clean
'n Clear
™
Bayonet Style Water Filtration System
WF60 is shipped in crisper drawer. See water filter
installation and operating instructions for
specifics.
1. Flush air and impurities from water line by
turning on water supply and running a pint or
more of water into a bucket.
2. Remove plastic cap from water valve fitting.
Connect copper tubing to water valve with
brass nut and brass sleeve. Insert copper tubing
completely into water valve inlet port. Connect
brass nut on copper tubing to water valve inlet
port fitting. Confirm copper tubing is secure by
pulling on copper tubing.
3. Turn on water supply to refrigerator and check
forleaks. Turn off water supply to
refrigerator and correct any leaks. Repeat
this process until no leaks exist. Completely
turn on water supply to refrigerator.
4. Verify drain pan is installed and aligned.
5. Replace toe grille with air vents to the top.
Kitchen flooring must allow toe grille to be
removed. See "Installation Specifications" for
height clearance. See "Custom Finishing
Options" when using a custom toe grille.
Clip
Toe grille
Air vents
Screws
Handle screw
insert
RS1200001 8 November 1996
Installation Instructions
Freezer Door 3/4" Raised Panel
1. Slide out handle screw insert and remove handle
by removing screws with a Phillips
screwdriver. Handle is in 2 pieces, reinstall if
pieces come apart.
2. 1/2" x 3 1/2" notch is required on hinge side.
3. Remove top handle trim and 1 side trim piece for
ease of installation.
4. Align panel brackets and screws.
5. Align panel in trim and push evenly. Start at one
end and work across. For smoother installation
apply bar soap on door trim and freezer trim. If
panel binds loosen top or side door trim. Adjust
panel and retighten.
6. Install handle with screws. Install screw strip
(supplied) by starting in one corner and pushing
the length of the strip down.
Door Stop Adjustment
1. Remove center grille blade from top air grille.
2. Remove top air grille by removing (4) 1/4” screws
with a magnetic screw driver. Pull assembly
forward.
3. Open refrigerator door so door stop arm and
shoulder screw are accessible. Shoulder
screws should be in 110° door opening position.
4. Remove shoulder screw and place shoulder
screw
in the 90° or 120° door opening position.
Freezer Door
120° door
opening
position
110° door
opening
position
90° door
opening
position
Door stop arm
Shoulder
screw
Hinge Adjustment
Verify proper door alignment. Wait until panels are
installed for door settlement. Only the top hinge is
adjustable.
Adjust top hinge by completing the following:
1. Remove air grille blade and air grille assembly.
2. Loosen top hinge screws.
3. Align refrigerator door by lifting.
4. Tighten screws.
5. Install air grille.
6. Replace air grille assembly.
Interior Setup
1. Remove interior packaging.
2. Turn shelves upright.
3. Move dairy module to desired position on
refrigerator door. See "Model Diagram".
4. Twist cardboard in ice bin to release freezer
tray.
5. Remove literature packet from freezer tray and
give to consumer. Complete "Installation
Checklist" with consumer.
Top hinge
Top hinge
screws
Screws
Handle screw
insert
Handle
November 1996 9 RS1200001
Sound Information
Normal Operating Sounds
This new refrigerator may be replacing a differently
designed, less efficient or smaller refrigerator.
Today’s refrigerators have new features and are more
energy efficient. As a result, certain sounds may be
unfamiliar. These sounds are normal and will soon
become familiar. These sounds also indicate the
refrigerator is operating and performing as designed.
• Freezer and fresh food fan air rushes and whirs.
• Sealed system (evaporator and heat exchanger)
refrigerant flow gurgles, pops or sound like boiling
water.
• Defrost heater sizzles, hisses or pops.
• Condenser fan air rushes and whirs.
• Compressor has a high pitched hum or pulsating
sound.
• Ice cubes from ice maker drop into ice bucket.
• Ice maker water valve hookup buzzes when ice
maker fills with water. This occurs whether or not
refrigerator is connected to water supply. If
refrigerator is not connected to water supply, stop
sound by raising ice maker arm to off position.
• Foam insulation is very energy efficient and has
excellent insulating capabilities. However, foam
insulation is not as sound absorbent as previously
used fiberglass insulation.
RS1200001 10 November 1996
System Diagnosis
Pressure and Relationship Chart
Condition Suction
Pressure
Variation
from Normal
Head Pressure
Variation from
Normal
T1 Inlet
Temperature
Variation from
Normal
T2 Outlet
Temperature
Variation from
Normal
T3 Suction
Temperature
Variation from
Normal
Wattage
Variation from
Normal
Refrigerant
Overcharge
Increase Increase Warmer Warmer Colder Increase
Refrigerant
Shortage
Decrease
Decrease or Increase
See "Refrigerant
Shortage Symptoms"
Colder Warmer Warmer Decrease
Partial
Restriction
Decrease
Decrease or Increase
See "Restriction
Symptoms"
Colder Warmer Warmer Decrease
Air in System
Near Normal Increase Warmer Warmer Warmer Increase
Low Ambient
Installation
(Reverse for
High Ambient
Installation)
Decrease Decrease Colder Warmer Warmer Decrease
Additional
Heat Load
Increase Increase Warmer Warmer Warmer Increase
Inefficient
Compressor
Increase Normal or Decrease Warmer or Colder Warmer Warmer Decrease
November 1996 11 RS1200001
System Diagnosis
Refrigerant Overcharge Symptoms
• Above normal freezer temperature.
• Compressor running continuously.
• Freezing in refrigerator due to Chef’s Pantry
™
.• High suction and head pressure.
• High wattage.
• Warm evaporator inlet and outlet temperature.
• Below ambient suction tube temperature. Check for
separated heat exchanger when suction temperature
is colder than ambient.
• Refrigerant will flood out causing suction line to frost
or sweat, if defrost system fails and cooling coil is not
defrosted. Correct problem instead of purging
refrigerant.
• Freezer colder than necessary (normal package
temperature is 0° to 2°F).
• Evaporator fan motor not running.
Refrigerant Shortage Symptoms
• Rise in refrigerator and freezer temperatures.
Warm beverages will be first indication of
possible refrigerant shortage. Frozen meats and
vegetables will not thaw immediately. Some freezing
may occur in refrigerator section due to additional run
time because of Chef’s Pantry
™
. Capillary line will not
have full column of liquid with refrigerant shortage. A
noticeable hissing sound in evaporator will be heard.
Hissing should not be mistaken for regular refrigerant
boiling sounds.
• Long or continuous run time.
• Traces of oil caused by leak or cracked refrigerant
line.
• Lower than normal wattage.
• Compressor will feel hot due to heat generated by
motor windings from continuous running. Compressor
will not be as hot as it would be with full charge and
long run times caused by reasons such as dirty
condenser.
• Condenser will feel room temperature.
• Capillary tube will feel warmer than normal.
• If high side leak, both gauges will show lower than
normal readings. As charge becomes less, readings
will lower. Suction pressure gauge will probably
indicate a vacuum.
• If low side leak, suction pressure gauge will show
lower than normal readings, probably in a vacuum.
Head pressure gauge will show higher than normal.
Readings will probably rise because of air drawn in
through leak is compressed by compressor and
accumulates in high side (condenser) of system.
• Partial frosting of evaporator.
Restriction Symptoms
• Refrigeration cooling occurs on low pressure side of
partial restriction.
• Total restriction will stop circulation of refrigerant and
no cooling will occur.
• Touch refrigeration lines. Most common place for
restriction is at drier filter or capillary tube inlet or
outlet.
• If partial restriction there will be temperature
difference at restriction point. Evaporator side will be
cooler. In most cases, frost and/or condensation will
be present. Longer time is required for system to
equalize.
• Kinked line will cause restriction. Visually check entire
system for kinks.
• Slight restriction will give same indications as
refrigerant shortage with lower than normal back
pressure, head pressure, wattage, and warmer
temperatures.
• If total restriction is on discharge side of compressor,
higher than normal head pressures and wattages will
occur. This is only true while low side is being pumped
out and if restriction was between compressor and
first half of condenser.
Diagnose restriction by completing the following:
1. Discharge system.
2. Replace drier-filter.
3. Evacuate and recharge system with specified
refrigerant charge.
If refrigerator performs normally, the following
conditions may exist:
• refrigerant loss
• partially restricted drier
• moisture in system
If refrigerator performs as previously described,
capillary line or condenser may be restricted. Locate
and correct restriction point.
Restriction reduces refrigerant flow rate and heat
removal rate. Total restriction may be caused by
moisture, poorly soldered joint, or solid contaminants
in system. Moisture freezes at evaporator inlet end of
capillary tube. Solid contaminants collect in drier.
Wattage drops because compressor is not circulating
normal amount of refrigerant.
If restriction is on low side suction, pressure will be in
a vacuum and head pressure will be near normal. If
restriction is on high side, suction pressure will be in a
vacuum and head pressure will be higher than normal
during pump out period. In both cases, it will take
longer than 10 minutes for head pressure to equalize
with low side after compressor stops.
RS1200001 12 November 1996
System Diagnosis
Air in System Symptoms
Air in system can be caused by low side leak or
improper servicing. If low side leak occurs,
temperature control will not achieve temperatures
and compressor will run continuously. Compressor
will eventually pump low side into a vacuum, drawing
air and moisture into system. Air and R134a do not
mix. Air pressure will be added to normal head
pressure, resulting in higher than normal head
pressures.
Determine if air is present by reading head pressure
gauge with refrigerator off and evaporator and
condenser at same temperature. Verify temperature
on condenser outlet tube. Temperature should be
within 3° or 4°F of what "Pressure and Temperature
Relationship Chart" shows for a given idle head
pressure. If temperature of condenser outlet is
considerably lower than idle head pressure of gauge,
air is in system.
Diagnose air in system by completing the following:
1. Thoroughly check for leaks.
2. Correct leak source. Do not attempt to purge air
off. This could result in an undercharged system.
3. Discharge system.
4. Replace drier-filter.
5. Evacuate and recharge system with specified
refrigerant charge.
Low or High Ambient Temperature
Installation Symptoms
Lower ambient air temperature reduces condensing
temperature and temperature of liquid entering
evaporator. Increase in refrigeration due to operation
in lower ambient results in decrease in power
consumption and run time. At lower ambients there is
reduction in cabinet heat leak which is partially
responsible for lower power consumption and run
time.
An increase in refrigeration will not occur below
certain minimum ambient temperature. Temperature
varies with type and design of refrigerator.
Ambient temperatures lower than 55°F will affect
efficiency. The higher the ambient temperature, the
higher the head pressure must be to raise the high
side refrigerant temperature above condensing
medium. Head pressure will be higher as ambient
temperature raises. Refrigerators installed in ambient
temperatures lower than 55°F will not perform
effeciently because system pressures are generally
reduced and unbalanced. Lower head pressure forces
less liquid refrigerant through capillary line, resulting
in symptoms of refrigerant shortage. The lower the
ambient temperature, the more pronounced the
condition.
When ambient temperature is below cut-in of
temperature control, compressor will not operate.
Drain traps will freeze in ambient temperatures of
32°F.
Heat Load Symptoms
Increased heat load can result from addition of large
supply of foods, excessive door openings, poor door
sealing, interior light remaining on, etc.
Increased heat being absorbed by refrigerant in
evaporator will affect temperature and pressure of
gas returning to compressor. Refrigerator and freezer
temperatures, power consumption, discharge, and
suction pressures are all affected by heat load.
Pressures will be higher than normal under heavy
heat load.
November 1996 13 RS1200001
HFC134a Service Information
HFC134a is alternative refrigerant for CFC12.
HFC134a has an ozone depletion potential (ODP)
factor of 0.0 and a global warming potential (GWP)
factor of 0.27. HFC134a is not flammable and has
acceptable toxicity levels. HFC134a is not
interchangeable with CFC12. There are significant
differences between HFC134a and CFC12 which
must be considered when handling and processing
refrigeration system.
Health, Safety, and Handling
Health, safety and handling considerations for
HFC134A are virtually no different than those for
CFC12.
Health, Safety, and Handling CFC12 HFC134a
Allowable overall exposure limit 1,000 ppm Same
Vapor exposure to skin No effect Same
Liquid exposure to skin Can cause frostbite Same
Vapor exposure to eye Very slight irritant Same
Liquid exposure to eye Can cause frostbite Same
Above minimum exposure limit Can cause Asphyxiation, Same
Tachycardia, and Cardia
Arrhythmias
Safety and handling Wear appropriate skin and eye Same
protection. Use with adequate
ventilation.
Spill management Remove or extinguish ignition or Same
combustion sources. Evacuate
or ventilate area.
Fire and explosion hazards May decompose if contact with
flames and heating elements.
Container may explode if heated
due to resulting pressure rise.
Combustion products are toxic.
Storage conditions Procedures/rules for CFC12 Same
also apply for HFC134a
Disposal procedures Recycle or reclaim Same
Comparison of CFC12 and HFC134a
Properties
Properties/Characteristics CFC12 HFC134a
Ozone Depletion Potential (ODP) 1.0* 0.0*
Global Warming Potential (GPW) 3.2* 0.27*
Molecular weight 121 102
Boiling point at 1 atmosphere -22°F (-30°C) -15°F (-26°C)
Vapor pressure at 77°F (25°C) 80 psig 82 psig
Liquid density at 77°F (25°C) 82 lb/ft3 75 lb/ft3
Flammability No No
High-side system operating HFC134a approximately 3 psig
Pressure at 65°F (18°C) ambient higher than CFC12
Low-side system operating HFC134a approximately 2 psig
Pressure at 65°F (18°C) ambient lower than CFC12
* Compared to CFC 11 = 1
Caution
To minimize contamination, exercise extreme
care when servicing HFC134A sealed systems.
• No trace of other refrigerants is allowed in HFC134a
systems. Chlorinated molecules in other refrigerants
such as CFC12, etc. will lead to capillary tube
plugging.
• Ester oil is used in HFC134a systems. Do not use
mineral oil. HFC134a and mineral oils cannot be
mixed. If mineral oils were used in HFC134a systems,
lubricant would not return to compressor and would
cause early compressor failure. If significant amount
of oil has been lost from compressor, replace oil
rather than adding oil.
• Ester oils used in HFC134a systems are so
hydroscopic that by the time an inadequate system
performance is detected, oil will be saturated with
moisture.
• CFC12 has much higher tolerance to system
processing materials, such as drawing compounds,
rust inhibitors, and cleaning compounds, than
HFC134a. Such materials are not soluble in HFC134a
systems. If materials were to be washed from system
surfaces by ester oils, they could accumulate and
eventually plug capillary tube.
• Care must be taken to minimize moisture from
entering HFC134a system. Do not leave compressor
or system open to atmosphere for more than 10
minutes. Excessive moisture in HFC134a system will
react with compressor oil and generate acid.
• Compressor must be replaced when performing low
side leak repair.
• Drier filter must always be replaced with service drier
filter, part #B2150504.
Important: Unbrazing drier filter from tubing will drive
moisture from desiccant and into system, causing
acids to form. Do not unbraze filter drier from tubing.
If CFC12 service drier was installed in HFC134A
system, drier could overload due to excessive
moisture.
• HFC134a compatible copper tubing, part
#R0174075 (1/4" O.D. X 18" length) and part
#R0174076 (5/16" O.D. X 24" length) must be used
when replacing tubing.
• Avoid system contamination by using Towerdraw
E610 evaporating oil, part # R0157532, when flaring,
swaging, or cutting refrigeration tubing.
RS1200001 14 November 1996
Service Equipment
Listed below is equipment needed for proper
servicing of HFC134a systems. Verify equipment is
confirmed by manufacturer as being compatible with
HFC134a and ester oil system.
Equipment must be exclusively used for HFC134a.
Exclusive use of equipment only applies to italic
items.
• Evacuation pump
Check with vacuum pump supplier to verify
equipment is compatible for HFC134a. Robinair,
Model 15600, 2 stage, 6 cubic feet per minute pump
is recommended.
• Four-way manifold gauge set, with low loss hoses
• Leak detector
• Charging cylinder
• Line piercing saddle valve
(Schroeder valves). Seals must be HFC134a and
ester oil compatible. Line piercing valves may be used
for diagnosis but are not suitable for evacuation or
charging, due to minute holes pierced in tubing. Do
not leave mechanical access valves on system.
Valves eventually will leak. Molecules of HFC134a are
smaller than other refrigerants and will leak where
other refrigerants would not.
• Swaging tools
• Flaring tools
• Tubing cutter
• Flux
• Sil-Fos
• Silver solder
• Oil for swaging and flaring
Use only part #R0157532
• Copper tubing
Use only part #R0174075 and #R0174076
• Dry nitrogen
99.5% minimum purity, with -40°F or lower dew point
• Crimp tool
• Tube bender
• Micron vacuum gauge
• Process tube adaptor kit
• Heat trap paste
• ICI appliance grade HFC134a
Drier Replacement
Prior to opening refrigeration system, recover
HFC134a refrigerant for safe disposal.
Every time sealed HFC134a system is repaired, drier
filter must be replaced with, part # B2150504.
Cut drier out of system by completing the following
steps. Do not unbraze drier filter. Applying heat to
remove drier will allow moisture into system.
1. Score capillary tube close to drier and break.
2. Reform inlet tube to drier allowing enough space
for large tube cutter.
3. Cut circumference of drier at 1-1/4", below
condenser inlet tube joint to drier.
4. Remove drier.
5. Apply heat trap paste on post condenser tubes to
protect grommets from high heat.
6. Unbraze remaining part of drier. Remove drier
from system.
7. Discard drier in safe place. Do not leave drier with
customer. If refrigerator is under warranty, old
drier must accompany warranty claim.
HFC134a Service Information
DANGER
To avoid death or severe personal injury, cut
drier at correct location. Cutting drier at incorrect
location will allow desiccant beads to scatter.
Completely clean area of beads, if spilled.
November 1996 15 RS1200001
HFC134a Service Information
Replacement Service Compressor
HFC134a service compressors will be charged with
ester oil and pressurized with dry nitrogen. Before
replacement compressor is installed, pull out 1 rubber
plug. A pop from pressure release should be heard. If
a pop sound is not heard, do not use compressor.
Positive pressure in compressor is vital to keep
moisture out of ester oil. Do not leave compressor
open to atmosphere for more than 10 minutes.
Compressor Testing Procedures
• Refer to “Temperature and Relationship Chart” for
operating watts, test points, and temperature
relationship test.
• Temperature testing is accomplished by using 3 lead
thermocouple temperature tester in specific locations.
Test point T-1 is outlet on evaporator coil and T-2 is
inlet. Test point T-3 is suction tube temperature
midway between where armaflex ends and suction
port of compressor (approximately 12 inches from
compressor).
• Thermocouple tips should be attached securely to
specified locations.
• Do not test during initial pull down. Allow one off cycle
or balanced temperature condition to occur before
proceeding with testing.
• Refrigerator must operate minimum of 20 minutes
after thermocouples are installed.
• Turn control to colder to obtain required on time.
• Wattage reading must be recorded in conjunction with
temperature test to confirm proper operation.
• Suction and head pressures are listed on
“Temperature and Relationship Chart” Normally these
are not required for diagnosis but used for
confirmation on systems which have been opened.
Refrigerant Charge
Refrigerant charge in all capillary tube systems is
critical and exact amount is required for proper
performance. Factory charges are shown on serial
plate. Do not use refrigerant other than shown on
serial plate.
Leak Testing
Undetected leaks lead to repeated service calls and
eventually result in system contaminations,
restrictions, and burned out compressors.
After recharging, sealed system must be thoroughly
tested for leaks. If a very small leak is difficult to
isolate, coat area with soap suds and observe
location of bubbles.
To avoid death or severe personal injury, never
use oxygen, air or acetylene for pressure testing
or cleanout of refrigeration system. Use of
oxygen, air, or acetylene may result in violent
explosion. Oxygen may explode on contact with
oil and acetylene will spontaneously explode
when under pressure.
WARNING
Evacuation and Charging
Vacuum Pump
.6 cm Copper
Tubing
Compressor
Compressor
Process
Tube
Charging Hose
Thermistor
Vacuum Gauge
Low Side Gauge
E
Valve
B
D
Valve
High Side Gauge
Charging Hose
Drier/Process Tube
F
Valve
Charging
Cylinder
C
A
RS1200001 16 November 1996
HFC134a Service Information
Before opening system evaporator coil must be at
ambient temperature to minimize moisture infiltration
into system.
1. After capturing refrigerant, replacing drier and
making any repairs, evacuate system from high
side through drier/process tube and low side
through compressor process tube simultaneously.
Evacuation should not be done through line
piercing valve but through I.D. opening of tubes.
2. With valves “C” and “F” closed to thermistor
vacuum gauge and charging cylinder, open all
other valves and start vacuum pump.
3. At approximately 29 inches of vacuum, open valve
“C” to thermistor vacuum gauge and take micron
reading.
4. Continue evacuating system until thermistor
vacuum gauge registers 600 microns.
5. At 600 microns close valve “A” to vacuum pump to
allow micron reading in system to balance. Micron
level will rise. If in 2 minutes, micron level
stabilizes at 1000 microns or below, system is
ready for charging.
• If micron rises above 1000 micron level and
stabilizes, open valve “A” to vacuum pump and
continue evacuating.
• If micron reading rises rapidly and does not
stabilize, a leak still exists in system. Close valve
“A” to vacuum pump and “C” to thermistor vacuum
gauge. Invert charging cylinder and open charging
cylinder valve “F” to add partial charge for leak
checking. With leak detector, check manifold
connections and system for leaks. After locating
leak, capture refrigerant charge, repair leak, and
begin at step 1.
6. Once system is ready to charge, close valve “A”
(vacuum pump), “C” (thermistor vacuum gauge),
and “E” (low side manifold gauge).
7. Check serial plate for correct charge and set scale
on dial-a-charge cylinder for corresponding
HFC134a pressure reading. Do not use captured or
recycled refrigerant in Amana
®
refrigerators. Use
of captured or recycled refrigerant voids any
warranty.
8. Open valve “F” to charging cylinder and let exact
amount of refrigerant out of cylinder. Close valve.
Low side gauge pressure should rise shortly after
opening charging cylinder valve as system
pressure equalizes through capillary tube. If
pressure does not equalize, a restriction typically
exists at capillary/drier braze joint.
WARNING
To avoid severe personal injury or death from
fire keep system free from contamination due
to presence of air. Follow instructions exactly.
9. If no restriction exists, open valve “E” (low side
manifold gauge) and pinch off high side drier
process tube.
10. Start compressor and draw remaining refrigerant
in charging hoses and manifold into compressor
through compressor process tube. To check high
side pinch-off drier process tube, close valve “D”
(high side gauge). If pinch-off is not leaking, high
side pressure will not rise. If high side pressure
gauge shows an increase, repeat high side pinch-
off and open valve “D”. Repeat until high side
pinch-off no longer leaks.
11. Pinch-off compressor process tube and remove
charging hose. Braze stub closed while
compressor is operating.
12. Unplug refrigerator from electrical outlet.
Remove charging hose and braze high side drier
process tube closed.
November 1996 17 RS1200001
Refrigerant Flow
RS1200001 18 November 1996
Air Flow
November 1996 19 RS1200001
Machine Compartment Assembly
Component Function and Testing
RS1200001 Rev. 1 20 April 1998
Capacitor Run capacitor connects to relay terminal.
Capillary tube
Compressor When compressor electrical circuit is energized, the
start winding current causes PTC relay to heat. After an
amount of starting time the start winding circuit turns
off. PTC relay will switch off the start winding circuit
even though compressor has not started (as when
attempting to restart after momentary power
interruption).
With "open" PTC relay, compressor will not start
because there is little or no current to start windings.
Overload protector will open due to high locked rotor
run winding current.
With "shorted" PTC relay or capacitor, compressor will
start and overload protector will quickly open due to
high current of combined run and start windings.
With open or weak capacitor, the compressor will start
and run as normal but will consume more energy.
Check for resistance between:
Terminals "S" & "C"
Terminals "R"& "C"
Ground Test
Disconnect power to refrigerator .Remove compressor leads and use an
ohmmeter set on highest scale. Touch 1 lead to compressor body (clean
point of contact) and the other probe to each compressor terminal. If a
reading is obtained, compressor is grounded and must be replaced.
1. Disconnect power to refrigerator.
2. Remove capacitor and disconnect capacitor wires.
3. Discharge capacitor by shorting across terminals with a resistor for
1 minute.
4. Check resistance across capacitor terminals with ohmeter set on
"X1K" scale.
• Needle should jump towards 0 ohms and quickly move back to
infinity.
• If needle does not move, the capacitor is open.
• If needle reads a constant value at or near 0 ohms, the capacitor is
shorted.
• If needle jumps towards 0 and then moves back to a constant high
resistance (not infinity), the capacitor has a high resistance leak.
Operation Test
If motor winding tests fail to show cause for failure:
1. Disconnect power to refrigerator. Wire a test cord to disconnect
switch.
2. Place time delayed fuse, with U.L. rating equal to amp rating of motor,
in test cord socket.
3. Remove overload and relay.
4. Connect start, common, and run leads of test cord on appropriate
terminals of compressor.
5. Attach capacitor leads of test cord together. If capacitor is used,
attach capacitor leads to a good capacitor of same capacity.
6. Plug test cord into volt-watt meter to determine start and run wattage
as well as check for low voltage which can also be a source of
trouble.
7. With power to volt-meter, press start cord switch and release. If
compressor motor starts and draws normal wattage compressor is
okay and trouble is in capacitor, relay, overload, freezer temperature
control, adaptive defrost control, or elsewhere.
Capillary is sized in diameter and length to
feed proper amount of refrigerant to
evaporator.
Capillary is soldered to suction line to transfer
heat from capillary and add additional
superheat to gas refrigerant in compressor
suction line.
Capillary discharges into evaporator.
WARNING
To avoid electrical shock which can cause severe personal
injury or death, discharge capacitor through a resistor before
handling.
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