Download Electrolux EI23BC36 Service manual
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All About Servicing 2012 Service Updates ™ ©2012 Electrolux Home Products Inc. 10200 David Taylor Drive Charlotte, NC 28262 Publication #5995612875 May 2012 Section 1 Refrigeration Safe Servicing Practices Avoid personal injury and/or property damage by observing important Safe Servicing Practices. Following are some limited examples of safe practices: 1. DO NOT attempt a product repair if you have any doubts as to your ability to complete the repair in a safe and satisfactory manner. 2. Always Use The Correct Replacement Parts as indicated in the parts documentation. Substitutions may defeat compliance with Safety Standards Set For Home Appliances. 3. Before servicing or moving an appliance: • Remove power cord from the electrical outlet, trip circuit breaker to the OFF position, or remove fuse. 4. Never interfere with the proper operation of any safety device. 5. Use ONLY REPLACEMENT PARTS CATALOGED FOR THIS APPLIANCE. Substitutions may defeat compliance with Safety Standards Set For Home Appliances. 6. GROUNDING: The standard color coding for safety ground wires is GREEN, or GREEN with YELLOW STRIPES. Ground leads are not to be used as current carrying conductors. It is EXTREMELY important that the service technician reestablish all safety grounds prior to completion of service. Failure to do so will create a hazard. 7. Prior to returning the product to service, ensure that: • All electrical connections are correct and secure. • All electrical leads are properly dressed and secured away from sharp edges, high-temperature components, and moving parts. • All non-insulated electrical terminals, connectors, heaters, etc. are adequately spaced away from all metal parts and panels. • All safety grounds (both internal and external) are correctly and securely connected. • All panels are properly and securely reassembled. © 2012 Electrolux Home Products, Inc. WARNING This service manual is intended for use by persons having electrical and mechanical training and a level of knowledge of these subjects generally considered acceptable in the appliance repair trade. Electrolux home products cannot be responsible, nor assume any liability, for injury or damage of any kind arising from the use of this manual. 1-1 of 1Contents Table Section Refrigeration Safe Servicing Practices................................... 1-1 Table of Contents............................................. 1-2 Section 1 - Refrigeration................................. 1-3 Side-by-Side Models.........................................1-3 Excessively Cold Freezer Temperatures on Side-by-Side Counter Depth Models with VCC........1-3 Strong Odor Inside Side-by-Side Models................1-3 Flashing Code “4” on Side-by-Side Models.............1-4 French Door Models.........................................1-4 No Ice in Freezer; Freezer Drawer Freezing Shut on French Door Non-Dispenser Models.......................1-4 Frozen Freezer IM Fill Tube on French Door Non-Dispenser/Dual-Ready Models........................1-5 Recommendation for Use of Stationary Door Rack on French Door Models with Bullet-Style FFIM........1-5 Recommendation for Use of Gasket to Seal FFIM Housing on French Door Models with Bullet-Style FFIM...........................................1-6 Model Transition from Bullet-Style to Flex Tray FFIM on French Door Dispenser Models.................1-6 Warm Fresh Food Condition on French Door Models................................................................1-7 Flipper Mullion Improvement.................................1-7 Recommendation for Use of FFIM Gaskets on French Door Dispenser Models with Flex Tray FFIM...........1-8 Frozen FFIM Fill Tube on French Door Models with Flex Tray FFIM..............................................1-8 Folded FFIM Fill Tube Flange on French Door Models with Flex Tray FFIM...................................1-9 Ice Clumping in Ice Bin on French Door Models with Flex Tray FFIM...................................1-9 FFIM Defrost Failure on French Door Dispenser Models with Flex Tray FFIM...................................1-10 Noisy FFIM Fan on French Door Dispenser Models with Flex Tray FFIM...................................1-10 Auger Motor Freeze-Up on French Door Models Flex Tray FFIM..........................................1-10 Improved Ice Dispensing with Ice Breaker Blade on French Door Units with Flex Tray FFIM..............1-11 Improved Position of Flex Tray Ice Maker Fill Tube....................................................1-11 Elimination of Magnets from Stabilizer Bar on Frigidaire French Door Models...............................1-11 “SY CE” Error on French Door Models with Flex Tray Ice Maker.....................................................1-12 Side-By-Side and French Door Models............1-12 Water Dispenser Dripping on Side-by-Side and French Door Models.............................................1-12 Improved Water Filters for Side-by-Side and French Door Models.............................................1-13 1-2 New User Interface Kits for ICON and Electrolux Side-by-Side and French Door Models....................1-13 Top Mount Models............................................1-14 Excessive Frost in the Freezer on Top Mount Models................................................................1-14 Improved Top Mount Cabinet and Gasket Design......................................................1-15 All Freezer/Refrigerator Models......................1-15 Crisper/Deli Drawer Difficult and/or Noisy to Open or Close on Tall Twin Models....................1-15 Door Seal Adjustment on Upright Freezers.............1-16 Excessive Evaporator Fan Noise on Frost Free Models.........................................................1-16 Section 2 - Dishwashers...................................2-1 Door Gaskets.......................................................2-1 Pumps.................................................................2-1 Controls...............................................................2-1 Dispensers...........................................................2-1 Heaters...............................................................2-1 Turbitity Sensor...................................................2-1 Drain Valve..........................................................2-1 Odor...................................................................2-1 Tips on checking the detergent dispenser..............2-2 Long Run times on E- Star model dishwashers.........................................................2-2 Flashing Codes.....................................................2-3 Detergent Usage Guide........................................2-4 Section 3 - Cooking.......................................... 3-1 Push Button Microwave Door Does Not Open Easily...................................................3-1 Melting Knobs on Gas Range................................3-1 Faint gas smell when using the “Twin Burner” simmer position...................................................3-1 316354300 Knob Heat Shield Installation Instructions.........................................................3-2 F68 / F69 Fault codes on Electronic Oven Controls – Electric Freestanding Ranges................3-3 EOC Will Not Program on New Range- Gas and Electric Ranges..............................................3-3 Auto Rack Sticking After Self Clean – Gas and Electric Ranges....................................................3-3 Cooktop Lockdown Conversion..............................3-3 Cooktop Lockdown Conversion Instructions...........3-4 Glass or Ceramic Cooktop Damage .......................3-4 Broken Cooktop Examples....................................3-6 Damage Due to Defect.........................................3-8 Instructions for installing resistor on glass cooktop units with serial numbers starting with 3F...............................................................3-9 Section 1 Refrigeration Side-By-Side Models Excessively Cold Freezer Temperatures on Sideby-Side Counter Depth Models with VCC (RF1101) Freezers on Side-by-Side Counter-Depth refrigerators operate at excessively low temperatures even though the set point is at zero. This condition can also contribute to freezing of the drain (see RF1103) or excessively cold conditions in meat and crisper drawers (RF1004). Symptoms: Reported temperatures are as low as -14F. May also freeze items in crispers and deli pan. Models Affected: EI23CS, EW23CS, FGHC23, FPHC23, LGHC23 Figure 1-1 Serial Numbers: 4A740xxxxx to 4A131xxxxx Strong Odor Inside Side-by-Side Models (RF1106) Solution: Replace Main Control Board. Main control software was updated to correct freezer temperatures. Also, see Freezing or Excessively Cold Condition in Meat and Crisper Drawers (RF1004). When meat or crisper pans are freezing, install kit 5303918489 and determine if Main Control Board needs to be replaced also. Foam blocks located on the sides of the evaporator coil may be deformed by heat from the defrost heater. (see figure 1-2) Symptoms: Consumers may detect an objectionable odor sometimes described as “plastic” or “chemical”. Models Affected: All Side-by-Side models Serial Numbers: 4A010xxxxx – 4A122xxxxx Freezing Drain on Side-by-Side Models (RF1103) Frozen drain prevents proper draining of water during defrost. (see figure 1-1) Solution: Install kit 5303918593 for 23’ StandardDepth or 5303918594 for 23’ Counter-Depth and 26’ Standard Depth units. Kits contain replacement foam blocks, replacement defrost heater and air filters. Symptoms: Water breaches the drain area, the freezer compartment, and may potentially leak out of the front of the unit. Ice formation on freezer floor. Models Affected: All Side-by-Side models Serial Numbers: Prior to 4A109xxxxx Solution: Diagnose and repair the following conditions known to have the potential to cause or contribute to freezing of the drain: • Drain tube not seated flush against the freezer liner floor. • Drain trough opening misaligned with the drain tube opening. • Excessively cold temperatures in the freezer on Standard-Depth VCC models. (Refer to RF1101) Figure 1-2 1-3 Section 1 Refrigeration Flashing Code “4” on Side-by-Side Models (RF1203) French Door Models Side-by-Side refrigerators equipped with Beta Control experience damper failure demonstrated by flashing code 4 in fresh food temperature display. On models equipped with single-digit temperature display, the compressor fails to start up following flashing code 4. (see figure 1-3) No Ice in Freezer; Freezer Drawer Freezing Shut on French Door Non-Dispenser Models (RF1102) (see figure 1-4) Symptoms: Flashing “4” error code, loss of cooling (on single-digit display control models only), poor cooling performance (varied depending on position of damper at the time of failure). Models Affected: Side-by-Side models with temperature controls located inside FF compartment. Serial Numbers: Prior to 4A137xxxxx Solution: For single-digit display models: • If cooling is lost, it can be restored immediately by cycling power to the unit. This is a temporary resolution intended to restore cooling until diagnosis and repair can be completed. • Loss of cooling following flashing 4 error indicates that the unit needs a replacement control board with software revision 1.2 (Single-Digit models only). For all affected models, follow procedures outlined in the service flash to properly diagnose and repair the cause of flashing code 4 error. Procedures focus on identifying poor electrical connections and on preventing moisture migration into the unit and into the damper housing. Figure 1-3 1-4 Non-Dispenser French Door units exhibit issues with management of water flow to the freezer ice maker. Water continues to drip into the fill cup after water dispensing stops. This condition can lead to ice build-up in the fill cup. As a result, freezer ice maker may stop producing ice. In addition, once ice builds-up all the way to the fill tube, additional dispensed water may spray onto drawer slides and freeze the drawer shut. Symptoms: No ice in FZ FZ drawer frozen shut Models Affected: Electrolux & ICON - EI28BS36 & 51, EI23BC36 & 51, E23BC68, EI27BS16 Frigidaire - FGHN Serial Numbers: Electrolux & ICON: 4A931xxxxx to 4A106xxxxx Frigidaire: 4A022xxxxx to 4A106xxxxx Solution: For Electrolux & ICON models, install kit 5304482109. For Frigidaire models, install kit 5304482110. Both kits retrofit the unit with triple water valve, which prevents water drip-on into the fill cup. Figure 1-4 Section 1 Refrigeration Frozen Freezer IM Fill Tube on French Door Non-Dispenser/Dual-Ready Models (see figure 1-5) Recommendation for Use of Stationary Door Rack on French Door Models with Bullet-Style FFIM (RF1001) (see figure 1-6) Water in the freezer ice maker tube may freeze. This may be caused or intensified by several conditions, including low fresh food temperature setting, air leak around the air duct, or geometry of the fill tube. Note that this condition is not related to that addressed in RF1102. Units built with tilt-out door rack must be retrofitted with stationary door rack. Tilt-out door rack has the potential to keep the door from closing completely when the rack is overloaded. This results in poor temperature performance and excessive frosting. In addition, on units equipped with Fresh Food Ice Maker an open freezer door will initiate freezer recovery mode and will stop ice production. Symptoms: No ice in FZ Models Affected: Electrolux & ICON - E23BC68, EI23BC36 & 51, EI27BS16 & 26, EI27BS26, EI28BS36 & 51 Frigidaire - FGHB2846, 69 & 78, FGHG2344, FGHN2844 Crosley - CFD28 Lowe’s - LGHB2869, LGHN2844, LGUB2642 Serial Numbers: Prior to 4A210xxxxx Solution: Replace freezer ice maker fill tube with kit 5303918600. This kit contains an improved fill tube. When the new fill tube is installed, the connecting water line must be shortened by 2-2.5” to prevent kinking. Foam pad needs to be placed on the tube only if it was present on the original tube in the unit. Also, investigate sealing of the air duct to the liner. Air leak in this area can contribute to freezing of the fill tube. Use kit 5303918479 if needed to improve seal. Symptoms: No ice in FF ice maker, FZ drawer does not close completely. Models Affected: 23 cu.ft. and 28 cu.ft. Electrolux & ICON models with Bullet-Style FFIM. Not applicable on 27 cu. ft. models. Serial Numbers: Prior to 4A110xxxxx Solution: Replace door rack with 241824008 for Electrolux and 241824009 for ICON models. Figure 1-6 Recommendation for Use of Dielectric Grease on French Door Models with Bullet-Style FFIM (RF1207) (see figure 1-7) Figure 1-5 Water intrusion into electrical connections within the FFIM causes intermittent interruption of ice production and melting of ice in the bin. 1-5 Section 1 Refrigeration Symptoms: No ice in FF Ice melting in the ice bin while FFIM is turned on Models Affected: All ICON, Electrolux and Frigidaire models with Bullet-Style FFIM Serial Numbers: Prior to 4A113xxxxx Solution: Use dielectric grease 5304485963 to improve electrical connections inside the FFIM. Application is recommended on EEV, TH3, TH1 and fan connectors, however it can also be used on any connector within the FFIM assembly. In general, if all diagnostics pass and the unit has 8.1/8.5 FFIM board yet the unit is either not producing or not maintaining ice, water intrusion into electrical connection can be suspected and dielectric grease may resolve the problem. Solution: Use two pieces of gasket 241869708 to seal the gap. In addition, if excessive frost is found on the ice mold, inspect the ice chute door to ensure it is sealing properly. * Note: Do not use weather stripping. Due to the variety of such products available, we cannot ensure that acceptance criteria for materials in indirect contact with food will be met. Figure 1-8 Figure 1-7 Recommendation for Use of Gasket to Seal FFIM Housing on French Door Models with Bullet-Style FFIM (see figure 1-8) Due to variation in flatness of the liner, the original FFIM housing gasket may not provide sufficient sealing at the top. This allows the relatively warm and moist FF air to enter into the FFIM compartment. Moisture then can collect on the FFIM mold and impede or stop ice production or cause excessive clumping of ice in the bucket. Symptoms: No ice in FF Models Affected: All models with Bullet-Style FFIM Serial Numbers: Prior to 4A113xxxxx 1-6 Model Transition from Bullet-Style to Flex Tray FFIM on French Door Dispenser Models (NF1102) (see figure 1-9) In the span of Q1, 2011 all French Door dispensing units transitioned from Bullet-Style to Flex Tray FFIM. Models Affected: All ICON, Electrolux, Frigidaire, Crosley and Lowe’s models with Bullet-Style FFIM Electrolux & ICON - E23BC78, EI23BC56, EI27BS26, EI28BS56, EW23BC71, EW28BS71 Frigidaire - FGHB2844, 46, 69 & 78, FGUB2642, FPHB2899, FPHF2399 Crosley - CFD26, CFD28 Lowe’s - LGHB2869, LGUB2642 Serial Numbers: Transition took place from 4A106xxxxx through 4A114xxxxx. Units built prior to wk.6 are equipped with Bullet-Style FFIM. Units built wk. 14 and on are equipped with Flex-Tray FFIM. It is of utmost importance to use engineering digit number when ordering replacement components, as model numbers did not change. Section 1 Refrigeration Key characteristics to determine FFIM type: Figure 1-9 Warm Fresh Food Condition on French Door Models (see figure 1-10) Symptoms: Fresh Food temperatures 7-10F above set point. Freezing in crisper drawers Freezing water tank Freezing FZ ice maker fill tube Models Affected: Main board replacement applicable only to Bullet-Style models - CFD26, FGHB2869, FGHB2878, FGUB2642, FPHB2899, LGHB2869, LGUB2642 Other solutions applicable to all French Door models. Serial Numbers: Main board replacement applicable for serial numbers prior to Flex Tray transition (4A106 – 4A114). All serial numbers for other solutions. Solution: Determine and address root cause. • Air duct leak around the bottom can cause warm FF in the middle and towards the top of the cabinet. This will always be combined with excessively cold temperatures at the bottom of the FF which may result in frozen veggies, water tank, and fill tube. Install kit 5303918479 to seal air leak. • Air leak between the back of the air duct and liner can satisfy the FF thermistor prematurely before the cabinet reaches set point temperature. If seal between the air duct and the liner is not tight, bypass is possible. Seal air leak. If air duct does not have mounting tabs, replace. If the outer part of the air duct is prevented from sealing to the liner by the other components of the assembly, correct the assembly. • Replace main board for affected models. Substitutions are in place. Order per parts list. Figure 1-10 Flipper Mullion Improvement (see figure 1-11) Flipper mullion is constructed of metal face inserted into a plastic housing. Due to dissimilar rates of thermal expansion, flipper mullion bows in operating conditions. Since the plastic housing contracts more than the metal face, ends of the mullion bow towards the cabinet. This creates gaps between the mullion and door gaskets at the top and bottom of the mullion (similar to bi-metal effect). Symptoms: Moisture on the flipper mullion or gaskets. Poor cooling in FF Models Affected: All French Door Models Serial Numbers: Prior to 4A120xxxxx Solution: Replace flipper mullion. New mullion has flexible inserts at the top and bottom at the metal to plastic interface. This allows the mullion to contract without bending of the metal face when under operating temperatures. 1-7 Section 1 Refrigeration Serial Numbers: From Flex Tray transition (4A106 – 4A114) Solution: Use gasket kit 5303918578. It contains all gaskets in need of replacement. * Note: Gaskets need not be replaced when servicing the Flex Tray ice maker apparatus as the air handler is not disturbed in the process. Frozen FFIM Fill Tube on French Door Models with Flex Tray FFIM (see figure 1-13) Figure 1-11 Recommendation for Use of FFIM Gaskets on French Door Dispenser Models with Flex Tray FFIM (RF1206 ) (see figure 1-12) Whenever service is performed within the air handler assembly of the Flex Tray FFIM, all affected gaskets must be inspected. If deformed, torn, or otherwise damaged, gaskets must be replaced. If the air handler is loosened or removed, gasket kit is required. Models Affected: All ICON, Electrolux, Frigidaire, Crosley and Lowe’s models with Flex Tray FFIM When small ice cube size is selected and water supply pressure is low, the quantity of water filling the ice tray is extremely low. In this condition the individual ice cube molds will be partially filled, causing small ice cubes, or may not get filled at all, resulting in only a few ice cubes being produced at a time. When quantity of water in the tray is low, the heat is removed quickly and the remaining cooling capacity in the FFIM compartment causes excessively low temperatures. These low temperatures can cause water remaining in the FFIM fill tube to freeze over time. Models Affected: All ICON, Electrolux, Frigidaire, Crosley and Lowe’s models with Flex Tray FFIM Serial Numbers: From Flex Tray transition (4A106 – 4A114) Solution: ▪ Remove FFIM fill tube and clear ice accumulated inside; reinstall the fill tube. ▪ Select ice cube size appropriate for the water supply pressure. 1-8 Figure 1-12 Figure 1-13 Section 1 Refrigeration Folded FFIM Fill Tube Flange on French Door Models with Flex Tray FFIM (see Figure 1-14) Ice Clumping in Ice Bin on French Door Models with Flex Tray FFIM (see figure 1-15) When FFIM fill tube flange is folded over, it blocks water from entering the ice tray and causes it to cascade over the FFIM housing and onto the shelf below. Large ice clumps with smooth bottom or section which resembles curvature of the ice bin are indicative of water entering the ice bin. This typically occurs due to overfilling of the ice tray or splashing during fill. Symptoms: FFIM not making ice from installation or from FFIM service Water on top shelf under FFIM Sheet of ice on the liner wall next to FFIM Sheet of ice on top of the FFIM housing Models Affected: All ICON, Electrolux, Frigidaire, Crosley and Lowe’s models with Flex Tray FFIM Symptoms: Makes ice but cannot dispense Models Affected: All ICON, Electrolux, Frigidaire, Crosley and Lowe’s models with Flex Tray FFIM Serial Numbers: From Flex Tray transition (4A106 – 4A114) Serial Numbers: From Flex Tray transition (4A106 – 4A114) Solution: ▪ Lower fill time to prevent overfilling of ice tray during fill Solution: Fill tube is folded when the FFIM housing is not installed correctly. FFIM housing should be slid to the back first and then raised into position to prevent interference with the gasket and funnel assembly on FFIM housing. ▪ Inspect water entry path for cause of splashing; typically this will be the fill tube assembly or funnel. Reinstall or replace funnel or fill tube assembly. ▪ Correct fill tube misassembly; replace fill tube if necessary. ▪ After reassembly, run several manual fills (FFIM service mode test 55C) to ensure water is entering ice tray. ▪ Check for splashing and correct if needed; adjust fill tube and funnel. ▪ Run several manual fills (FFIM service mode test 55C) to ensure water is not entering the ice bin. * Note: Ice clump with irregular shape is typically caused by sublimation of ice in low-usage situations. This is a normal condition. Discard clumped ice and replenish ice bin. * Note: In service mode, the FFIM may be disconnected and removed from the unit when running manual fills. Figure 1-15 Figure 1-14 1-9 Section 1 Refrigeration FFIM Defrost Failure on French Door Dispenser Models with Flex Tray FFIM (see figure 1-16) Noisy FFIM Fan on French Door Dispenser Models with Flex Tray FFIM (RF1205) (see figure 1-17) Most commonly, due to poor electrical connection or pin back out. May also be due to shorted defrost heater or wires damaged during brazing of the FFIM evaporator. FFIM fan makes intermittent, buzzing noise. Over time, the fan may stop completely and the ice maker will stop producing ice. Symptoms: Made ice, then stopped Slow ice production Models Affected: All ICON, Electrolux, Frigidaire, Crosley and Lowe’s models with Flex Tray FFIM Symptoms: No ice Slow ice production Fan noise Models Affected: All ICON, Electrolux, Frigidaire, Crosley and Lowe’s models with Flex Tray FFIM Serial Numbers: From Flex Tray transition (4A106 – 4A114) Serial Numbers: From Flex Tray transition (4A106 – 4A114) through 4A206xxxxx Solution: Diagnose reason for defrost failure and correct. ▪ Check for pin back-outs at connections shown and at main board ▪ Inspect condition of wires ▪ Check defrost heater; should read approx. 197 Ohm resistance Solution: DO NOT replace the fan, unless you determine it to be defective. Resolution focuses on prevention of ice build-up and directing defrost water away from the fan. Remove mastic pad, ensure all refrigerant lines are pushed back towards the liner and that neither the tubes nor wires are pinched against the evaporator cover. ▪ Check defrost thermostat Figure 1-17 Auger Motor Freeze-Up on French Door Models Flex Tray FFIM (see figure 1-18) Auger motor operates inside the air handler housing in a humid and freezing environment. Moisture collecting on the exposed portion of the rotor can cause the rotor to freeze up. Rotor can be freed by approx. 30 sec. of paddle activation, however this is a nuisance to the consumer. Improved design covers rotor completely and prevents ice build-up. Order 241816602. Figure 1-16 Symptoms: Not dispensing ice Models Affected: All ICON, Electrolux, Frigidaire, Crosley and Lowe’s models with Flex Tray FFIM Serial Numbers: From Flex Tray transition (4A106 – 4A114) through 4A139xxxxx 1-10 Section 1 Refrigeration Figure 1-19 Improved Position of Flex Tray Ice Maker Fill Tube (see Figure 1-20) Figure 1-18 Improved Ice Dispensing with Ice Breaker Blade on French Door Units with Flex Tray FFIM (see Figure 1-19) Pyramid-shaped ice produced by the Flex Tray Ice Maker tends to clump more than Bullet-Style ice. Ice breaker blade was introduced to help break-up clumped ice prior to dispense. Fill tube position is essential to proper filling of the ice maker tray. Ridge and notch were added to provide a guide to proper installation of the replacement FFIM fill tube. To service units built prior to implementation of this design, the servicer must remove the ridge to allow the part to fit into the old conduit. PN 241920103. Models Affected: All Flex Tray FFIM FDBM models. Serial Numbers: New part implemented 4A137xxxxxx Symptoms: Cannot dispense ice Slow ice dispense Clumped ice Models Affected: All ICON, Electrolux, Frigidaire, Crosley and Lowe’s models with Flex Tray FFIM Serial Numbers: From Flex Tray transition (4A106 – 4A114) through 4A141xxxxx Replace the ice bucket with the latest design. To obtain the latest bucket, order per parts list. Substitutions are in place. Figure 1-20 Elimination of Magnets from Stabilizer Bar on Frigidaire French Door Models. (see Figure 1-21) Magnets were removed from the upper basket stabilizer bar (basket front). Symptoms: Upper basket does not pull out when the freezer drawer is opened. It must be pulled out manually to access stored items. 1-11 Section 1 Refrigeration Models Affected: FGHB2844, FGHB2846, FGHB2869, FGHB2878, FGHF2344, FGHF2346, FGHF2369,FGHF2378, FGHG2344, FGHN2844, FPHB2899, FPHF2399, FPHG2399, FPHN2899, FSGH30,CFD28, MSBG30, WSBH30 Serial Numbers: Starting with 4A125xxxxx Solution: This is not a manufacturing defect, but an intentional change. Consumers who find this objectionable may order a replacement stabilizer bar PN 241953202. * Note: This repair is not covered by warranty and is intended to be completed by the consumer. Instruction Sheet PN 242218100 is provided with the part. Solution: First, verify electrical continuity between UI and Main Board. Check connections above the FF door hinges, at UI and at Main Board. If error persists, order replacement Main Board per parts list. All prior variants were substituted to the latest versions. * Note: SY-CF error indicates communication was not established at power up. SY-CF error is not affected by this software change. Side-By-Side and French Door Models Water Dispenser Dripping on Side-by-Side and French Door Models (see Figure 1-22) Several conditions can cause or exacerbate water dripping from the water dispenser. Depending on the nature of the drip, there are several possible root causes and solutions. Symptoms: Water dripping from the water dispenser Models Affected: All single and dual-paddle Side-by-Side, French Door Dispenser Models Figure 1-21 “SY CE” Error on French Door Models with Flex Tray Ice Maker SY-CE error indicates that communication between the UI and Main Board was initially achieved upon power up but then was lost. At times, this is a legitimate error indicating Main Board or UI failure or loss of electrical continutity between them. In some conditions this error is caused by a software problem. Symptoms: SY-CE error Models Affected: All French Door models with Flex Tray FFIM/ice dispenser Serial Numbers: From Flex Tray transition (4A106 – 4A114) through: Frigidaire - prior to 4A205xxxxx Electrolux – prior to 4A214xxxxx Serial Numbers: All serial numbers starting with 4A; except as noted below. Solution: ▪ If water drips continuously, fast or slow, but never stops, the issue is a leaking water valve. Replace valve. ▪ If water stops dripping after a few drops, the issue is most likely a burr on the end of the tube. Remove burrs or frayed edges or replace tube if necessary. In addition, for French Door Models with Flex Tray FFIM built 4A106xxx to 4A148xxxxx ONLY ▪ If water stops dripping after approx. ¼ cup or so, whether the drip was fast or slow, the issue is most likely poor seal with the in-line fitting located on the back of the unit. Another possibility, but less likely cause is a crack or pinhole in the water tube itself – probably underneath the left hinge cover. ▪ Replace water dispenser tube with longer tube 241965906 to move location of connection below the dispense point. Shorten the lower tube accordingly. 1-12 ▪ Replace fitting Section 1 Refrigeration New User Interface Kits for ICON and Electrolux Side-by-Side and French Door Models (see Figure 1-24) Service User Interfaces for affected models have changed. Replacement parts must be installed in combination with a Main Board and a dispenser module harness extension. Figure 1-22 Improved Water Filters for Side-by-Side and French Door Models (see Figure 1-23) New, more robust cassette-style water filters are now in production and available for service. Symptoms: Cracked water filter Models Affected: Electrolux Side-by-Side, Electrolux & ICON French Door....... EWF01 Frigidaire Side-by-Side.................... WF2CB ICON Side-by-Side.......................... EWF2CBPA Kenmore Side-by-Side.................... 9911 Kenmore Elite Side-by-Side............. 9916 Note: The faceplate on the new filter is removable. If the faceplate is not fully seated, the consumer may not be able to insert the filter into the housing. In addition, filter installation instructions will be included with the individually packaged filters. Symptoms: Loss of User Interface function or erratic function Missing segments No display Models Affected: Side-by-Side - EI23CS55, EI23SS55, EI26SS55, EW23CS65, EW23CS70, EW23SS65, EW26SS65. French Door - E23BC78, EI23BC56, EI28BS56, EW23BC71, EW28BS71 Serial Numbers: Varied, use engineering digit and parts lists to select replacement UI’s. Solution: New replacement User Interface kits are now available and are published in current parts lists. Refer to current parts list to select appropriate replacement User Interface. Any old printed parts lists should be discarded. * Note: User Interface kits 5303918539, 5303918540, 5303918560 are no longer available or appropriate as replacement components. NEW UI Corresponding connections OLD UI NEW UI OLD UI A * A on NEW only B C D * B on OLD only - electronic board is mounted within the black housing - electronic board is mounted externally Figure 1-24 Figure 1-23 1-13 Section 1 Refrigeration Top Mount Models Excessive Frost in the Freezer on Top Mount Models (RF 1202) (see Figure 1-25) Freezer compartment demonstrates excessive frost buildup. Prolonged frosting may result in warming of the fresh food compartment. The following conditions can cause or contribute to excessive frost in the freezer: • • • • Excessive infiltration of warm, moist air due to poor door seal. Poor function of the defrost system. Infiltration of warm, moist air through the drain tube or ice maker fill tube opening. Inefficient dehumidification of air due to bypass of air around the evaporator coil. Symptoms: Frost build-up in the freezer Warm fresh food compartment Models Affected: Frigidaire, Crosley, White Westinghouse, Lowe’s, Sears Top Mount Models. See note below for select models. Serial Numbers: All serial numbers starting with 4A or BA. Solution: Solution focuses on sealing of the cabinet and ensuring that air is well circulated and dehumidified. Ensure the unit is properly tilted back to assist in door closing. Service defrost thermostat improves defrost. Kit 5303918597 contains all applicable components and detailed instruction to resolve the issue. Kit 5303918599 contains the defrost thermostat and components needed for proper installation. Additionally, for models FFUI1826, FGUI1849, FPUI1888, LGUI1849, XFUT1826 ONLY, replace the adaptive defrost control (ADC) 242011003. 1-14 Figure 1-25 Section 1 Refrigeration Improved Top Mount Cabinet and Gasket Design (see Figure 1-26, 1-27, 1-28, 1-29) New design improves cabinet seal and prevents excessive infiltration of moisture. Flush flange design and improved gasket construction provide tighter door seal. Wider mullion provides more sealing area under varied door loading conditions. Captured eliminator tube ensures good contact to the mullion and prevents collection of moisture. Models Affected: All Top Mount Models Serial Numbers: Production starting early Q2, 2012 Key Features: • Redesigned cabinet liner is flush with cabinet flange. Provides flat sealing surface. • Robust gasket design to complement flange design. Improved cross section provides appropriate reach for new flange. • Wider million for better gasket engagement. • Captured eliminator tube always in place. Figure 1-28 Figure 1-29 Figure 1-26 All Freezer/Refrigerator Models Crisper/Deli Drawer Difficult and/or Noisy to Open or Close on Tall Twin Models (RF1204) (see figure 1-30) Crisper or Deli Drawer interferes with the frame when opening and closing. Drawer may be noisy when opened and closed and a small amount of white plastic shavings may collect beneath the drawers. Models Affected: E32AR75JPS, EI32AR65JS, FPRH19D7LF Serial Numbers: Prior to WA152xxxxx Figure 1-27 Solution: Correct engagement of drawers into rail clips to ensure drawers are well seated. This will prevent interference with the frame and eliminate noise and shaved plastic. See RF1204. 1-15 Section 1 Refrigeration Figure 1-31 Figure 1-30 Door Seal Adjustment on Upright Freezers (see figure 1-31) Poor freezer door gasket seal may cause excessive frost build up inside the cabinet. Models Affected: FPUH1, FKCH17, FFUU17, GLFH17, LFFH17, LFFU17, LFUH17, FFH17, FFU17, FPUH19, FFFU20, FFUU21, FKFH21, GLFH21, LFFH21, LFUH21, FFU21, FFH21 Serial Numbers: All Serial Numbers starting with WB Solution: Identify and correct the root cause of poor seal as follows: 1. Verify door gasket is in good condition. If pin holes or other damage are evident, replace gasket. 2. If gasket appears to shrink away from cabinet: • With the door in closed position, heat the gasket with a hair dryer or heat gun to form gasket to cabinet • Loosen all door panel screws located under gasket ½ turn (see diagram) • Allow freezer temperature to reach below 10 F and check seal 3. Measure gap between door and cabinet where gasket does not seal: • If gap is < 7/8”, replace gasket • If gap is > 7/8” on handle side, replace door • If gap is > 7/8” on hinge side, continue to check bottom hinge 4. Check bottom hinge for damage: • If bottom hinge is damaged, replace hinge • If bottom hinge is not damaged, replace door 1-16 Excessive Evaporator Fan Noise on Frost Free Freezer Models (see figure 1-32) Models Affected: Single door frost free freezers and refrigerators with propeller fan assemblies. Built-in 17 cu.ft and 19 cu.ft. refrigerators and freezers are not affected. Serial Numbers: All Serial Numbers starting with WA and WB Solution: Identify and correct the root cause of the excessive noise as follows: • Check for loose or missing evaporator cover screws Loose or missing screws can cause the evaporator cover to vibrate. • Check for loose fan mount screws (2). Replace with 297174300 if necessary. • Check for broken fan mount speed nuts (2). Replace with 297367000 if necessary. See Pic.1. • Check for loose or broken motor to bracket screws (2). Replace with 216912401 if necessary. • Check for any loose tape or debris in the vicinity of the fan blade or in the air duct. • Ensure the fan blade is pushed fully onto the motor shaft. There is a stop at the end of the blade hub. • Rotate the blade and check for bent fan blades. Replace with 216325600 if necessary. • Check motor for bent shaft. Replace with 297250000if necessary. • The propeller fan motor assembly uses a pitched mounting bracket that pitches the blade upward by 5 degrees. The motor windings and wire leads are positioned up and the rear motor hub should be visible through the hole in the mounting bracket. See Pic. 2. • If after the above steps there is vibration of the rear inside wall near the fan assembly then applying a dampening material to the rear wall can change the resonance frequency and reduce the vibration. Section 1 Refrigeration The steps above should identify and correct any noise issues as a result of vibration. The other source of evaporator fan noise is airflow noise. If the location of this freezer or refrigerator is such that the customer is still dissatisfied with the evaporator fan noise then consider replacing the propeller fan blade with an impeller fan blade 297259600. See Pic. 3. Fan blade must be installed along with mounting bracket 127112. The drawback to the impeller assembly is the 100% run capacity of the freezer will be 2°F warmer and the energy consumption of the freezer or refrigerator will be 4% greater. Impeller Blade and Replacement Bracket Shown. Figure 1-32 1-17 Section 2 Dishwashers DOOR GASKETS DISPENSERS • Talc has been removed • New gasket can only be identified by the half- moon shaped paint mark – this may not be located exactly half way on the gasket. Gasket should be aligned at the bottom edges – working from the sides – up to the middle. There should be no excess gasket - do not cut off excess, instead rework the gasket so the entire gasket fits in the track. Let the door seat the gasket. 154845301 • Dispenser not opening or not dispensing - remove the top lip of dispenser mold. • Electrolux dispensers will have the top lip removed. (darker color) • Products to consider for washibility issues: Finish-Power-Ball, Lemi-Shine, Turbo Dry • Consider placement of large dishes – could interfere with dispenser. • RTV may be used on metal tubs but should not be used on plastic tubs. HEATER PUMPS • The heater is programmed to come on during the wash cycle, not the prewash / initial rinse. • Reasons for squealing pumps - seal damage due to wiggling the pump in order to get the seals to properly seat. • First 30 minutes of wash cycle is for the heater, this time is not counted in the time for the wash cycle. • Use liquid soap on o-rings when seating a new pump. • MUST HAVE HAPPY ENZYMES! 130-135 degrees • Must have happy bleachers - 140-145 degrees. • Dishwasher must be removed for proper pump installation. • Pumps generally will draw .73 amps when in use. • Technicians may find loose connections due to a crimping issue during manufacturing. If loose connectors are found on the pump, replace the pump. TURBITITY SENSOR • Sensors always compare to the last known reading. A power-on reset will reset the control and thus give the sensor nothing to compare to; therefore we recommend multiple cycles be ran before making any changes to controls and sensors. CONTROLS • “ER” is a keypad issue, not a control issue. DRAIN VALVE • Check for proper installation of the dishwasher. The keypad should have ½ clearance from the countertop. A tight fit could cause contact with the control – resulting in an erroneous error code. • E11 code - Insulation strip in the drain valve can get in the way of the Main Control’s interpretation of the location of the drain valve. • 2410 and 2491 Medea DW – lights on the control will go out when the door is closed. This is normal. • Part # should be dated after September 2011. There should be an * after the part number. Ex. 01/10/11 (dd/MM/yy). • Some units have a time fill – regardless if water is present or not. ODOR • Use Rinse and Hold cycle each time you load the dishwasher if you are not going to run your DW for a few days. 2-1 Section 2 Dishwashers Tips on checking the detergent dispenser Long Run times on E- Star model dishwashers The best way to test the detergent dispenser on the dishwasher is twofold. By completing these two tests the detergent dispenser is completely checked for operation. 1.Start unit into the Water Service Test. In this test you want to see that the wires from the control to the dispenser are good and the dispenser will open. All wash cycles have two programmed heat delays to insure proper water temperature in the main wash and the final rinse. These heat delays are needed due to the reduced amount of water used per fill and the limitations on supplied water temperature from the home. To start this test you need to check the Service Data sheet supplied with the unit. The first phase of the test fills the dishwasher and sends power to the dispenser. The dispenser should open in 30to 45 seconds after power is applied to the wax motor on the dispenser. After the wash motor starts check to make sure the cover on the dispenser did open. Once this is checked manually, advance out of the Water Test to the drain phase and drain the water from the unit. If the cover did not open check the wires from the control to the dispenser wax motor and rerun the Water Test. 2.After the dispenser successfully runs through the water test, select the shortest wash cycle on the dishwasher. The shortest cycle could be Light Wash, Upper Rack Only, China Crystal, or Energy Saver. This test is to test operation of the dispenser in a programmed wash cycle. After starting the cycle the dispenser should open after the second fill. When the wash motor starts, following the second fill, the control sends power tothe dispenser and it should open in 30 to 45 seconds. Control goes dead on the FPHD2491KF model dishwasher. This dishwasher is programmed for the console lights to go out when the door is closed. The Owner’s Manual reads the lights will stay on but the manual was misprinted. 2-2 Section 2 Dishwashers Flashing Codes Codes will flash in the console telling the customer there is a problem with the dishwasher. Some codes the customer may see are listed below: PF or flashing High Temp Wash & Air Dry Lights The control has lost power and the power has been restored. HO or HD The dishwasher is in a heat delay. CL or CD Close the door to start operation. LO The rinse aid in the dispenser is low. This does not affect dishwasher operation. These Codes are product failure and need to be checked for dishwasher operation: ER flash ER This is a key pad or User Interface problem. Shorted or stuck pad. ER flash UO The control believes the vent baffle is stuck open. This code will keep the wash motor from running. ER flash UF The control is not seeing the vent fan running properly. ER flash CE This is a problem with the Main Control. Kill power to the control for 15 seconds or more and reapply power. This code should go away. If not, replace control. Electrolux Dishwasher Kits: 154791501 Filter Upgrade Kit for Electrolux dishwasher with serial numbers before TH934: Filter screen, volute cover, lower spray arm, upper rack bracket, and heater support bracket kit. 154838201 Heater Support Bracket Kit for Electrolux dishwasher before serial number TH040: Heater bracket, hoses on both ends of heater, 4 new hose clamps for hoses, and mounting clip for bracket. 154860901 Water Level Reed Switch Kit: Reed switch assembly, mounting nut, o-ring seal, reed switch assembly gasket, and float cup with magnet. 154825501 Upgrade Kit for Electrolux dishwasher with serial numbers before TH927: All hoses and clamps under unit, drain pump, drain valve, turbidity sensor, o-ring, wire harness, both 154838201 and 154860901 kits, and hose clamp to mount drain hose under sink cabinet with screw. 2-3 Section 2 Dishwashers Detergent Usage Guide Cycle Soft Water (0-3 grains) Medium Hard Water (4-8 grains) Hard Water (9-12 grains) Very Hard Water* (over 12 grains) Power Plus or Normal Wash 2 teaspoons (each cup-1/4 full) 5 teaspoons (each cup-fill to line above “Regular”) 8 teaspoons (each cupcompletely full) Each CupCompletely Full (water softener recommended) Top Rack 2 teaspoons (Main Wash cup-1/4 full) 5 teaspoons (Main Wash cup-fill to line above “Regular”) 8 teaspoons (Main Wash cupcompletely full) Main Wash CupCompletely Full (water softener recommended) Rinse Only No Detergent No Detergent No Detergent No Detergent (water softener recommended) 2-4 Section 3 Cooking Push Button Microwave Door Does Not Open Easily Faint gas smell when using the “Twin Burner” simmer position See Service Flash CK1103 – Issued 11/1/11. There is an improved lever 5304485407 for smoother door operation interaction. Some complaints of faint gas odor have been reported when using the simmer position on the Twin Burner found on several range models. If you really try hard you can find the exact sweet spot that allows a small amount of gas flow from the main burner when using the simmer burner only. This small amount will not be enough to light the outer burner but does sometimes produce a faint odor. This does not present a safety issue. To eliminate this odor make adjustments to the burner control valve by following the instructions outlined below. OTR Microwave Vent Issues All of our OTR microwaves have a self-protection feature, “auto vent”, which automatically turns the vent fan on if it senses the unit is getting too hot. This is also a selfprotection mode to cool its internal components. The microwave does not have to be working/running for this vent to sense it’s too hot; it is usually triggered from the cooking surface and/or oven below. In addition, some OTR microwaves use the exhaust fan motor to drive the internal cooling fan. On these models the exhaust or vent fan will run whenever the microwave is operating. Melting Knobs on Gas Range There have been reports of melted warmer drawer knobs from higher BTU burner in left rear of some gas ranges. Operating the burner on the highest setting for long periods can damage the control knob. Use the highest setting to bring food to a boil then reduce the heat to maintain cooking. This is a use and care issue, not a product defect. Refer to the Owner’s Manual – Setting Surface Controls for information on proper burner adjustment. On freestanding gas ranges that feature solid metal surface burner control knobs many customers notice that these knobs feel significantly hotter than the plastic knobs found on their previous range. The actual temperature of the metal knobs is the same as the plastic knobs, but due to the difference in how metal transfers heat they feel hotter. To assist these consumers the Customer Service Department can send replacement plastic knobs to be used. Turn screw A (see figure 2-1) counterclockwise one complete turn and have the customer use the burner to see if this fixes their issue. This adjustment increases the amount of gas flow to the main burner on the low setting so that it will light sooner, thus eliminating the unburned gas flow they are experiencing. This does affect the way that the main burner operates on MEDIUM and increases the BTU output slightly. So it is a bit of a trade off but should not cause a problem. If there is still detectable gas odor after this adjustment then turn screw A another half turn counterclockwise and test again. Figure 2-1 There are also heat shields that can be installed on the valve shaft behind the knob to block some of the heat from the oven cavity from migrating through the opening that the shaft passes through. The part number for the heat shield is 316354300. One shield is needed for each of the front panel mounted valves. They are easily installed by the consumer. See Page 3-2 3-1 Section 3 Cooking 316354300 Knob Heat Shield Installation Instructions Fig. C 1. Pull the knob in direction of arrow as shown in Fig. A to remove it from range. 2. Slide the heat shield onto the valve shaft as shown in Fig. B and Fig C. 3. Using a plastic pen or other blunt non-metallic tool, push the shield through the cut out hole until it is completely behind the panel as shown in Fig. D and Fig E. 4. Reinstall the knob onto the shaft. Repeat these steps for each of the burner knobs. Fig. A Fig. B 3-2 PULL Fig. D Fig. E Fig. E F68 / F69 Fault codes on Electronic Oven Controls – Electric Freestanding Ranges These fault codes may appear whenever there is a high voltage or low voltage condition present in the power supply to the range. Frequently this happens in late night or early morning hours when the power company may reduce the voltage from the generator plant or heavy use in the area may cause a drop in voltage. This is not an indication of a product failure and replacing the EOC or other parts will not eliminate the issue. The first step is to reset the power supply and see if the fault code clears. If it does, but then returns again at a later time, the failure is definitely related to the power supply. If the fault code reappears immediately the service technician should measure the incoming line voltage to the range using a volt meter. If the voltage is high or low then the power company should be notified. For customers who have continuous problems with this issue there is a possibility that the factory may be able to provide a modified Electronic Oven Control that will better tolerate these short term high or low voltage conditions without producing the fault code. The service technician can contact the Tech Line for more information regarding this possible solution. No charge parts can only be shipped for products that are still under the original factory warranty or are covered by an Electrolux/ Frigidaire Extended Service Agreement. EOC Will Not Program on New Range- Gas and Electric Ranges If a newly installed range will not allow the time of day to be set or the oven to be set for a bake or broil cycle many servicers will immediately suspect that the EOC (Electronic Oven Control) is defective and order a replacement only to discover that the new EOC exhibits the same symptoms. The cause is almost always a loose harness connector to the oven temperature sensor probe. When the range is first connected to the power supply the EOC goes through a diagnostic check and if it detects a faulty component or circuit it will not allow the user to proceed with any programming such as setting the time of day or starting bake or broil. Test the temperature probe circuit and connections before assuming the EOC is defective. Section 3 Cooking Testing the temperature probe and harness can be done very easily from the harness connector on the EOC itself. Unplug the connector that has the two violet wires that connect to the temperature sensor and use your ohm meter to check for proper resistance between the wires. 1080 – 1100 ohms is typical at room temperature. Auto Rack Sticking After Self-Clean – Gas and Electric Ranges On models that have automatic oven racks, the racks and rods should always be removed before running a self-clean cycle. If the racks and rods are not removed the glide coating on the racks will melt and bond the racks to the oven wall making it almost impossible to open the door when the oven cools down. To get the door open without causing further damage, turn the oven on at 550 degrees for 30 to 45 minutes to soften the glide coating on the racks and allow the door to open more easily. The oven racks will probably be damaged and need replacing. It is also likely that residue from the glide coating on the Auto Rack will be stuck to the oven wall. This can damage the porcelain oven liner but does not make the range unusable. This type of damage is due to customer neglect and will not be covered by the product warranty. Consumers should be charged parts and labor for damage of this nature. Cooktop Lockdown Conversion Most freestanding gas ranges manufactured prior to 2011 utilized spring clips to secure the cooktop to the body of the range. In order to remove the manifold panel that covers the burner valves it was necessary to first remove the cooktop by dismounting all surface burners, release the spring clips by using a putty knife, then lift off the cooktop to access the screws that secure the manifold panel. Beginning in 2011 a new design was introduced to make removing the manifold panel and the cooktop much easier for the service technician. This design has replaced the previous method and will be used on all models with sealed burners going forward. (See Page 3-4) 3-3 Section 3 Cooking Cooktop Lockdown Conversion Instructions The cooktop lockdown brackets are attached at the same locations as the current corner gussets. (Right side bracket shown). (1) Screw connection to the body side and (1) screw connection to the manifold pipe bracket. Repeat for left side bracket. After the cooktop lockdown brackets are installed, the cooktop can be installed by sliding the cooktop “front-to-back” to engage the bracket with the underside of the cooktop. Then attach (2) screws. Note: If cooktop holes are missing….refer to page 2. After the cooktop is attached, the manifold panel is installed by engaging the interlocking tab with the slot in top of the manifold panel. (Cooktop removed to illustrate interlocking tab engagement). Once the interlocking tab is engaged, the manifold panel is attached as previous, using screws on the bottom side of the manifold panel. Page 1 of 2 3-4 Section 3 Cooking Marking & Drilling Clearance Holes in the Cooktop Some cooktops may not have the 2 clearance holes to lock it down properly. The following may aid in creating those clearance holes. Apply tape to the approximate affected areas of the cooktop flange. Set cooktop in position as shown, with cooktop setting on top of the lock down brackets. Mark the 2 hole positions using the lockdown bracket holes as a template. Remove the cooktop & place upside down to drill or punch. The holes should be approximately centered on the flange. Drill the 2 clearance holes using approximately a .210” diameter drill bit (#75) Page 2 of 2 3-5 Section 3 Cooking Due to this design change the original manifold panels for models that used the spring clip lockdown method will become obsolete once current stock is depleted. When that happens if a servicer orders one of the older style manifold panels the part number will be substituted with a service kit which includes the new style panel, new corner gusset brackets, screws and the instruction sheet (See handout). In some cases it may be necessary for the servicer to drill two holes in the underside of the cooktop to install the screws that secure the cooktop to the brackets. Broken Cooktop Examples Photo 1 Glass or Ceramic Cooktop Damage Over 95% of the claims filed for “defective” glass or ceramic cooktops are due to customer misuse, abuse, or damage of some type. Cosmetic defects or damage are not covered by the product warranty. This includes staining of any type, scratches, metal marks from aluminum or copper pans, etc. Consumers often describe “bubbles” in the cooktop. Once the glass top has been manufactured it is not possible for air bubbles to form inside the glass. These “bubbles” as described by consumers are most often residue from food or metal marks that cannot be removed. Glass breakage is covered only in the case of a thermal crack. While it is often not possible to determine for sure what caused the glass to break there are certain characteristics that can be used as a guide when inspecting a broken top. Information and pictures in the handout offer some excellent examples of broken cooktops and describe how they were broken. See Handout. 3-6 Photo 1 was sent by consumer to show us the “Thermal Break” that occurred in their cooktop. Red lines have been drawn in the photo to outline the location of the cracks. Using only this photo it is not possible to accurately determine if the crack is due to defect so additional photos were requested. Section 3 Cooking The consumer sent photo 2 and pointed with their finger the “beginning point” of the crack. This photo still did not provide enough evidence to make a determiniation because it does not show all areas of the cooktop affected by the cracks. Photo 2 Photo 3 sent by the consumer clearly shows an impact point that was the beginning of the two cracks that pass over the element in photo 1. The consumer was advised that this damage was obviously caused by an impact on the outer edge of the glass and would not be covered by warranty. Photo 3 Photo 4 is typical of impact or compressive stress breakage on a glass cooktop. The indicators are that the break pattern resembles a spiders web, having multiple break lines that radiate out from a common point. Photo 4 This could be caused by dropping something on the glass top or by some other method of exerting excessive force onto a small area of the glass. This is not a product defect and would not be covered by the product warranty. 3-7 Section 3 Cooking Damage Due To Defect Photos 5 and 6 illustrate damage that occured to a cooktop and to the cook ware that was being used at the time of failure. The consumer reported that as soon as they began using the element there was a popping sound and some sparking seen between the tea kettle and the cooktop glass. Damage seen on the bottom of the kettle (photo 6) matches the general pattern of the damage to the glass. When this type of damage appears it can sometimes be attributed to the consumer leaving the range unattended and allowing the pan to boil dry. When that happens the pan can overheat and cause damage to the pan as well as the glass top. Photo 5 In this specific case it was fairly easy to determine that the root cause of this failure was an electrical short and burn out that occurred in the heating element which penetrated the glass from the underside and damaged the tea kettle. Photo 7 shows a close up view of the damaged area of the cooktop glass. It is easy to see that the damage is isolated to one small spot and when the element was examined the shorted area of the element aligned with this spot. In cases where the pan is allowed to boil dry there will be more damage to the top and to the cookware with numerous burn marks in the element area. The overall condition and appearance of the range can be an indicator of the type of use and care that the product receives. Photo 6 Photo 7 3-8 Section 3 Cooking Instructions for installing resistor on glass cooktop units with serial numbers starting with 3F. The 609T013S06 resistor that is included in kit 5304461323 can be used to eliminate nuisance glowing of indicator lights that glow faintly when power to the element is off and the elements are cool. In some cases the resistor can be installed directly onto the light assembly. In the case of some cooktops with serial numbers beginning with 3F there is not sufficient clearance to install the resistor on the light assembly. In these situations the resistor can be installed across the switch terminals that power the indicator light and will work with the same results as installing it accross the light assembly. Photo A Terminal 4 Terminal P1 The photos to the right show how to install the resistor on the surface element switch to eliminate the faint glowing indicator. Photo A shows the unit after the glass cooktop has been removed and the element switches have been accessed through the control panel. Photo B shows a close up of the Right Front element control switch. The resistor will be connected to terminal #4 and P1 on the switch. On this switch there are two spade connectors for terminal P1, so the resistor can be plugged on to the adjacent spade. If there is only one spade connector as seen on terminal 4 you must plug the resistor on first then use the extra flag terminal of the resistor to reconnect the original wire that was installed on the terminal. Photo B Photo C shows the Right Front element control switch after the resistor has been installed accross terminals 4 and P1. The resistor leads can be bent carefully to provide adequate clearance from any metal surfaces or other wiring connections. Photo C 3-9