CyberChiller Series Installation, Operation & Maintenance Manual
4.3Field Service
It may be necessary to perform repairs on the refrigeration system. If field repairs are necessary, the following procedures apply:
NOTE
Do not attempt to make repairs without the proper tools.
4.3.1Leak Detection
Several methods can be used to detect a leak in the refrigeration system. The most modern and easiest method is to use an electronic leak detector. Follow the manufacturer’s directions and any leak can be quickly located. A second method is to use soap bubbles. Apply a solution of soapy water with a brush or sponge to the joints and connections in the refrigeration lines. A leak in the lines will cause bubbles to form.
NOTE
Halogen leak detectors are ineffective with R- 407C refrigerant because unlike
4.3.2Leak Repair
When a leak is located, properly reclaim the remaining refrigerant charge before attempting repairs. Adjacent piping must be thoroughly cleaned by removing all paint, dirt and oily film. Use wire brush, sandcloth or sandpaper and wipe the area with clean, dry cloths. Protect nearby parts from heat damage by wrapping with
4.3.3Refrigerant Piping
When replacing components within the cabinet of the unit, the following consumable materials are recom- mended: Use Silfos alloy for
When component replacement is complete, remove all traces of flux. After any repair, pressure check the system, checking for leaks prior to recharging the system.
4.3.4General Common Repairs/ Component Replacement
4.3.4.1 Compressor Failure
The compressor is the most important component of the air conditioner. Numerous safety devices are provided to protect the compressor from failing.
If a compressor failure has occurred, determine whether it is an electrical or a mechanical failure. An electrical failure will be indicated by the distinct pungent odor once the system has been opened. If a burnout has occurred, the oil will be black and acidic. A mechanical failure will have no burned odor and the motor will attempt to run, an abnormal or excessive noise may be present.
An analysis of the oil is the only way to ensure the proper procedure for cleaning the refrigerant system. Acid test kits are available from several manufacturers for measuring the acid level in the oil. These are capable of making accurate acid measurements, but if they are not available, a check of the oil by sight and smell can give a quick indication if contamination remains in the system. Since refrigeration oils vary in color, a sample of the new oil in the replacement compressor should be removed prior to installation and sealed in a small glass bottle for comparison pur- poses. If the oil has been exposed to refrigerant, the bottle should not be tightly capped, since the residual refrigerant may create a high pressure if tightly sealed and exposed to high temperature.
CAUTION 
Avoid touching or contacting the gas and oil with exposed skin. Severe burns will result. Use long rubber gloves in handling contaminated parts.
All electrical connections should be checked to be sure that they are tight and properly made. Check all circuit breakers, contactors and wiring. The contactor should be examined and replaced if contacts are worn or pitted.
If there is acid in the oil, there has been an electrical failure which has caused the compressor motor to burn out. The acid diffuses throughout the refrigeration system and must be removed by using a burnout filter kit before a new compressor is placed in service. Not only must the compressor be replaced, but also the entire refrigeration circuit must be cleaned of the
|
|
| (©October, 2006) | |
|
|
|
|
|
|
|
|
|
|