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Panasonic OCU-CR1000VF8A, Service Manual

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Panasonic OCU-CR1000VF8A Service Manual Download Page 4

Service Valve Operation Method 

1. Location of service valves and access ports 

2. Method of operating service valves 

The service valves fall into two categories types as follows. 

Notes: 1. 

Copper packing, Cap and Nut must be installed after the work. (Gas leak prevention) 

2. Check Gland nut loosening of the service valves, and fasten them if any looseness  

exists. 

3. Fastening torques are as follows. 

Cap: 

30 

 

5 N

・

m, 

Nut: 

13 

 

1 N

・

m, 

Gland Nut: 

10 

 

1 N

・

m 

3. Relationship between each seat position and refrigerant flow direction 

A

 

Back seated position 
(Counterclockwise  

turn limit) 

C

 

Front seated 
positon 
(Clockwise turn  

limit) 

B

 

Mid-position 
(Stem height approx. 15 mm) 

Access port of low pressure  
service valve 

Access port of high pressure  
service valve 

Detail of access ports location 

Packing 

Nut 

Stem 

Copper packing 

Cap 

Gland nut 

Access port 

Copper 

packing 

Cap 

Packing 

Nut 

Access port 

Stem 

Gland nut 

High pressure and low pressure  

service valve 

Oil service valve 

A

: Back seated position  

(Turn the stem fully counter-  
clockwise) 

 
 
 
 

Access port is 

Access port is 

Open

. 

Closed

. 

B

: Mid-position 

(Stem height approx. 15mm) 

・

High pressure side  

Approx. 3 and

 

a 

half turns 

・

Low pressure side  

 

 

 Approx. 3 turns 

 

All three service valve openings  

are accessible. 

C

: Front seated position 

(Turn the stem fully clockwise) 

 
 
 
 

 

Access port is 

Access port is 

Closed

. 

Open

. 

Location of service valves 

Front of refrigeration unit 

4 

Summary of Contents for OCU-CR1000VF8A

Page 1: ...1 Outdoor Type Refrigeration Unit Non fluorocarbon Refrigeration Unit with CO2 Refrigerant Engineering Service Manual Model No OCU CR1000VF8A OCU CR1000VF8ASL ...

Page 2: ...5 Evacuation Mode 7 Refrigerant Releasing Procedure 8 Airtight T est Procedure 9 Vacuum Pump Attachment and Evacuation Procedure 10 Refrigerant Charging Procedure 11 Gas Leak Repair Procedure 13 Compressor Replacement Procedure 14 Oil Replenishing Procedure 17 Filter Dryer 20 Suction filter 21 Failure Diagnosis 22 Service Parts List 24 Exploded View 25 2 ...

Page 3: ...mponents to connect to locally procured components 3 Service piping SPK TU125 Service piping Packing attachment Note 1 Install the packing by avoiding the adherence of dust 2 Fasten the nut with fastening torque of 13 1 N m Locally procured components SPK TU125 has a bent part here Service Maintenance connection Joint valve Swagelok etc Joint Swagelok etc Packing Nut Service piping ...

Page 4: ...n Clockwise turn limit B Mid position Stem height approx 15 mm Access port of low pressure service valve Access port of high pressure service valve Detail of access ports location Packing Nut Stem Copper packing Cap Gland nut Access port Copper packing Cap Packing Nut Access port Stem Gland nut High pressure and low pressure service valve Oil service valve A Back seated position Turn the stem full...

Page 5: ...ult to fasten slightly loosen the nut and gradually try to align it in parallel with the male thread of the service valve Note Fastening the nut with a tool while the threads are not fully aligned would break the thread and lead to a gas leak Access port is closed Packing Nut Service piping Nut 2 places CO2 charging hose or 1 4 pipe Connected to the CO2 manifold gauge set Front seated positon Turn...

Page 6: ... service piping should be purged 3 Detach the service piping After detaching the service piping Install the nut originally used on the service valve by hand Refer to 2 Service piping attachment 4 Fasten the nut by using a tool Fastening torque of 13 1 N m is recommended Refer to 3 Fastening the service piping 5 Check the gland nut loosening of the low pressure and high pressure service valves and ...

Page 7: ...unit 2 Turn ON the operation switch Seesaw switch S1 3 Turn ON the DIP switch SW13 1 on the CRD2 EN PCB 4 Set the Slide switch SW15 Control Check on the CRD2 EN PCB to Check 5 Turn ON the ground fault interrupter Supply power to the refrigeration unit 6 The 7 segment LED indicates Low pressure High pressure unit outlet pressure Vacuum uAcU Operation switch S1 ON Attached to Electrical box 7 CRD2 E...

Page 8: ...is recommended for the nuts Note Fastening the nut too tight may deform the packing 2 Refrigerant releasing 1 Set the evacuation mode 2 Set the low pressure and high pressure service valves to the back seated position The access ports are open 3 Slowly open the joint valve to release refrigerant The rapid release of refrigerant could cause refrigeration oil to be released together with refrigerant...

Page 9: ...ping Joint valve CO2 charge hose or 1 4 pipe Caution 1 Preparation for airtight test 1 Connect the joint valve of the service piping SPK TU125 and the manifold gauge set exclusively for CO2 refrigerant by using a CO2 charge hose or 1 4 pipe 2 Connect a nitrogen cylinder and the manifold gauge set by using a CO2 charge hose or 1 4 pipe Low pressure service valve High pressure service valve Back sea...

Page 10: ...e Access port is open Vacuum pump Charging valve CO2 manifold gauge set Low side gauge High side gauge Service piping Joint valve CO2 charge hose or 1 4 pipe Caution 1 Vacuum pump attachment and piping connection 1 Connect the joint valve of the service piping SPK TU125 and the manifold gauge set exclusively for CO2 refrigerant by using a CO2 charge hose or 1 4 pipe 2 Connect a vacuum pump CO2 ref...

Page 11: ...on for refrigerant charging 1 Connect the joint valve of the service piping SPK TU125 and the manifold gauge set exclusively for CO2 refrigerant by using a CO2 charge hose or 1 4 pipe 2 Place a CO2 refrigerant cylinder on a platform scale and connect the manifold gauge set by using a CO2 charge hose or 1 4 pipe Charging valve Low side gauge High side gauge Platform scale CO2 manifold gauge set Ser...

Page 12: ...ss port of the high pressure service valve the front seated position and make the refrigeration unit in cooling operation condition to adjust refrigerant quantity using the access port of the low pressure service valve the back seated position Note In order to avoid overcharging maintain the charging rate at approx 20 g in 5 seconds 3 After completing charging operation close the refrigerant cylin...

Page 13: ... used do not use any flux containing chlorine Shield plate heat insulation plate wet waste cloth Blow and replacement nitrogen 2 Carry out brazing operation Since the copper pipes used with the CO2 refrigeration unit have a thicker wall than the HFC refrigeration unit make sure that the melted brazing material is fully wetting the target position Notes 1 Maintain a flow of oxygen free nitrogen thr...

Page 14: ... reaches zero and the refrigerant release sound is no longer heard 7 Remove the sound deadening insulation and terminal cover of the compressor and disconnect all lead wires of U V and W phase from the compressor terminal block S W R and C T 8 Disconnect the oil level switch wire connection Trace the connection from the oil level switch 9 Remove the crank case heater under the compressor 2nd stage...

Page 15: ...aces in the front and one in the back of the compressor to be replaced 3 Remove the compressor from the refrigeration unit 4 Remove the compressor pipe left on the refrigeration unit side by heating the cut end Notes 1 In order to avoid radiation of the heating flame make sure to cover the wiring heat insulation material and MOV1 oil control electronic expansion valve with a wet waste cloth 2 Duri...

Page 16: ...er for suction pipe Discharge gas temperature sensor Heat insulation material Crank case heater Sound deadening insulation of the compressor 8 After completing evacuation charge the specified quantity of refrigerant Compressor Replacement Procedure Caution For safety purposes always wear protective gear during operations 3 Service compressor installation 1 Place the service compressor in its origi...

Page 17: ...on perform an assessment in accordance with the Installation Instructions Oil Level Control and Oil Addition Assessment Criteria in Oil Level Control Method Caution Access port is closed Oil service valve Service piping Compressor Back seated positon Turn the stem fully counterclockwise When setting each service valve to the front seat recheck in advance that there is no slack in the nut of each s...

Page 18: ...ating Oil level confirmation mode 7 Connect the manifold gauge set exclusively for CO2 refrigerant DIP switch SW13 Electronic expansion valve opening E g 480 steps Knob Rotary switch Digital display example DIP switch SW13 Upper limit and vacuum pump to the service piping attached to the 1st stage discharge service valve and while applying evacuation open the joint valve of the oil service valve t...

Page 19: ...frigerant in the pipes remove the service piping and attach a nut fastening torque 13 1 N m at the access port At the end of operations check for a loose gland nut fastening torque 10 1 N m at each service valve and refasten and then attach the cap fastening torque 30 5 N m Without the operation shown above the oil control electronic expansion valve MOV1 cannot return to automatic control Caution ...

Page 20: ...Connect the filter dryer to the liquid line between the refrigeration unit outlet and the evaporator by brazing 4 During brazing operation protect the filter dryer from heat by covering it with wet cloths etc 5 Install with arrow pointing in direction of flow Reverse flow may cause internal damage Refrigeration Unit Model No Filter dryer Model No Filter dryer Type Connection Diameter OCU CR1000VF8...

Page 21: ...the suction filter to the suction line between the refrigeration unit inlet and the evaporator by brazing 3 During brazing operation protect the filter dryer from heat by covering it with wet cloths etc 4 Install with arrow pointing in direction of flow Reverse flow may cause internal damage Refrigeration Unit Model No Suction filter Model No Connection Diameter OCU CR1000VF8A S 008T 19 05 mm You ...

Page 22: ...o the Oil Level Control Method E101 Discharge gas temperature anomaly 1st to 2nd incident Discharge gas temperature increased to 118 C or higher and generated an abnormal stop Or discharge gas temperature sensor shorted Comply with the Failure Diagnosis at the time of Abnormal DischargeGas Temperature 1 Search for the cause of increasing discharge gas temperature 2 Check the connection of control ...

Page 23: ...ssor 7 Check if inverter V1000 output is connected to fan motor E80 Split cycle outlet temperature sensor anomaly Split cycle outlet temperature sensor became abnormal open circuit condition 1 Check the connection of control PCB 2P7 S outlet connector 2 Check the resistance value of the split cycle outlet temperature sensor Refer to Method of Checking Sensor Characteristics E81 Intermediatepressur...

Page 24: ...0223412154000 GUARD 1 19 80203530111001 AIR FILTER 1 20 42049602250 THERMISTOR 0 066W 1 21 42649600421 SOLENOID VALVE COIL 2 22 42649600430 SOLENOID VALVE COIL 2 23 80205202579000 SOLENOID VALVE COIL 1 24 1FJ4H1C0082001 CRANK CASE HEATER 1 25 42049602260 THERMISTOR 0 066W 2 26 42049602050 THERMISTOR 0 005W 1 27 1FA4M4A0226002 DC MOTOR 750W 1 28 85402501326004 FAN 1 29 80105313129002 THERMISTOR 0 0...

Page 25: ...Exploded View OCU CR1000VF8A 25 ...

Page 26: ...Exploded View OCU CR1000VF8A 26 ...

Page 27: ...Exploded View OCU CR1000VF8A 27 ...

Page 28: ...Memo 28 ...

Page 29: ...re occurs by incorrect installation the product becomes out of warranty Panasonic Corporation Website www panasonic europe com 0619 0 Sales company in EU Panasonic AppliancesAir Conditioning Europe PAPAEU Panasonic Marketing Europe GmbH Hagenauer Str 43 65203 Wiesbaden Germany Authorized representative in EU Panasonic Testing Centre Panasonic Marketing Europe GmbH Winsbergring 15 22525 Hamburg Ger...

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