CyberAiR DX Floor Mounted IOM Manual
4.3
Field Service
NOTE
Do not attempt to make repairs without the
proper tools.
It may be necessary to perform repairs on the A/C
system. If field repairs are necessary, the following
procedures apply:
WARNING
If refrigerant gas is released in an enclosed
area it will displace oxygen and act as a
suffocant. Always ensure adequate
ventilation during refrigeration repairs.
WARNING
Always recover all refrigerant prior to any
system repairs, failure to do so may result in
system over pressurization and rupture.
4.3.1 Leak 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
refrigerant lines. A leak in the lines will cause bubbles
to form.
4.3.2 Leak Repair
When a leak is located, properly reclaim the
remaining refrigerant charge before beginning
repairs. Adjacent piping must be thoroughly cleaned
by removing all paint, dirt and oily film. Use a wire
brush, sandcloth or sandpaper and wipe the area
with clean, dry cloths.
Protect nearby parts from heat damage by
wrapping with water-soaked cloths.
4.3.3 Refrigerant Piping
When replacing components within the cabinet of
the unit, the following consumable materials are
recommended: Use Silfos alloy for copper-to-
copper (piping discharge or suction line repairs).
Silver solder (Stay- Silv #45) and flux are to be
used on copper-to-brass or copper-to-steel repairs.
For liquid line repairs at the drier, strainer, sight
glass, or expansion valve, use a 95% tin to 5%
antimony solder with flux.
When component replacement is complete, remove
all traces of flux. After any repair, pressure check
the system to ensure there are no leaks prior to
recharging the system.
4.3.4 General 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 pro- vided 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 determine
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.
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 ensure
they are tight and properly made. Check all circuit
breakers, contactors and wiring. The contactors
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 com- pressor be replaced, but also the entire
refrigeration circuit must be cleaned of the harmful
contaminants left by the burnout. See section 4.3.4.3
(Burn-Out/Acidic Cleanup) for the proper cleaning
procedure.
If there is no acid in the oil, there has been a
mechanical failure. See section 4.3.4.2
(Standard Cleanout) for the proper cleaning
procedure.
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