CyberOne EC DX 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 refrigeration
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.
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 refrigeration 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, sand cloth or sandpaper and wipe
the area clean before attempting repair. Protect nearby
parts from heat damage by wrapping with water-soaked
cloths.
4.3.3
Refrigerant Piping
When replacing refrigeration components, the following
consumable materials are recommended:
For R407C repairs use Silfos alloy for copper-to-copper
(piping liquid line or suction line repairs). Silver solder (Safety-
Silv #45) and flux are to be used on copper-to-brass or
copper-to-steel repairs.
Wrap wet rags around the pipes between the areas to be
brazed and any nearby refrigeration components to keep
excessive heat from traveling through the pipe and causing
damage.
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 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 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. 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 purposes. 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 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 compressor be
replaced, but also the entire refrigeration circuit must be
cleaned of the harmful contaminants left by the burnout. See
“4.3.4.3 Burn-Out/Acidic Cleanup Procedure” on page 39
for the proper procedure.
If there is no acid in the oil, there has been a mechanical failure.
See “4.3.4.2 Standard Cleanout Procedure” on page 39
(Standard Cleanout) for the proper cleaning procedure.
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