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Maintenance
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
Confined Space Hazards!
Failure to follow instructions below could result in
death or serious injury. Do not work in confined spaces
where refrigerant or other hazardous, toxic or
flammable gas may be leaking.
Refrigerant or other gases could displace available
oxygen to breathe, causing possible asphyxiation or
other serious health risks. Some gases may be
flammable and or explosive. If a leak in such spaces is
detected, evacuate the area immediately and contact
the proper rescue or response authority.
.
WARNING
Refrigerant under High Pressure!
Failure to follow instructions below could result in an
explosion which could result in death or serious injuryor
equipment damage.
System contains refrigerant under high pressure.
Recover refrigerant to relieve pressure before opening
the system. See unit nameplate for refrigerant type. Do
not use non-approved refrigerants, refrigerant
substitutes, or refrigerant additives.
Leak Detection
WARNING
Explosion Hazard!
Failure to follow safe leak test procedures below could
result in death or serious injury or equipment or
property-only-damage. Never use an open flame to
detect gas leaks.
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.
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,
44
dirt and oily film. Use a wire brush, sand cloth or
sandpaper and wipe the area with clean, dry cloths. Protect
nearby parts from heat damage by wrapping with water-
soaked cloths.
Refrigerant Piping
When replacing components within the cabinet of the unit,
the following consumable materials are recommended:
1. Use Sil-Fos alloy for copper-to-copper (piping
discharge or suction line repairs).
2. Use silver solder (Stay-Silv #45) and flux on copper-to-
brass or copper-to-steel repairs.
General Common Repairs/Component
Replacement
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
is indicated by a distinct pungent odor when the system is
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.
Analysis of the oil is the only way to determine the proper
cleaning procedure for the refrigerant system. Acid test
kits are available from several manufacturers for
measuring the acid level in the oil. These are capable of
making quite 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.
All electrical connections should be checked to ensure they
are tight and properly made. Check all fuses, 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
that caused the compressor motor to burn out. The acid
diffuses throughout the refrigeration system and must be
removed using a burnout filter kit before a new
compressor is placed in service. The entire refrigeration
circuit must also be cleaned of harmful contaminants left
by the burnout. See Section
Procedure," p. 45
If there is no acid in the oil, there has been a mechanical
failure. See
Section"Burn-Out/Acidic Cleanup Procedure,"
p. 45
for the proper cleaning procedure.
POE oil is used in systems with R407C refrigerant. If a
replacement compressor is provided, ensure that it is filled
with POE oil before installing.
Important:
Damage to a replacement compressor
caused by improper system cleaning
constitutes abuse under the terms of the
warranty. This will void the compressor
"Burn-Out/Acidic Cleanup
AH-SVX008C-EN
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