Panasonic OCU-CR1000VF8A Bedienungsanleitung

Outdoor Type Refrigeration Unit

(Non-fluorocarbon Refrigeration Unit

with CO2Refrigerant)

Engineering Service Manual

Model No. OCU-CR1000VF8A

OCU-CR1000VF8ASL

Table of Contents

Table of Contents 2

Service Piping (Optional Accessories) 3

Service Valve Operation Method 4

Service Pipe Connection/Disconnection Method 5

Evacuation Mode 7

Refrigerant Releasing Procedure 8

Airtight Test 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

Service Piping (Separately sold components)

Service piping components are required when connecting the refrigeration unit and vacuum

pump, cylinders, etc. during installation.

Use these components to connect to locally procured components.

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)

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

Back seated position

(Counterclockwise

turnlimit)

Front seated

positon

(Clockwise turn

limit)

Mid-position

(Stem height approx. 15 mm)

Access port of low pressure

service valve Access port of highpressure

service valve

Detail of access ports location

Packing

Nut

Stem

Copper packing

Cap

Glandnut Access port

Copper

packing

Cap

Packing

Nut

Access port

Stem

Glandnut

High pressure and low pressure

service valve Oil service valve

: Back seated position

(Turn the stem fullycounter-

clockwise)

Access port is Access port is

Open. Closed.

: 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

areaccessible.

: Front seated position

(Turn the stem fully clockwise)

Access port is Access port is

Closed. Open.

Location of service valves

Front of refrigeration unit

Service Pipe Connection/Disconnection Method

1. Preparation for attachment of the service piping

1) To front seat service valves, turn the stem of the high pressure and low pressure service

valves clockwise as far as possible.

Notes: 1. Use a new packing.

2. Check that there is no adhering foreign objects.

2. Service piping attachment

1) Remove the nut and packing included with the service valve (2 places).

2) Assemble the service piping.

▪Turn the nut by hand until the packing needs to be fastened with a tool.

▪If it is difficult 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 (2places) CO2 charging hose or 1/4”pipe

Connected to the CO2 manifold gauge set

Front seatedpositon

Turn the stem fullyclockwise

2) Attach a packing to the service piping (2 places).

Service piping (SPK-TU125)

Joint (High pressure joint: Swagelok, etc.)

Locally procured

Jointvalve

(High pressure valve: Swagelok, etc.)

Locally procured

Nut and packing

(Included with

thevalve)

Fasten by

hand

Servicepiping

Remove

(Install after work)

3. Fastening the service piping

Fasten the nuts by hand up to the condition shown below, and then fasten them with a tool.

Fastening torque of 13 1 N•m is recommended for the nuts.

Note: Fastening the nut too tight may deform the packing.

4. After completing service operation

1)After completing service operations such as evacuation

and refrigerant charging, turn the stem of the high

pressure and low pressure service valves clockwise

as far as possible. (The access port isclosed.)

2)Any remaining nitrogen or refrigerant in the 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

fasten them if any looseness exists. Fastening torque is 10 2 N・m.

Service Pipe Connection/Disconnection Method

Service piping

(SPK-TU125)

High pressure

service valve

Joint valve

Low pressure

service valve

Nut

Access port is

closed.

Front seatedpositon

Turn the stemfully

clockwise

Nut (Included with the valve)

Glandnut

Evacuation Mode

1. Evacuation mode

In the evacuation mode, fully open the electronic expansion valve and solenoid valve in the

refrigeration unit.

Note: If the refrigeration unit is not set to the evacuation mode, the electronic expansion valve

and solenoid valve in the unit do not open, thus leading to incomplete the evacuation.

2. Evacuation modeprocedure

1) Turn OFF the ground faultinterrupter.

Note: The evacuation mode cannot be started with power supplied to the refrigeration 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 refrigerationunit.)

6) The 7-segment LED indicates

Low pressure → High pressure → unit outlet pressure → Vacuum （uAcU）

Operation switch S1(ON) (Attached to Electrical box)

CRD2-EN-PCB (Attached to Electrical box)

Slide switch (SW14)

AUTO/FORCED Slide switch (SW15)

CONTROL/CHECK

8P DIPswitch(SW13)

(Turn ON No.1 at the top

Rotary switch(SW11)

7-segmentLED CHECK (Yellow) LEDALARM (Red)LED

Lights up or blinks

when abnormality

alarm isactivated

▲(UP)and

▼(DOWN)

buttons

(ON)

Refrigerant Releasing Procedure

1. Preparation for refrigerant releasing

1) Check that the access ports of the high pressure and low pressure service valve have been

closed. (The front seatedposition)

2) Attach the service piping with the joint valve in "Closed" condition.

3) Fasten the nuts by hand up to the condition shown below, and then fasten them with a tool.

Fastening torque of 13 1N・m 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 areopen.)

3) Slowly open the joint valve to release refrigerant.

The rapid release of refrigerant could cause refrigeration oil to be released together

with refrigerant.

Service piping

(SPK-TU125)

High pressure

service valve

Joint valve

Low pressure

service valve

Nut

Access port is

open.

Back seated positon

Turn the stemfully

counterclockwise

Caution

2. Airtight test

1) Set the evacuation mode in accordance with

" Evacuation Mode".

2) Perform the airtight test of interconnecting

pipes (the liquid line and suction line).

When performing the airtight test of interconnecting

pipes, set the low pressure and high pressure

service valves to the back seated position.

(The access ports are open.)

Note: Airtight test of the refrigeration unit was completed at the time of factory

shipment.Pressure testing should only be carried out by personal /

companies who have necessary certification. Consider carefully local

regulations and EN378.

Design pressure in Factory

Nitrogen cylinder

Charging

valve

CO2 manifold gaugeset

Lowside

gauge High side

gauge

Servicepiping

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 seatedpositon

Turn the stemfully

counterclockwise

Access port is open.

Liquid line

(High pressure part) Suction line

(Low pressure part)

8MPa 8MPa

Airtight Test Procedure

(Execute this test after competing piping work and airtight test but before starting heat

insulation work)

Make sure to close the vacuum valve of CO2manifold gauge set.

Consider special local regulations and consider Installation of all

equipment have to be in accordance to pressure directive 2014/68/EU

and European norm EN378.

2. Evacuation

1) Set the evacuation mode in accordance with

“Evacuation Mode".

2) Set the low pressure and high pressure service

valves to the back seated position (the access

ports are open), and operate the vacuum pump.

3) Continue the evacuation until the low side gauge

indication reaches -0.1MPa and continue

evacuation for an additional 1 to 3 hours.

Note: When the intended vacuum level (-0.1MPa) cannot be reached after 2 hours, check

the setup for any leaks.

Vacuum Pump Attachment and Evacuation Procedure

Back seated positon

Turn the stemfully

counterclockwise

Access port is open.

Vacuumpump

Charging

valve

CO2 manifold gaugeset

Lowside

gauge High side

gauge

Servicepiping

Joint valve CO2 charge hoseor

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 refrigerant cylinder, and the manifold gauge set by using a

charge hose or 1/4" pipe.

Note：The low side gauge for this operation should be able to indicate the vacuum level to

be reached (-0.1MPa).

Low pressure service valve

High pressure service valve

Evacuation should be performed after completing the airtight test.

Please follow local regulations and EN378.

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