Panasonic OCU-CR1000VF8A User manual

1
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
2

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.
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)

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
turnlimit)
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 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
A
: Back seated position
(Turn the stem fullycounter-
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
areaccessible.
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

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
5
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
Nut
Access port is
closed.
Front seatedpositon
Turn the stemfully
clockwise
Nut (Included with the valve)
Glandnut
6

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)
7
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
Nut
Access port is
open.
Back seated positon
Turn the stemfully
counterclockwise
Caution
8

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
9
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
10
Evacuation should be performed after completing the airtight test.
Please follow local regulations and EN378.

Refrigerant Charging Procedure
3) Check that the joint valve is closed and set the high pressure service valve to the back
seated position (the access port is open), and the low pressure service valve to the front
seated position.
Note: Do not charge the refrigeration unit with liquid refrigerant from the low pressure side
under any circumstances.
4) Adjust the zero point of the platform scale.
Caution Make sure to close the vacuum valve of CO2 manifold gauge set.
1. Preparation 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
Lowside
gauge High side
gauge
Platformscale
CO2 manifold gaugeset
Servicepiping
Joint valve
CO2 charge hose or 1/4"pipe
Low pressure service valve
High pressure service valve
CO2cylinder
Access port isclosed.
Front seatedpositon
Turn the stemfully
clockwise
Back seatedpositon
Turn the stemfully
counterclockwise
Access port is open.
11

Refrigerant Charging Procedure
2. CO2 refrigerant grade
Charge CO2 refrigerant (R744) that is compatible with the following specifications.
12
3. Refrigerant Charging
1) With the refrigeration unit being stopped, open the joint valve and gradually charge the
refrigeration unit with refrigerant in the liquidstate.
When it is difficult to adjust the charging speed by using the joint valve or the charging valve
of manifold gauge set, install a capillary tube between the CO2 refrigerant cylinder and
manifold gauge set.
Note: Do not install a capillary tube between the service piping and manifold gauge set.
2) When the liquid refrigerant no longer goes into the refrigeration unit, close the access 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 cylinder valve and check that the
access ports of the low pressure and high pressure service valves have been closed.
4) Gradually open the purge valve of the manifold gauge set, and release the refrigerant
remaining in the service piping, manifold gauge set, and charge hose (or 1/4" pipe).
When detaching the service piping, refer to “Service Pipe Connection/Disconnection
Method”.
Item Specifications
Purity > 99.9% (volume)
Moisture < 0.005% (volume)
Total sulfur < 0.03ppm (weight)
Inert gas (H2, N2, O2,Ar) < 0.01% (volume)

Gas Leak Repair Procedure
1. Gas leak position identification
1) When using a liquid type leak detector
Identify the position where oil is leaking.
Find gas leaks by applying the liquid type leak detector and checking for foaming.
2) When using a leak detector
Identify the position where oil is leaking.
Detect gas leaks by bringing the leak detector probe near the identified position.
Note: Use caution not to blow air during the detection process. Detector reacts to blown air.
2. Releasing refrigerant
Release refrigerant in accordance with “Refrigerant Releasing Procedure".
3. Brazing repair operation
1) Prepare for brazing operation.
You will need the following tools during brazing operation:
- Brazing burner
- Phosphor copper solder
If silver brazing solder is to be 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 through the brazing position at a very low
pressure during brazing. Nitrogen displaces the air and prevents the formation of
copper oxides in the brazing position.
2. During brazing, make sure that there is no refrigeration oil residue on the surface.
4. Airtight test
Carry out the airtight test in accordance with "Airtight Test Procedure ".
5. Evacuation
Carry out the evacuation in accordance with "Vacuum Pump Attachment and Evacuation
Procedure".
6. Refrigerant Charging
Charge the refrigeration unit with refrigerant in accordance with "Refrigerant Charging
Procedure".
13

1. Preparation for compressor replacement
1) Release refrigerant in accordance with “Refrigerant Releasing Procedure”.
2) Remove the heat insulation material of the 1st stage suction pipe (cut out bundling ties).
3) Remove the anti-vibration rubber for the 1st stage and 2nd stage suction pipes (cut out
bundling ties).
4) Remove the temperature sensor of the 2nd stage discharge pipe.
5) Remove the compressor securing bolts (3 places).
6) Turn OFF the ground fault interrupter, when the pressure indication on the control PCB
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 dischargepipe
2nd stage suctionpipe
1st stage suctionpipe
Anti-vibration
rubber
Compressor terminal block
R phase lead wire(Red)
Notation of circuit diagram U.
C（T）phase lead wire(black）
Notation of circuit diagram W.
14
S（W) phase lead wire(White).
Notation of circuit diagram V.
Compressor Replacement Procedure

Caution For safety purposes, always wear protective gear during operations.
2. Compressorremoval
1)After completing the preparation for compressor replacement, cut the compressor piping at
five places (1st stage suction, 1st stage discharge, 2nd stage suction, 2nd stage discharge,
and oil return) by using a pipe cutter or cable cutter.
Notes: 1. The cutting position should be on the compressor side of the welded part as
follows. Cutting the refrigeration unit side would disable recovery.
2. Use sufficient caution not to deform the welded part of the pipe duringcutting.
2) Remove the securing bolt, spring washer, flat washer, and protection rubber washer, etc. in
three places (two places in the front and one in the back) of the compressor to be replaced.
3) Remove the compressor from the refrigerationunit.
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. During heating, supply nitrogen gas by using the service piping (SPK-TU125).
Nitrogen displaces the air and prevents the formation of copper oxides in the
heating position.
5) Remove the secured part of the piping. (Prevention of bending deformation)
Compressor Replacement Procedure
1st stage discharge
pipe cutting position
Oil return pipe
cutting position
2nd stage discharge
pipe cutting position
2nd stage suction
pipe cutting position
1st stage suction
pipe cutting position
15

2) Insert each pipe into the compressor and connect it by brazing.
Note: During brazing, supply nitrogen gas by using the service piping (SPK-TU125).
Nitrogen displaces the air and prevents the formation of copper oxides in the brazing
position.
3) After completing brazing, perform an airtight test of the brazed part.
4) Reconnect the removed wires in their original configuration.
▪Compressor wiring, terminal cover
▪Oil level switch wiring
5) Turn on the power and confirm that it is in the evacuation mode (indication of “uAcU” on
the control PCB). (Refer to “Evacuation Mode”.)
6) Release the nitrogen used for the airtight test and apply evacuation.
7) During evacuation, install the remaining heat insulation materials, anti-vibration materials, etc.
▪Anti-vibration rubber 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 original position, and install the securing bolt, spring
washer, flat washer, and protection rubber washer, etc. (three places)
Make sure that there is no contact between the sound deadening insulation
of the compressor and the crank case heater.
Caution
Securing
bolt
Spring
washer
Anti-vibration
fitting
Flatwasher
Protection
rubber washer
Collar
Cushion
rubber
Compressor
leg
A
A
B
Anti-vibration fitting
Compressor Securing
bolt
Spring
washer
Flatwasher
Collar
Compressor
leg
Cushion
rubber
Protection
rubber washer
Details of A Part Details of B Part
16

Oil Replenishing Procedure
1. Turn operation switch S1 to "OFF" to stop the operation of the refrigerationunit.
2. Confirm that the access ports of the compressor oil service valve are closed (back seated
position), and connect the service piping with an attached (closed) joint valve to each access
port.
Before starting the operation, 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 stemfully
counterclockwise
When setting each service valve to the front seat, recheck in advance that there is
no slack in the nut of each service valve, or in the joint of the service piping.
A loose nut or pipe joint may cause the refrigerant to leakout.
Caution
17

Oil Replenishing Procedure
4. Set the rotary switch (knob) on the CRD2-EN-PCB to “ON“ position, and turn ON the DIPswitch
13-5, and press the ▲button to align the opening level of the oil control electronic expansion
valve (MOV1) to 480 steps, and then return the rotary switch (knob) to ”Operation” position.
5. Slowly open the joint valve of the service piping attached to the 1st stage discharge service
valve to release the refrigerant in the compressor, and then connect the extension pipe (CO2
charging hose or 1/4” pipe) to the joint valve of the oil service valve.
6. Set the rotary switch (knob) to “OPERATION MODE" and
return the DIP switch 13-5 to OFF, and then turn ON the
DIP switch 13-7 for activating “Oil level confirmation mode”.
7. Connect the manifold gauge set exclusively for CO2 refrigerant
DIP switch SW13 Electronic expansion valve opening
(E.g. 480steps)
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 to suck up oil and add oil until the oil level reaches
the upper limit.
<Digital display example> (E.g.) Oil level indication before and after addingoil
8. After adding oil, close the joint valve of the oil service valve and remove the extension pipe, and
continue evacuation from the 1st stage discharge service valve. Continue evacuation until
vacuum level 133 Pa (1 Torr) is reached and continue for a further 1 to 3hours.
18
Mid level
Lower limit
Lower limit indication Upper limit indication

Oil Replenishing Procedure
10. After completing evacuation, close the joint valve of the service piping attached to the 1st stage
discharge valve, and remove the manifold gauge set and then open each valve (1st stage
suction, 1st stage discharge, 2nd stage suction, and 2nd stage discharge) around the
compressor as well as the oil service valve (back seated positon: turn the stem of the service
valve in a counterclockwise direction to close the access port).
11. Slowly open the joint valve of each service piping, and after completing the release of
refrigerant 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
Copper
packing
Cap
Packing
Nut
Accessport
Stem
Glandnut
DIP switch SW13
9. Set the rotary switch (knob) to “ON” and turn ON the DIP switch 13-5 and press the ▲·▼button
until the digital display indicates “1.oFF” and then return the rotary switch (knob) to “Operation
(運転)“.
<Digital display example>
19
Expansionvalve
No.（MOV1) Expansion valve
automaticcontrol

Filter Dryer
1. Filter dryer to be applied
1) The filter dryer (one is shipped with each refrigeration unit) is a standard component.
2) In the case of replacement, use the same filter dryer shown below as the standard
component.
2. Filter dryer attachment
1) The filter dryer has an expanded tip on both ends.
2) Do not remove the filter dryer cap until immediately before use.
3) 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 internaldamage.
Refrigeration Unit
Model No. Filter dryer Model No. Filter dryer Type Connection Diameter
OCU-CR1000VF
8A
D-155T CO-085-S 15.88 mm
You must not use a filter dryer for HFC refrigerant under any circumstances as it
does not meet the pressure requirement.
Caution
Cap
278 mm
20