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.