Premium PFV90 User manual

Service Manual for upright freezer
PREMIUM MODEL
PFV90

1
Content Table
Main feature and product appearance--------------------------------------------2
Unit Specification-----------------------------------------------------------------------3
Safety during maintenance or service --------------------------------------------3
Electrical Diagram ---------------------------------------------------------------------4
Cooling System Diagram ------------------------------------------------------------5
Part Lists and explanation -----------------------------------------------------------5
Disassembling and replacing of the components ------------------------------------6
Check the breakdowns of the cooling system ----------------------------------7
Table for quick answer for the field problem ------------------------------------9
Note of the cooling system maintenance with R134a refrigerant ---------13
The performance testing requirement after service---------------------------14
Maintenance parts list ----------------------------------------------------------------15

2
Main feature：
Product appearance：
PFV90
Model Door Gasket seal
for the door
Hinge Accessory Structure
PFV90
Integrated
Foaming Door
with painting
sheet metal
and
simple ,beautif
ul handle
Recessed
door gasket
seal, easy
to be
discharged
and
cleaned.
Plastic
material,
simple
and
practicall
y
。
One basket
inside
Front, Left and
right side shell
compose to
whole “U” shape
shell, with
aluminum internal
tank with cotton
ginning, and
unitary plastic
linear mouth. It
has inside hidden
evaporator and
condenser, and
unitary foaming
insulation.

3
Unit Specification：
No. Model PFV90
1 Net Capacity（L）232
2
Voltage
（
V
）
115
3 Frequency（Hz）60
4 Refrigerant R134a
5 Refrigerant Amount (g) 115g
Safety during maintenance or service:
In order to be safety during maintenance, must obey the following basic attention:
1. During service:
Pay attention to the flame or ignition nearby, particularly after welding using gas
too, must turn off the flame first, then can do other maintenance work, because
the refrigerant will produce the toxic air when it touch with flame, sparkle or
capacitor.
Do not do the welding work in the airtight or bad air circulation room.
When discharging the refrigerant, must keep the room good air circulation
condition.
When cutting the suction pipe or discharging pipe of the compressor, pay
attention to the surplus refrigerant and internal pressure in cooling system pipe
2. Unplug the unit:
When you are ready to proceed the maintenance, must first unplug the freezer
first to ensure the safety.
3．Avoid electrical shock:
Normal when proceeding the maintenance, must open the power supply first. But
if you must check the field wiring or the component of the unit with power supply
in, must be very carefully and don’t touch the live parts. If you find out the wiring is
aged, please replace it in time.

4
4．Correct use the components:
If the component is damaged and need to be replaced, be sure to replace with the
component with same model，do not use other models or other brand
components, and not use the changed component.
5．Correct use the service tools:
Ensure to use the appropriate service tool right. Otherwise it will cause bad
electrical contact or loose fixing, and the incidence will happen.
6．Wiring connection:
When re-connecting the cut wire, be sure to use soldering method or terminal
connection, and then wrap the connection point with insulation tape, ensure the
good connection.
7．Insulation resistance measure:
After completing the service and assembly，must use the multi-meter to measure
the insulation resistance, if it is greater than 1 million ohm, then you can plug on
the unit.
8．Grounding test:
After maintenance, use the multimeter to measure the grounding resistance to
ensure the grounding resistance is less than 0.1 ohm.
9．Pay attention to the child or infant nearby:
When maintenance, don’t let the child or the infant nearby.
10．Cleaning:
After service, do the necessary cleaning work and tell the customer the necessary
precaution.
Electrical Diagram

5
Please note, maybe some units are without RUNNING CAPACITOR marked in
red color in above diagram, according to the used compressor model.
Cooling System Diagram:
Note:Arrow direction means the flowing direction of the refrigerant.
Capillary
Dry Filter
Evaporator Condenser
Compressor
Air Suction Pipe

6
Part Lists and explanation：
1、PFV90
No.
Parts Name
Quantity
Note
1
Door
1
2 Hinge 2
3 Shelf 3
4 Freezer Cabinet 1
5 Thermostat cover 1
6 Compressor base 1
7
Condensate Water Drain
cap 1
8 Fixing feet 2
Disassembling and replacing of the components:
When replacing the components, must unplug the unit first, in order to be safety.
1．Replace the thermostat：
Unscrew the fixing screw of the thermostat box, remove the thermostat box, then
remove the old thermostat, install the new thermostat with same model, and reinstall
back the whole thermostat box with same fixing screw.

7
2．Replace the PTC starter and overload protector of the compressor：
Remove the clamp of the connecting terminal cover of the compressor and the
terminal cover, toward the vertical direction, remove the broken-down starter or overload
protector, install back the new starter or overload protector, then fix back the terminal box
cover and its clamp.
3．Replace the door gasket seal:
Remove the old door gasket seal from the groove of the door linear, then install the
new gasket seal into the four sides of the groove, install it oven as possible, open and
close the door several times, ensure that the door is sealed.
4．Replace the compressor：
（1）、 First cut the welding point of the technical pipe of the compressor to discharge
the refrigerant inside the cooling system, then weld the old point to disconnect the pipe
to the compressor, remove the compressor to replace with a new one, pay attention to
replace with a new refrigerant dry filter.
（2）、 Install the new compressor, weld the high pressure side and low pressure side
pipe to the compressor, check the system leakage, after completing vacuum the
cooling system, charge the correct amount refrigerant into the system from low
pressure side pipe. After this, run the unit to check the cooling performance is ok or
not, then weld and close the technical pipe.
Check the breakdowns of the cooling system：
Following the next illustration to check the problem:

No
frost
Compressor
Check t he f r ost
on t he cabi net
l i ner sur f ace
Leakage
check Cut of f t he
l ow pr eesur e pi pe
No refrigerant
air spurt out
Leakage
poi nt ?
On the
pipe joint Ref r i ger ant
Leaks
Cut of f t he l ow pr essur e
pi pe and spur t out t he
r esi dual r ef r i ger ant
Repai r t he wel di ng,
cl ean t he pi pe and
r epl ace t he dr y f i l t er
Vacuumi ng and
r echar gi ng Leakage
check agai n
Refrigerant
air spurt out
Cut of f t he hi gh
pr essur e pi pe
Normal suction of
the comressor low
pressure pipe
Char ge t he
ni t r ogen t o t he
condenser pi pe
No air on the
low pressure side
Pi pe
cl ogged
Repl ace t he di r t y and
cl ogged par t s and
cl ean t he syst em pi pe
Little
frost
No air suction on
the compressor
low pressure pipe
Cut of f t he hi gh
pr essur e pi pe
Bad compression
of the compressor Repl ace t he
compr essor
Leakage
checki ng
Detected Leakage
poi nt ?
Cut of f t he
l ow pr eesur e pi pe
A little
refrigerant air
spurt out Leaks
slowly
A little
refrigerant air
spurt out
Repai r t he wel di ng,
cl ean t he pi pe and
r epl ace t he dr y f i l t er
Vacuumi ng and
r echar gi ng
Leakage
check agai n
Big quantity
refrigerant air
spurt out
Cut of f t he hi gh
pr essur e pi pe
Normal suction of
the comressor low
pressure pipe
No air suction or weak
suction on the compressor
low pressure pipe
Compr essor
br eaks down
Repl ace t he
compr essor
Char ge t he
ni t r ogen t o t he
condenser pi pe
Not sufficient nitrogen
air return back the low
pressure side
Pi pe i s
cl ogged
slightly
Repl ace t he di r t y and
cl ogged par t s and
cl ean t he syst em pi pe
Condensate dew
but no frost
Check t he hi gh
pr essur e si de pi pe
and compr essor
Too high
temperature
Check l ow
pr essur e pi pe
Frost
Too mor e
r ef r i ger ant
Frost
Rechar ge appr opr i at e
quant i t y r ef r i ger ant
Cooling
discontinuously
Pi pe i s cl ogged
withice Repl ace t he dr y f i l t er
and cl ean t he syst em
pi pe wi t h war m ni t rogen
Compressor
not working
Check t he el ect r i cal par t s such
as PTC st ar t er, capaci t or , over l oad
pr ot ect or , t hermost at et c.
Broken-down
Repl ace t he
br oken- down par t s
Good
Measur e t he
r esi st ance of t he
compressor wi ndi ng
Abnormal
resistance
Normal
Repl ace t he
compr essor
Over l oad
pr ot ect or act s
Over l ar ge
cur r ent Repl ace t he
compr essor
Compr essor
goes wr ong
Yes
No
Problem and check point Cause Solution

9
Check the frost on the cabinet liner surface, if find like following:
1) No frost, then do the leakage detecting.
A). If the leakage point is found, then first cut off the low pressure pipe to discharge
the left refrigerant in the system, then clean the pipe, replace with a new dry filter and
welding again, again recharge the refrigerant and do the leakage detecting.
B). If the leakage can not be found, cut off the low pressure pipe, if there is no
refrigerant omitting, then recharge the refrigerant and do the leakage detecting again; If
there is refrigerant omitting, cut off the high pressure pipe(means that compressor
suction is normal), charge the condenser pipe with pressurized nitrogen, if no air at low
pressure side, means the pipe is blocked, then replace the blocked parts and clean the
system pipe; If no air suction at compressor low pressure side, cut off the high pressure
pipe, means air compression of the compressor is not good, please replace the
compressor.
2).A little frost on the surface, also do the leakage detecting first.
A) If the leakage point is confirmed, then cut off the low pressure pipe, if a little
refrigerant air spurt out, means that the system leaks slowly on the leakage point, you
should repair the welding of cut pipe and the leakage point and clean the system pipe by
the high pressure nitrogen, replace the dry filter, after completion these work, re-vacuum
and recharge the refrigerant, at last do the leakage detecting again.
B). If big quantity refrigerant spurt out, cut off the high pressure pipe to check the
suction of the compressor low pressure pipe is normal or not: if no suction or weak
suction, it means not good compression and need to replace the compressor; if normal
suction, then charge the clean and warm nitrogen to the condenser pipe, if you find the
returned nitrogen of the low pressure side is not sufficient, it means that the system pipe
is clogged lightly, please replace the clogged parts and clean the pipe.
3). No frost, but have condensate water on the surface on the cabinet liner, check the
temperature of the high pressure side pipe and the compressor, you will find it is too high
temperature and check the low pressure pipe with frost, if like this, means too more
refrigerant in the system, please recharge with appropriate quantity refrigerant once
more.
4) The unit works discontinuously, maybe the system is clogged with ice, please replace
the dry filter and clean the system with clean and warm nitrogen.
5) Compressor doesn’t run.
Please check the electrical parts, such as PTC starter, capacitor, overload protector,
thermostat etc., if you find the parts go wrong, then replace a new one with same type
and specification. If all of these parts are good, please measure the resistance of the
compressor winding, if the resistance is abnormal, must replace the compressor;
otherwise check the overload protector act or not, means the over large current and
compressor goes wrong, also replace the compressor.

10
Table for quick answer for the field problem：
Item Phenomeno
n Check point and the detail Caused by
(A).
Not cool
completely
Power indicator
is not on and
compressor
doesn’t run
Check that other
appliances are
working or not.
No power
supply in
neighbor house
Field power
supply is cut
off.
All of other
appliances in
house don’t
work
Main fuse is cut
off.
Only this
freezer doesn’t
work
Power supply
outlet has
problem
Compressor
doesn’t run, but
power indicator
is on.
If the cooling thermostat is shorted of
the circuit or turn the thermostat to the
coldest point, the compressor can run.
Thermostat is
breakdown
There is sound when turning the knob
of the thermostat.
The knob is
broken or is not
installed
properly.
Thermal protector
may be overloaded.
Check it is
cutoff or not by
the multi-meter.
If it is cutoff,
means it is
broken down.
PTC Starter
Check it is
cutoff or not by
the multi-meter.
If it is open,
means it is
broken down.
Check the circuit
wiring
Check it have
broken point or
not in the
circuit wiring
according the
electrical
diagram
Maybe the lead
is broken or the
connection
point is loosing
Compressor
problem
Measure the
winding
resistance of
the compressor
The winding is
broken or burnt

11
Measure the
insulation
resi
stance by
meg-ohm
meter, if the
insulation
resistance < 1
MΩ,the unit
can’t be used
for long time.
The winding is
burnt.
Power supply
voltage
The voltage is
too low.
(Maybe lower
than 175V)
Compressor
can’t start
because of
under voltage.
Compressor can
run
Cooling system
There is no
sound of
refrigerant
flowing in
cooling system
and it leaves oil
on the welding
point
Leakage of
refrigerant
There is no
sound of
refrigerant
flowing in
cooling system
and no oil on
the welding
point.
Inside leakage
of cooling
pipe or the
pipe is
blocked.
Compressor
No air is
discharged out
on the
discharging
mouth of the
compressor.
Compressor
valve is
breakdown
There is
abnormal
sound inside
compressor
Compressor is
breakdown

12
(B)、
Compressor
runs but
cooling
effect is not
good.
Incorrect using
Check the thickness of frost(>5mm?) The frost is too
thick
Thermostat is set at higher
temperature (lower digit)?
Set it to lower
temperature
There is too more food in cooling
compartment, too crowded, ensure
good air circulation inside freezer
Too more food
Is there high temperature food, like
hot soup etc., inside freezer?
Hot
temperature
food let the
temperature
inside freezer
cooling
compartment
rise.
Too more times of openin
g of the
door It will affect the cooling effect
Leakage of
cooling air
Check the door gasket sealing strip
is broken or deforming
Broken of the
door gasket
sealing strip
Check the door is warded off by the
food and the door is closed tightly or
not.
The door is not
closed tightly
The unit is not
placed at good
position
The freezer is inside direct sunshine
The unit can
not dissipate
the heat
because
sunshine
The back of the unit is too close to
the wall
Too close will
affect the heat
dissipation
There is heat source near the unit.
Over-hot
environment
will affect the
heat
dissipation
(C)、
Temperature
is too low Abnormal action
of thermostat
Check the sensor head of the
thermostat is loosing or not Incorrect temperature
sensing of
thermostat
Thermostat is not at good quality
Thermostat is
breakdown

13
(D)、
Water
condensate
There is
condensed
water on the
closure
The environment is too wet
The relative
humidity is too
high
(E)、
Leakage
of electricity
Electrical shock
sense on the
enclosure
Confirm the insulation resistance is
lower than 1 MΩ by the meg ohm
meter
Insulation is
not good
Check the electrical parts of the unit
are wet
Insulation is
not good
Check the electrical parts touch with
the metal enclosure or not, and the
groundin
g lead is not grounded
properly
Electricity
leakage
Check it have static electricity
influence Static electricity influence
(F)、
Too noisy
and
vibration
There is sound
inside
compressor
Check the compressor has abnormal
sound or not.
Compressor
abnormal
There is
vibration sound
Check the pipe is touched each
other or not
Pipe touching
produce
resonance
Check the
installation ground is flat
and the feet is adjusted at proper
position or not
The unit is not
placed evenly
Note of the cooling system maintenance with R134a refrigerant：
The requirement of the cooling system parts：
Because refrigerant R134a and its lubricating oil grease is of strong water
absorbability and oxidation ability, and will cause catalysis reactivity with chloride
to produce impurity to be silt. So during service process, you should pay more
attentions to the water quantity, oxide quantity, chloride quantity, oil quantity and
impurity quantity in the cooling system, and control it more strictly.
·Left water quantity control：
1）If the cooling system parts, like condenser, evaporator, compressor, or the
dry filter etc., need to be replaced, the replaced parts should be stored charging
with dry nitrogen with pressure 0.2~0.3Mpa, and if these parts have leakage of
nitrogen, they must be dried in the high temperature chamber and be taken out of
the water before using.
2）The molecular dry desiccant inside dry filter must be controlled strictly,
guaranteed that the left water quantity must be lower than 1.5WT%.And normally,
after the dry filter is opened from vacuum package, must be welded to the pipe
system within 5 minutes.

14
If at wet condition (relative humidity>50%), must take measure to be protected
from humidity, and the dry filter must be connected to the system pipe at once
after removing from package, so as to produce the sealing system.
The requirement of the service equipment：
①No need recycling equipment, except charging machine, if the equipment is
special for R134a refrigerant system, must mark it clearly to avoid use each
other. (except welding machine, pliers, electronic balance）
②The vacuum machine and charging machine are special used for R134a
refrigerant system.
Service Procedure：
Special requirement during service process：
(a). Duration of from opening of compressor to vacuuming process must be less
than 10 minutes, and for other parts not more than 12 minutes.
(b)．Vacuuming duration should not loess than 20 minutes.
(c)．If refrigerant leakage happens, it need to replace the compressor. Before
welding, dry the cooling system by the nitrogen air.
(d)．If the dust blockage happens in cooling system pipe, if can be blow out by
the nitrogen, don’t need to replace the compressor, otherwise the cabinet
is no useful (and the evaporator is no useful).
(e)．If ice blockage happens in the system pipe, must replace the compressor.
f．Change the dry filter only if the system is opened.
Main point of service：
①The replaced compressor must return back to the compressor manufacturer to
be treated.
②The compressor can’t be tested through direct absorbing atmosphere, it will
damage the compressor.
③If the system pipe is opened for a long time or leakage happens, you can dry
the system by nitrogen during service.
④All of the welding material must be protected from wet condition. And ensure to
use a little as enough as possible.
⑤Check the compressor is pressurized or not when opening.
⑦When storing the R134a refrigerant, must keep it sealed and not touch with
atmosphere directly.
The performance testing requirement after service:
After completing the service, normally need to be done test running for 1-2days.
When proved to be safely and good cooling performance, then move to the customer
or user. During test running, we suggest that you can do following item:

15
1、Insulation and safety：
Before plugging in, use the DC 500 meg-ohm meter to measure the
insulation resistance between the live parts and dead metal enclosure, ensure the
result is not lower than 1 meg-ohm.
2、Starting capability：
The compressor can start smoothly, and can start or stop normally. If the unit
can’t start or stop normally, must find the root cause and delete the cause, then
you can plugging it in to let it run.
3、Cooling performance：
After running for 24 hours, check that the frost on the surface of the cabinet
linear is oven or not, and there is no frost on the suction pipe.
4、Electrical structure and safety：
After service, check all of the electrical parts, ensure the connection
terminal of the electrical parts don’t loose and the grounding wire is ok.
5、Leakage checking：
After running for 24 hours, check one by one of welding point by using
halogen leakage detecting device or suds. If leakage happens again, then
should service again.
Maintenance parts list：
No.
Parts name
PCS/unit
Note
1
Compressor
1
2
Thermal protector of
compressor 1
3
PTC starter
1
4
Feet of compressor
4
5 Refrigerant dry filter 1
6 Thermostat 1
7 Power cord assembly 1
8 Adjustable feet 1
9 Door gasket sealing strip 1
9
Running indicator
0
10
Power indicator
0