5-Servicing of

refrigerators

5-1Troubleshooting procedure(general)
-obtain description of problem by user
-identify, confirm and determine possible
cause
consult service manual
Trouble shooting chart
knowledge, right instrument and tool
experience and judgment needed
-identify specific remedy

5-2 Trouble shooting chart

- unit will no run
-Refrigerator section too warm
-Refrigerator section too cold
-Freezer section and
Refrigerator section too warm
-Freezer section too cold
-Unit runs all the time
-Stuck motor compressor

-Frost or ice on finned evaporator

-Unit runs all the time temperature
normal
-Freezer runs all the time temperature
too cold
-Freezer runs all the time temperature
too warm
-Rapid ice build up on the evaporator
-Doors on freezer compartment freezes
shut
-Freezer works and then warms up

5-3 Hermetic unit servicing guide

To service successively, know how should perform
when in good condition
5-3-1 External servicing
5-3-1-1cabinet
-shelving
-door
-seal
5-3-1-2Electrical
-connection ,open ckt, short ckt Ground fault
-main supply
-Functional check/ thermostat, motor, starting
device.

5-3-2 Internal servicing

- lack of refrigerant
Evaporator partially frosted
-sweating or frosted suction line
Liquid refrigerant in suction line, caused by
Brocken thermostat or too much refrigerant
- internal electric, motor and connections are rare
(3 Out of 1000)only by air & water in compressor
- Liquid refrigerant in compressor, removes the oil
as it evaporate to the condenser and valve may
broken as the compressor tries to pump.
-Restriction on High side/capillary tube, filter, dryer
continuous running, no refrigeration, condenser
cooler than normal.

5-3-3 Most frequent service

operations
- locating & repair refrigerant Leakage
- Purging and Charging
- cleaning or replacing capillary tube
- Replacing or installing filter Dryer
- Replacing compressor
- Replacing evaporator and condenser
Must attach gauges and servicing
devices

5-3-4 Radio and TV Interference

slight snap or click in radio or TV as the
refrigerator
start or stop.
can be Reduced by grounding the
motor frame
Excessive interference of continuous
nature indicate
-loose connection or fault on
mechanism of motor
Worn brush
Badly pitted commutator or loose

5-3-5 Motor compressor burnouts

mechanisms
- moisture, dirt and air in the system
-Too much current/ inaccurate safety device
-Stiff compressor
-Low voltage
-lack of refrigerant
-poor cooling of motor
-high head pressure/ high temperature
-Oil break down takes place forms carbon and
sludge if discharge line Temp. reaches 177C
condenser should be large enough/air flow
efficiently. Purge the system, clean the
condenser
with brush & gas pressure/ Air, CO, NO

Indications

strong pungent odor of the refrigerant

when a piercing valve is just opened
just
a little.

5-3-6 Starting a stuck compressor

when the unit has not been Run for log time or a
small piece of dirt in compressor, does not start
when connected.
Methods
Using extra capacitor in main winding.
turn on for 1 to 2 seconds/ 3 to 4 attempts
this will reverse the rotation.
Use an extra voltage for a second/ connect 120V
motor with 240V supply.
An extra torque method/ connect 240V, 100F
start capacitor across terminals of the run
capacitor
for no more than one second.

5-3-7 Short cycling

Unit starts and stops too frequently
Causes
thermostat not mounted securely
loose connection in the starting relay
Avoid taping the relay
If the relay will not function correctly
without being taped, it should be
replaced.

5-3-8 Watt reading to determine

motor trouble
To observe the condition of the motor,
using wattage consumption (watts
drawn).

combined reading/ 1 to 1 seconds

running winding reading

5-3-9 Dismantling systems

(to replace parts/ motor compressor,
condenser,
capillary tube, evaporator, accumulator,
filter-dryer)
- disconnect electrical circuit
-clean the entire mechanism
-install service valve and gauge
manifold
-remove the refrigerant/ according to
E.P.A
regulation.
-cut the tubing and remove the part to

Removing the refrigerant

using service valve or service valve
attachment plug
purged using recovery/recycling
unit.
Using piercing valve or valve adaptor.
well ventilated area and goggles

Removing the motor compressor

procedure
-disconnect electric circuit
-install gauge manifold
-discharge the refrigerant
-disconnect the lines
use pinching tool
use tubing cutter
-clean fittings at the compressor, put brazing
flux on connection, heat the joint, pull the
tubing out of the fittings. Plug openings
immediately.
-Remove the motor compressor
-If oil cooler line, pinch it and break. Removed
compressor tubing should be sealed.

Assembling the hermetic system

-clean and test the rest system
-Add filter drier
-clean capillary tube, evaporator, suction line,
oil cooler tubing, hot gas deforest lines by
forcing refrigerant through it. Filter dryer,
capillary tube may be removed for circulation
-Install filter dryer, suction line, discharge line and
oil cooler lines. Braze the joints.
-perform thorough leak test. Usually pressurized to
1 140kpa with nitrogen, bubble solution applied
to
joints it is possible to immerse parts in water
tank.

5-4 Condenser trouble

-Leak
-Lint and dirt on external part
Install piercing valve
Purge the refrigerant
repair the leak
test
evacuate
Charge and check out
If not repair, Replace

5-5 Repairing Evaporators

Stainless steel
Aluminum
couple/ aluminum and copper
5-5-1 Stainless steel/Brazed or weld(TIG)
-Locate the leak
- Discharge
-clean
-Purge nitrogen when brazing
-polish the weld
-Test the leak

5-5-2 Aluminum/Aluminum solder, braze,

weld, Epoxy
- Locate
-Remove refrigerant
-Clean/repair right after cleaning
Sand
File
clean with epoxy cleaner
-Mix the epoxy with catalyst
-Apply/ make sure there is no positive pressure
-Allow for hardening
-Sand the patch
-Test leaks/ if still leak, remove and install new
patch

5-5-3 Aluminum and copper coupling

Avoid brazing aluminum/ over heat
easily (annealing)
Aluminum solder(92-100%Zinc)
melting temperature(370-430C)
Aluminum solder / TIG

5-6 Hermetic service valves and adapters

- with service valve(most hermetic do not
have)
-Fitting to which valves may be attached
(valve removed after servicing)
-Neither service valve nor fitting
-Process tube
Service valve
To check internal pressure
To discharge/Charge/ Add refrigerant
To add oil
To evacuate the system
To make easy to replace dryer, motor,
compressor
evaporator and refrigerant control.

5-7 Process tube and adapter

Adapted in two ways

install piercing valve on process

tube

cut the end of process tube

Process tube left at the factory is used by
technician
to mount process tube adapter on it as a
means of
attaching manifold line.
Adapter sizes; 3/16, , 5/16, and 3/8
inch

To attach process tube

clean/ use sand paper
cut off the tip of process tube using
cutting pliers or cutter.
Wear goggles when charging and
discharging
Discharge a system in well ventilated
area
If process tube is short, braze an
extension
maintain internal pressure to blow out
metal chips

5-8 Locating refrigerant leakage

Since leaks are usually tiny, detecting
device are required.
Leak detection methods
bubble solution
Fluorescent dyes
Refrigerant dyes
Halide torch detection
Electronic detector
Pressure testing

5-8-1 Bubble solution

water-soap/ common
patented solution/ long lasting bubble film
5-8-2 Electronic Leak detection
most sensitive
principle
difference in heat conductivity of gases
dielectric differences of gasses
operation
Turn on and adjust in normal operation
pass the probe over the suspected surface
the detector will give sound or light or both
because the new gas changes the resistance in
the circuit.

5-8-3 Pressure Testing

Connecting gauge manifold
without allowing air, moisture, dirt
depends on the system
- both suction and discharge
service valve
-suction service valve adapter on
compressor
-process tube only
-process tube too short/ not
reachable

Procedure
apply pressure to the system/NO, CO or same
refrigerant
At the start 5 to 30 psi is necessary(positive
pressure)
look at the name plate for test pressure, if not
given
never go over 170 psi.
if any leak detected by pressure
reduction ?/pressure
drop after an hours.
if no detected, test again at or above normal
condensing pressure for the refrigerant used.
If leak found, recheck after repaired.

To repair leakage
The repair depend on the material(scrape
surface)
-steel/ gray-white, hard-magnet
-copper/reddish, non magnetic
-Aluminum/white, soft, non magnetic

Steel

Brazed

Resistance
welding

epoxy

TIG

Copper

Aluminu

5-9 Refilling refrigerant using vacuum

pump
Purging
Removing unwanted air, vapour, dirt or
moisture
Neutral gas or recommended refrigerant
allowed
to flow to force unwanted air and
vapours.
Evacuating
The system must contain only refrigerant
by connecting the system to a vacuum

Evacuating procedure
-connect the gauge manifold
-close valve A and open valve B
-switch on vacuum pump
-when sufficient negative pressure created,
switch off pump and open valve A
-Slightly open the refrigerant cylinder valve and
charge the system until it makes frost in the
evaporator.
-Then check the pressure to be stable at list for
24hrs.
-Pinch off the process valve and braze it.

5-10 Refilling refrigerant in the absence of

vacuum pump
-Connect the gauge manifold
-Fully close the pump hose(above) valve
one hose to cylinder and one hose to the
suction line.
-connect a nipple to sucking inlet by brazing
-purge the system/ connect a short piece of capillary
tube to the dryer of the refrigeration system.
For flushing, the motor has to run for short time
as the same time the cylinder valve should be
opened.
-close the cylinder valve and let the motor produce
vacuum.
-Control the status of the vacuum at the manifold gauge

-Close and seal the attached capillary tube

-Open the cylinder gas for short time, since
the motor
is running, the gas distributed within the
system
and the pressure will decrease. If the
pressure decreased, add more
refrigerant.
-If there is too much refrigerant in the
system(1-2bar),
purge some refrigerant by opening the
capillary tube attached to the filter dryer.
-If there is too much gas, icing will start at

5-11 Servicing capillary tubes

Cleaning
-Disconnect at both ends(if possible)
-Attach to tube cleaner (up to 20,000psi)
-Build up pressure to force the wax and
dirt out
-Flush the tube with refrigerant
- Install new filter dryer and reconnect
the capillary
tube.
-If needed new tubes must have same
inside diameter and same length with

5-12 Testing rebuilt system

-After the system has been assembled,
tested, evacuated and charged with oil
and refrigerant
it should be run with a thermometer
control
for at least for 24hrs to determine the
behaviour
-A recording thermometer should be
used
-If possible the cabinet should be placed
in warm
room(38C)