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PRODUCT: Refrigerators

PROCEDURE:
Procedure for repairs using
Isobutane gas
TECHNICAL STUDY
Document N: 3033
Date: 23/05/2002
How to use this manual
This document has been designed for those providing a technical assistance service
(TAS), and aims to facilitate the repair of the product to which it refers. It also provi-
des textual support for carrying out technical consultations.
The manual contains a series of notes regarding safety issues:
Copyright by Fagor Electrodomsticos S. Coop. 2.002. All rights reserved. No part
of this publication may be reproduced in any form or by any means without the prior
written consent of the copyright holder. Infringement of this copyright will be prose-
cuted in accordance with current legislation and could give rise to criminal procee-
dings.
FAGOR ELECTRODOMSTICOS reserves the right to make any alterations to the
characteristics of its products without prior notice.
Electrical danger: Identify any possible risk to the appliance, as
this could cause irreparable damage.
Warning: Identify any relevant data or circumstances that may
result in personal injury or death.
Important: Identify any critical information required for a correct
understanding of the product.
Contents
1- Warnings and precautions . . . . . . . . . . . . . . . . .1
2- Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3- Description of procedures . . . . . . . . . . . . . . . . .4
3.1- Gas removal procedure . . . . . . . . . . . . . . . . . . . . . . . .4
3.2- Replacing the refrigeration circuit compressor . . . . . . .6
3.3- Circuit vacuum procedure . . . . . . . . . . . . . . . . . . . . . .7
3.4- Gas charging procedure (Isobutane) . . . . . . . . . . . . . .9
Warnings and precautions
1
1- Warnings and precautions
Isobutane (R 600 a)
Isobutane (R 600 a) is a flammable gas. The appliances in which it is used can
be labelled as follows:
- R 600 a figures on the reference plate
- R 600 a figures on the compressor
- Flammable symbol on the compressor
Technical specifications
Isobutane is a slightly sweet-smelling, colourless gas.
Chemical formula: C
4
H
10
or CH(CH)
3
Name: Isobutane or methyl propane
Refrigerant reference: R-600a
Boiling temperature at 1013 mbar: -11.7 C
ODP: 0
GWP: 0
Flammable: Yes
Flash point: 80 C
Burning point: 462 C
R 600a dissolves in oil:
at 16 C approximately 72%
at 32 C approximately 50%
Warnings and precautions
2
Safety
The following criteria must be complied with in all repair operations using Isobutane
gas:
In all cases:
1.- The area where the repair is to be carried out must be well-ventilated.
2.- Ensure that there are no flames, sources of heat or electric arcs.
3.- Do not smoke.
4.- Eye protection and protective gloves must be worn. Do not wear clothing made
of synthetic fibre.
In the workshop:
A specific area (walled or semi-walled) must be reserved for use when only circuits
containing isobutane gas are being worked with.
In the users home:
Use an area with access to the outside for repair work. If necessary, move the refri-
gerator. Do not carry out repairs in enclosed spaces. Open doors and windows for
ventilation.
Lokring Fittings
For security reasons, it is recommended to use Lokring-type fittings for Isobutane
gas operations.
Features
3
2- Features
R 134a / R 600a Multigas Charging Unit
The charging unit is used for creating a vacuum and charging the gas.
It has three manometers, one for controlling the vacuum () and the other two () for
controlling the low pressures of the different gases used.
1 - Charging
Valve
Low Pressure Manometer
R 12 - R 134a
Low Pressure Manometer
R 600a
Vacuum Manometer
(Vacuum Meter)
2 - Isolation Valve
R 12 - R 134a
3 - Isolation Valve
R 600a
4 - Pump Isolation Valve
5 - Vacuum
M a n o m e t e r
Isolation Valve
Vacuum Control
Valve
Charging Inlet
Outlet
R 12 - R134a
Outlet
R 600a
0
10
-1
3
1
0 2
0
1000
mbar
2
3
1
4
5
6
bar
bar
6 - Charging Valve
Operation
4
3- Description of procedures
For safety reasons, before beginning any operation with the unit (compressor, filter,
etc.) the puncturing plier must be connected to the circuit filter.
When carrying out this operation, place the plier on the upper part of the filter, which
should be in vertical position.
Prepare the equipment as shown in figure 3.1. Then proceed as follows:
1.- Close all the vacuum unit valves.
3.1- Gas removal procedure
2.- Connect the hose to the low pressure manometer (N 2, 10 bar). If it is con-
nected to the other low pressure manometer (N 3, 3 bar) it may cause breakdown.
3.- Using a connector, connect the gas removal hose (yellow, 5 m) to the charging
unit so that the gas is removed more quickly.
4.- Adjust the puncturing plier to the filter and puncture the filter by turning the con-
trol lever. Before doing so, check that the point is inside the plier.
5.- Start up the vacuum pump.
6.- Open valve N 2.
7.- Open valve N 4.
8.- With the pump functioning, wait 5 - 10 minutes before removing the Isobutane gas
from the unit. Ensure that the gas is leaving the discharge hose correctly. This ope-
ration must be carried out with the refrigerator compressor functioning.
When the gas has been removed:
9.- Close valves N 2 and N 4.
10.- Disconnect the vacuum pump.
11.- Release the plier from the filter.
Operation
5
Figure 3.1- Gas removal procedure
Gas removal hose (yellow). Place the
outlet end in the open air.
Installation for removing gas from circuit:
Red hose.
High pressure tube
Charging tube
Puncturing plier
6 3 4 2
1
5
Operation
6
3.2- Replacing the refrigerator circuit compressor
Proceed as follows:
Before cutting the tubes:
1.- Clean the areas where the Lokring fittings are to be placed with sandpaper or a
flax sheet.
2.- Cut the tubes with the corresponding tools.
3.- Throttle the compressor tubes with a plier or seal them with insulating tape, so
that the gas mixed with oil does not leak from the tubes. Remove the damaged com-
pressor from its housing.
4.- Replace the compressor.
5.- Make the joints with the corresponding Lokring fittings using Lokprep liquid sea-
ler.
Note: For ease of operation, it is recommendable to start with the joints of most dif-
ficult access, normally those at the bottom of the housing.
For tubes of over 8 mm diameter, one of the jaws of the Lokring plier, named MB 10,
should be replaced. (Danfoss 9.53 mm compressor and 9 mm evaporator.)
Operation
7
To correctly create a vacuum in the refrigeration circuit, proceed as follows:
1.- Remove the threaded caps of the charging tube and the filter.
2.- Connect the red hose to the filter.
3.- Connect the blue hose to the charging tube.
4.- Connect the white hose to the charging bottle (Isobutane) through charging valve
N 2.
5.- Run the gas removal hose (yellow) outside into the open air, so that the gas remo-
ved from the circuit is evacuated outside.
6.- Start up the pump.
7.- Open valve N 4
8.- Open valve N 5
9.- Place the red needle of the vacuum manometer (vacuum meter) on its black
needle to establish the vacuum level.
10.- Carefully open valves N 2 and N 3.
11.- Open charging valve N 6.
12.- Keep the pump functioning for approx. 10 - 15 minutes.
13.-. Close pump valve N 4 (yellow).
14.- Check the black needle of the vacuum meter. It should coincide with the red
needle (wait approximately 5 minutes). If they do not coincide, check the connections
of the vacuum and charging unit.
3.3- Circuit vacuum procedure
Operation
8
Blue hose
Charging tube
Gas removal hose (yellow)
Valve 3
Valve 2
Valve 4
Compressor
Valve 5
Figure 3.2- Circuit vacuum procedure
Valve 6
Operation
9
This operation is carried out as follows:
1.- Close all the vacuum pump valves (Ns 1, 2, 3, 4, 5 and 6).
2.- Remove the red hose from the filter coupling and place the threaded cap on the
filter valve.
3.- Place the dosage support on the gas bottle.
Note: The bottle should be placed in gas position (with the outlet facing upwards).
4.- Place the bottle centrally on the scales (white label).
5.- Open the bottle charging dosage support valve.
6.- Calibrate the scales to 0 by pressing the ON/OFF key.
7.- Open valves N 6 (yellow) and N 3 (blue) and observe the amount of gas ente-
ring on the scales display.
Note: For speed of charging, the refrigerator compressor should be functioning.
8.- When the scales indicate the correct charge, first close valve N 6 (yellow) and
then valve N 3.
9.- Close the dosage support key and disconnect the scales.
10.- With the compressor functioning, take the reading of the R 600a low pressure
manometer, for guidance (See tables).
11.- Remove the blue hose from the charging tube and put the threaded cap in place
with a drop of Lokprep sealing liquid.
3.4- Gas charging procedure (Isobutane)
Operation
10
Figure 3.3- Isobutane gas charging procedure
Scales
Blue tube
White tube
Valve 3
Isobutane charging
bottle
Valve 2
Valve 6
Charging tube
Compressor
Dosage support
Operation
11
Comparative temperature/pressure table:
Gas temperature (C)
Manometer relative pressure
(bars)
R 12 R 134a R 600a
Latent heat vap.
R 12 R 134a R 600a
-0.372 -0.497 -0.732 169.59 222.88 391.89 -40
-0.206 -0.347 -0.652 167.48 220.10 387.70 -35
-0.009 -0.166 -0.553 165.33 217.20 383.44 -30
0.224 0.054 -0.435 163.15 214.19 379.10 -25
0.496 0.317 -0.294 160.92 211.05 374.67 -20
0.813 0.628 -0.128 158.64 207.79 370.15 -15
1.178 0.994 -0.067 156.31 204.40 365.53 -10
1.597 1.421 0.294 153.93 200.88 359.84 -5
2.073 1.915 0.556 151.48 197.22 355.95 -0
2.613 2.483 0.857 148.95 193.42 350.98 5
3.220 3.132 1.199 146.36 189.48 345.86 10
3.901 3.370 1.587 143.68 185.38 340.59 15
4.660 4.703 2.023 140.91 181.12 335.16 20
5.503 5.540 2.512 138.02 176.68 329.56 25
6.436 6.688 3.057 135.02 172.05 323.77 30
7.464 7.855 3.662 131.89 167.21 317.77 35
9.596 9.151 4.330 128.61 162.14 311.55 40
9.820 10.583 5.065 125.16 156.81 305.08 45
11.170 12.163 5.871 121.51 151.19 298.35 50
Table of condenser and evaporator temperatures and pressures:
Refrigerants
45 C
Condenser
-25 C
1-door refrigerator
-30 C
2-door refrigerator
and combis
R12 10 bars 0.2 bars 0 bar
R 134a 10.05 bars 0 bars 0.2 bar
R 600a 5 bars -0.45 bars 0.55 bar
These data are for guidance purposes only and may vary according to atmospheric
conditions, charge, etc...
FAGOR ELECTRODOMSTICOS, S. COOP. 2002
B San Andrs, s/n
20500 Mondragn (Gipuzkoa)
Espaa (Spain)

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