Domestics Refrigarator Manual

DOMESTIC REFRIGATOR REPAIRS TRAINER
INSTRUCTION cum REPAIRING MANUAL
FOR
DOMESTIC REFRIGATOR
REPAIRS TRAINER
1
WARRANTY CERTIFICATE
Supply of DOMESTIC REFRIGATOR REPAIRS TRAINER

The above instrument is warranted to be free from defects in workmanship and material and if it
proves so defective within 15 (Fifteen months) calendar months from the date of shipment to the
original purchaser, named above it shall be repaired or replaced free of. charge provided
The Purchaser sends promptly to M/s. SCI-TECH ENGINEERING PRIVATE LIMITED
102, Regency, New Link Road, Dahisar (West), Mumbai 400 068. INDIA. , notice of defect and
satisfactory proof thereof as abolishing that the instrument has been properly maintained and operated
within the limits of rated capacity and normal usages, and
 Assumes the obligation of all expenses of returning the defective instrument, properly packed
to the Factory at the address given in (a) above, if required.
 On parts of products incorporated in the instrument but not manufactured by M/s. SCI-
TECH ENGINEERING PRIVATE LIMITED, this warranty is limited to extending to the
purchaser the same warranty as given by the supplier of such part or products.
This guarantee dose not covers consumable parts such as Bulbs, Fuses, and Rubber Seals etc.
Under the circumstances shall M/s SCI-TECH ENGINEERING PRIVATE LIMITED , have any
liability whatsoever for loss of use or for any indirect or consequential damages.
We can only undertake to send our men to a distance to investigate and put right alleged defects on the
distinct understanding that we are paid for their time and expenses in every case.
M/s. SCI-TECH ENGINEERING PRIVATE LIMITED decision about repairing or replacing the
equipment or its parts will be final and binding on all concerned parties.
Unless superseded or in contractual form, this warranty is made expressly in lieu of all the other
liabilities and obligations on our part.
For SCI-TECH ENGINEERING PRIVATE LIMITED
Place: Mumbai/INDIA
2
INDEX
Sr. No. Description Page no.

1. WARRANTY CERTIFICATE 2
2. PICTORIAL DESCRIPTION 4
3. COMPONENTS OF SYSTEM 5
4 INSTALLATION PROCEDURE 7
5 PRECAUTION 9
6 SYSTEM DESCRIPTION 11
7 THEORY 13
9 17
10 20
11 22
3
PICTORIAL DESCRIPTION
4
COMPONENT LIST
5
COMPONENT LIST
After unpacking the consignment, you will find the following items mounted on the main
structure.

6
INSTALLATION PROCEDURE
7
INSTALLATION PROCEDURE
INSTALLING OF THE SYSTEM: --
For installing a new refrigerator equipped with sealed unit proceed as follows:
1. Remove wooden create and draw out refrigerator.
2. Inspect all the refrigerant lines and sides of the cabinet and inform the owner about defects
if any.
3. Read installation instructions provided by the manufacturer and proceed as per his
instructions.
4. Note the voltage stamped on the refrigerator name plate and compare it with the voltage at
power plug. If the voltage increases or decrease more than 10%, suggest the owner to use
voltage stabilizer with the refrigerator.
5. Place the refrigerator in a cool, airy & convenient place where there is no chance of its
being in the sun's rays. Because hot atmosphere does not allow the gas to condense and it
discolor the exterior finish of the refrigerator.
6. Remove the shipping bolt or any other packing provided under the sealed unit for
transporting purposes.
7. Set the refrigerator accessories like shelves, ice trays, chill tray and crispator etc. at proper
places.
8. Keep the refrigerator at least 6" away from back wall for proper air circulation.
9. Adjust the level of the refrigerator by adjusting the leveling screws provided at the feet og
the refrigerator.
10. Connect 3 pin shoe with the refrigerator cord and fix it into the power plug nearest to the
machine.
11. Switch on the machine and check its performance.
8
PRECAUTIONS
9
PRECAUTIONS
1. Do not open the cabinet door frequently or unnecessarily. Because this opening will admit
a large quantity of outside warm air and moisture into the food compartments. As a result of
which your refrigerator will run for a longer period and consumes much power.
2. Do not over crowd shelves with food stuff plates and containers.
3. Do not cover the shelves with paper or plastic sheet, because this will obstruct the free air
circulation necessary for keeping down the temperature of the whole cabinet.
4. Do not load food compartment with hot food, since this might cause the compressor motor
to run over loaded. Always allow hot food to cool down to room temperature before putting it
into the refrigerator.
5. Do not place more liquid into the freezer than recommended.
6. Always place food stuffs at proper places provided in the refrigerator for the particular
food stuffs.
7. Do not place liquid uncovered in the cabinet.
8. Do not disturb the temperature control unnecessarily. For normal operation the switch knob
should be set at normal or centre number of the range plate. The highest number is the coldest
setting, and this setting provides the lowest temperature in the food compartment.
9. Do not forget to defrost the freezer fortnightly or when there is a 1/4" thick layer of frost
on the walls of the freezer. Because this acts as an insulator and does not allow the heat to
flow from the substance to be cooled to the refrigerant.
10. Always use proper methods for defrosting and do not remove frost with knife or some
other pointed thing, because this sometimes injures the refrigerant lines and causes the
refrigerant to leak.
11. After defrosting wash the interior of refrigerator with a solution of warm water and
sodium bi-carbonate. Clean and dry it with a piece of cloth. The exterior of the refrigerator
should be cleaned and polished with waxpol . Do not use soap water.
12. Do not shut off the refrigerator in winter even when it is not in use. Because to shut it off
will upset its operation and cause pumping of oil or choking, etc.
13. Shut the refrigerator door very gently. Even a small push will shut it properly.
14. Clean the condenser with a piece of dry cloth once a week.
15. When the refrigerator is to be shifted to some other place, clamp or bolt the sealed unit
with refrigerator cabinet if it is mounted on springs.
10
SYSTEM DESCRIPTION
11
INTRODUCTION
Refrigerator is an enclosed the cabinet designed to provide low temperature. It is used for
preserving perishable food stuffs and medicines etc.
A refrigerator (colloquially fridge) consists of a thermally insulated compartment and a heat
pump (mechanical, electronic or chemical) that transfers heat from the inside of the fridge to
its external environment so that the inside of the fridge is cooled to a temperature below the
ambient temperature of the room.
REFRIGERATOR WORKING PRINCIPLE
The working principle of a refrigerator (and refrigeration, in general) is very simple: it

involves the removal of heat from one region and its deposition to another. When you pass a
low-temperature liquid close to objects that you want to cool, heat from those objects is
transferred to the liquid, which evaporates and takes away the heat in the process.
You may already know that gases heat up when you compress them and cool down when they
are allowed to expand. That’s why a bicycle pump feels warm when you use it to pump air
inside a tire, while sprayed perfume feels cold.
The tendency of gases to become hot when compressed and cold when expanded, along with
the help of a few nifty devices, helps a refrigerator cool the stuff being kept inside it.
CONSTRUCTION
It consists of a small double wall cabinet equipped with air tights door, the base between wall
is filled with some heat insulating material like glass wool, rock wool and cork etc.to
minimize the heat loss, the inner liner and outer surface of the cabinet are kept highly
polished with shinning white paints. The inner linear made of steels is divided into several
shelves for storing the food stuffs etc.
The refrigerators are equipped with an automatic cabinet light, controlling by the opening and
closing of the door, for controlling the temperature of the cabinet and making the working of
the refrigerator automatic, a thermostat switch is provided on the top or the right hand side of
the inner liner. Rest regarding the cooling system the evaporator is fitted at the top of the
inner liner and condensing unit on the base refrigerator.
Refrigeration is an essential food storage technique in developed countries. The lower
temperature lowers the reproduction rate of bacteria, so the refrigerator reduces the rate
12
of spoilage. A refrigerator maintains a temperature a few degrees above the freezing point of
water. Optimum temperature range for perishable food storage is 3 to 5 °C (37 to 41 °F).
A similar device that maintains a temperature below the freezing point of water is called
a freezer. The refrigerator replaced the icebox, which had been a common household
appliance for almost a century and a half.
Domestic refrigerators and freezers for food storage are made in a range of sizes.
Among the smallest is a 4 L Peltier refrigerator advertised as being able to hold 6 cans of
beer. A large domestic refrigerator stands as tall as a person and may be about 1 m wide with
a capacity of 600 L.Refrigerators and freezers may be free-standing, or built into a kitchen.
The refrigerator allows the modern household to keep food fresh for longer than before.
Freezers allow people to buy food in bulk and eat it at leisure, and bulk purchases save
money.
13
THEORY
14
THEORY
Early freezer units accumulated ice crystals around the freezing units. This was a result of
humidity introduced into the units when the doors to the freezer were opened condensing on
the cold parts, then freezing. This frost buildup required periodic thawing ("defrosting") of
the units to maintain their efficiency. Manual Defrost (referred to as Cyclic) units are still
available. These units used a counter that only defrosted the freezer compartment (Freezer
Chest) when a specific number of door openings had been made. The units were just a small
timer combined with an electrical heater wire that heated the freezer's walls for a short
amount of time to remove all traces of frost/frosting. Also, early units featured freezer
compartments located within the larger refrigerator, and accessed by opening the refrigerator
door, and then the smaller internal freezer door;. These older freezer compartments were the
main cooling body of the refrigerator, and only maintained a temperature of around −6 °C
(21 °F), which is suitable for keeping food for a week.
TYPES OF DOMESTICS REFRIGERATOR
 Domestic refrigerators and freezers for food storage are made in a range of sizes.
Among the smallest is a 4 L Peltier refrigerator advertised as being able to hold 6 cans
of beer. A large domestic refrigerator stands as tall as a person and may be about 1 m
wide with a capacity of 600 L. Some models for small households fit under kitchen
work surfaces, usually about 86 cm high. Refrigerators may be combined with
freezers, either stacked with refrigerator or freezer above, below, or side by side. A
refrigerator without a frozen food storage compartment may have a small section just
to make ice cubes. Freezers may have drawers to store food in, or they may have no
divisions (chest freezers).
 Refrigerators and freezers may be free-standing, or built into a kitchen.
Distinct classes of refrigerator are common:
15
Top Freezer Refrigerator :
Tried and true, this is the classic refrigerator style that’s been a kitchen mainstay for decades.
While the top freezer refrigerator means having the refrigerator at a lower level , which may
not be ideal for some customers (i.e. the taller ones), the low cost of these models may be an
agreeable tradeoff. This style is hands-down the most affordable option, making it a great
choice for buyers on a budget. It’s also available in a variety of sizes to fit into kitchens large
and small.
TOP FREEZER REFRIGERATOR
16
Side-by-Side Refrigerator :
If you’re looking for a slim style, side-by-side refrigerator models feature a vertical freezer
and refrigerator that sit directly next to each other. The slim profile does limit the sizes of the
foods that can be stored, and these models aren’t as energy-efficient as other available
refrigerator styles. However, it’s another incredibly budget-friendly choice. In addition to the
attractive low cost, Side-by-Side refrigerators also have the benefit of requiring a small door
swing space, making them ideal for kitchens with limited area. Most models also feature an
external ice machine and water dispenser.
SIDE BY SIDE REFRIGERATOR
17
Bottom Freezer Refrigerator :
The bottom freezer refrigerator is extremely popular with good reason. These models provide
a large block of storage space for both the refrigerator and freezer sections, allowing easy
accommodation of contents in a variety of sizes and widths. Many people also prefer the
convenience of having the refrigerator section directly at eye level, making it easier to
quickly find what they need.
BOTTOM FREEZER REFRIGERATOR
18
French Door Refrigerator :
the French door refrigerator brings a modern look into your kitchen. Not only does the lower-
freezer setup mean large blocks of storage space, but the ability to open only one refrigerator
door at a time minimizes the escape of cool air. Many models include a drawer-style freezer,
but some include French doors on the freezer area as well. The French doors require a small
swing space, and just like standard Bottom Freezer models, there’s lots of versatility in
accommodating wide or large items.
FRENCH DOOR REFRIGERATOR
19
Refrigerants
A refrigerant is a substance or mixture, usually a fluid, used in a heat pump and refrigeration
cycle. In most cycles it undergoes phase transitions from a liquid to a gas and back again.
Many working fluids have been used for such purposes. Fluorocarbons, especially
chlorofluorocarbons, became commonplace in the 20th century, but they are being phased out
because of their ozone depletion effects. Other common refrigerants used in various
applications are ammonia, sulfur dioxide, and non-halogenated hydrocarbons such as
propane.
The ideal working fluid or often called refrigerant would have favorable thermodynamic
properties, be noncorrosive to mechanical components, and be safe, including freedom from
toxicity and flammability. It would not cause ozone depletion or climate change. Since
different fluids have the desired traits in different degree, choice is a matter of trade-offs.
The desired thermodynamic properties are a boiling point somewhat below the target
temperature, a high heat of vaporization, a moderate density in liquid form, a relatively high
density in gaseous form, and a high critical temperature. Since boiling point and gas density
are affected by pressure, refrigerants may be made more suitable for a particular application
by appropriate choice of operating pressures.
A 2018 study by the nonprofit organization "Drawdown" put proper refrigerant management
and disposal at the very top of the list of climate impact solutions, with an impact equivalent
to eliminating over 17 years of US carbon dioxide emissions.[2]
The inert nature of many haloalkanes, chlorofluorocarbons (CFC) and hydro

chlorofluorocarbons (HCFC), particularly CFC-11 and CFC-12, made them preferred choices
among refrigerants for many years because of their non-flammability and non-toxicity.
However, their stability in the atmosphere and their corresponding global warming potential
and ozone depletion potential raised concerns about their usage. This led to their replacement
with HFCs and PFCs, especially HFC-134a, which are not-ozone depleting, and have lesser
global warming potentials. However, these refrigerants still have global warming potentials
thousands of times greater than CO2. Therefore, they are now being replaced in markets
where leaks are likely, by using a fourth generation of refrigerants, most prominently HFO-
1234yf, which have global warming potentials much closer to that of CO2.
In order from the highest to the lowest potential of ozone depletion are:
Bromochlorofluorocarbon, CFC then HCFC. New refrigerants were developed in the early
21st century that are safer for the environment, but their application has been held up due to
concerns over toxicity and flammability.
20
Compared to halogenated refrigerants, hydrocarbons like isobutane (R-600a) and propane (R-
290) offer several advantages: low cost and widely available, zero ozone depletion potential
and very low global warming potential. They also have good energy efficiency, but are
flammable and can form an explosive mixture with air if a leak occurs. Despite the
flammability, they are increasingly used in domestic refrigerators. EU and US regulations set
maximum charges of 57 or 150 grams of refrigerant, keeping the concentration in a standard
kitchen below 20% of the lower explosive limit. The LEL can be exceeded inside the
appliance, so no potential ignition sources can be present. Switches must be placed outside
the refrigerated compartment or replaced by sealed versions, and only spark-free fans can be
used. In 2010, about one-third of all household refrigerators and freezers manufactured
globally used isobutane or an isobutane/propane blend, and this was expected to increase to
75% by 2020.
India's CFCs / HCFC's Phase out Schedule
On the basis of financial help from the world bank Montreal protocol committee in its 29th
meeting in Nov., 1999 made a programmed to phase out production of CFC by the end of
year 2010 by reducing it at the following rates per year. But it achieved its target on 1-8-2008.
After it India stopped its production in future.
Montreal Protocol committee approved the quota for the production of 22588 metric tons
CFC's in the year 1999. By reduction at the rate of about 1882 metric tons per year, it
remained 11294 metric tons in the year 2005. Further it was decided to completely stop the
production by the end of the year 2010. But before the due dates it achieved its target on 1-8-
2008 and India completely stopped its production in future.
Usage of CFCs
Montreal Protocol committee in its 42nd meeting in March, 2004 decided to reduce the use of
CFCs by 1502 metric tons in the field of commercial Refrigeration and air conditioning, till
31-12-2009. To enforce this programmed , all the persons concerned with Refrigeration And
Air Conditioning field were awakened about the Montreal protocol restrictions. Many
training programmes and demonstrations were organized for the safe use and storage of
refrigerants. Instructions were given about not to allow the refrigerants to leak in the
atmosphere.
HCFC's Phase out management plan
Montreal protocol in its 19th meeting took the following decisions to reduce the production
and use of HCFCs.
1. The average production and use of HCFC's of the year 2009 and 2010 will be
considered as base.
21
2. In the year 2015, the production and use of HCFCs will be reduced by 10% of the
base.
3. In the year 2020, the production and use of HCFC's will be reduced by 35% of the
base.
4. In the year 2025, the production and use will be reduced by 67.5% of the base.
5. In the year 2030, the production and use will be reduced by 100% of the base.
6. From the year 2030 to 2040 the average production and use of HCFC's refrigerants
will be reduced by 2.5% per year of the remaining refrigerants left for the purpose of
servicing of refrigerating machines.
Groups of Refrigerants Based on Carbon And Chlorine
The refrigerants can be divided into following four groups on the basis of their structure with
carbon and chlorine atoms.
1. CFC Group (Chloroflurocarbon) : This group contains those refrigerants which have atoms
of carbon and chlorine. When this type of refrigerants are exposed to the atmosphere, their
atoms of carbon and chlorine stay many years in the atmosphere and release carbon and
chlorine, which destroy the ozone layer. These refrigerants are R11, R12, R114 and R502 etc.
2. HCFC Group (Hydrochloroflurocarbon): This group contains those refrigerants in which

hydrogen is mixed with CFC for reducing the affect of CFC in atmosphere. These refrigerants
do not destrroy the ozone layer badly. These refrigerants these refrigerants are R22
(Monochlorodifluromethane) and R123 (Dichlorotrifluro octhane) etc. Presently these
refrigerants are available in a few countries but it has been decided to phase out their total
production by the end of year 2030.
3. HFC Group (Hydro Flurocarbon) : This group contains those refrigerants which have
hydrogen and fluorine atoms but contain no chlorine atoms, therefore they do not destroy the
ozone layer badly. Due to presence of hydrogen and absence of chlorine atoms, these
refrigerants have no serious effect on ozone layer. The example of this type of refrigerant is
R134a (Tetra Fluoro ethane).
4. HCS Group (Hydrocarbons): This group contains those refrigerants which have hydrogen
and carbon atoms but have no chlorine or fluorine, thus these have a zero ODP. As these
refrigerants have only hydrogen and carbon atoms, they do not destroy the ozone layer but
they produce some global warming.
Properties of some important Refrigerants and Blends
Below are some notable blended HFC mixtures. There exist many more (see list of
refrigerants). All R-400 (R-4xx) and R-500 (R-5xx) hydroflurocarbons are blends, as noted
above.
22
 R-401A is a HCFC zeotropic blend of R-22, R-152a, and R-124. It is designed as a
replacement for R-12.
 R-404A is a HFC "nearly azeotropic" blend of 52 wt.% R-143a, 44 wt.% R-125, and 4
wt.% R-134a. It is designed as a replacement of R-22 and R-502 CFC. Its boiling
point at normal pressure is -46.5 °C, its liquid density is 0.485 g/cm3.
 R-406A is a zeotropic blend of 55 wt.% R-22, 4 wt.% R-600a, and 41 wt.% R-142b.
 R-407A is a HFC zeotropic blend of 20 wt.% R-32, 40 wt.% R-125, and 40 wt.% R-
134a.
 R-407C is a zeotropic hydrofluorocarbon blend of R-32, R-125, and R-134a. The R-
32 serves to provide the heat capacity, R-125 decreases flammability, R-134a reduces
pressure.
 R-408A is a zeotropic HCFC blend of R-22, R-125, and R-143a. It is a substitute for
R-502. Its boiling point is -44.4 °C.
 R-409A is a zeotropic HCFC blend of R-22, R-124, and R-142b. Its boiling point is
-35.3 °C. Its critical temperature is 109.4 °C.
 R-410A is a near-azeotropic blend of R-32 and R-125. The US Environmental
Protection Agency recognizes it as an acceptable substitute for R-22 in household and
light commercial air conditioning systems. It appears to have gained widespread
market acceptance under several trade names.
 R-438A another HFC blended replacement for R-22, with five components: R-32, R-
125/R-134a, R-600, and R-601a, blended in respective ratios 8.5+.5,-1.5%; 45±1.5%;
44.2±1.5%; 1.7+.1,-.2%; 0.6+.1,-.2%. The mean molecular weight of this mix is 99,
resulting in the tradename ISCEON MO99 from manufacturer DuPont (a line of
blended HFC products developed initially by Rhodia, and sold to DuPont).
 R-500 is an azeotropic blend of 73.8 wt.% R-12 and 26.2 wt.% of R-152a.
 R-502 is an azeotropic blend of R-22 and R-115.
 R-507 is a HFC zeotropic blend of R-143a and R-125.
23
INDIVIDUAL LEAK TEST FOR EACH REFRIGERANT
LEAK TEST FOR FREON
The leak of freon refrigerants can be easily detected by some instruments like halide torch
and electronic leak detector.
Halide torch produces an alcohol ignited colourless flame in ordinary conditions. But when
freon gas comes in contact with the flame, it changes its colour to bright green.
The latest and most sensitive leak detector is an electrically operated electronic leak detector.
It measures the electronic resistance of gas samples presence of freon in air, changes the flow
of current. This change in current flow is indicated on a milliammeter dial or by ringing a
bell.
LEAK TEST FOR SULPHUR DIOXIDE
By smell : Since sulphur dioxide is a gas possessing typical pungent odour, so we may be
able to detect the leakage by putting our nose close to the place having possibility of leakage
and find out the point of maximum intensity. Thus a leakage can be detected.
By ammonia : Even small leaks can be easily detected by this method. A small piece of cloth
or sponge may be secured to a wire and dipped into strong aqua ammonia and then passed
over the points where leak is possible. A dense white smoke forms, where the sulphur dioxide
and ammonia come in contact. The intensity of smoke will be maximum at the point of leak.
LEAK TEST FOR AMMONIA:
By smell: Because ammonia has a pungent odour, so it can also be detected by smell but in
case of bigger leakage it becomes difficult to locate the exact point of leakage by this test.
By sulphur candle: Contrary to sulphur dioxide test ammonia leaks can easily be detected by
moving the sulphur candle over the joints and places having possibility of leakage. The
candle will produce white smoke at the point of leakage.
By phinolpthlein paper test: When a moistened phinolpthlein paper strip which is colorless
in the beginning is brought close to the point having possibility of lekage, it turns the paper
pink in the smaller concentration. In the case of bigger leakage the pink colour will change
into a vivid scarlet colour (Blood colour)
24
LEAK TEST FOR CARBON DIOXIDE:
Carbon dioxide leaks are generally detected by common methods of leak detection like soap
bubble test. However leaks in water cooled condenser may be detected by using bronthymol
blue in the condenser water. In case of leakage the blue solution will change into yellow
colour.
REFRIGERATION TOOL MATERIALS:
Tube Cutter : Tube cutter is used to cut small diameter annealed (soft) copper or aluminium
tubes. Its consists of a 'V' block against which the tube rests and an adjustable round blade of
carbon steel which cuts the tube. After placing the tube in the V block , blade is adjusted and
tube cutter is revolved around the tube to cut it. Some tube cutters are equipped with a reamer
for removing the rough material at the cutting end of the tube. The size of the tube cutter
depends upon the maximum diameter of tube which it can cut.
Procedure :
1. Place the coil of 1/4" soft copper tube on a flat surface and unroll the tube properly.
2. Measure and mark the tube as desired in length.
3. Loose the tube cutter and place the tube in the "V" guide of the tube cutter.
4. Hold the tube in the left hand and tube cutter in the right hand.
5. Tight the thumb screw and set the blade on the mark of the tube.
6. Apply some pressure of blade on the tube and revolve the tube cutter around the tube.
7. Repeat this process until the tube is completely cut.
8. Remove the tube from the tube cutter.
9. Ream and file the end of the tube.
Precautions :
1. Do not apply too much pressure at a time while cutting, otherwise it will pinch
the tube.
25
2. Do not cut flat and pinched surfaces of tube with a tube cutter.
3. Always hold the open end of the tube down when reaming or filing, so that
metal chips may not go inside the tube.
Flaring Tool : Flaring tool is used for making flares of different sizes of copper tubes. It has
two parts, a flaring block and a yoke. The flaring block consists of two bars forming holes of
various sizes of tubing. These are clamped together with wing nuts and bolts. The face of
each hole is cut at 45 degree angle seat. The yoke containing die or cone is rotated against the
flare seat to produce a flare.
Procedure :
1. Cut two pieces of 1/4" soft copper tube with tube cutter as required in length.
2. Ream or file the ends of both the tubes.
3. Insert one flare nut in each piece of tube.
4. Make flares on the ends of each tube as follows.
5. Hold the tube in the flaring block leaving the end of the tube 3/16" above the surface..
6. Tight the wing nuts of the flaring block properly.
7. Set the yoke on the flaring block in such a way that the cone of the yoke may sit on
the ends of the tube..
8. Tight the yoke slowly upto the seat of the flaring block.
9. Unscrew the yoke, loose the wing nuts of the flaring block and remove the flared
tube.
10. Set the flares of tubes on the seats of 1/4" union and tight the flare nuts by hands.
11. Tight these flare nuts with double ended spanners to make gas tight joints.
26
Precautions:
1. Do not leave the end of the tube less or more than recommended above the surface of
flaring block while flaring. Less height of the tube above the surface produces a small
flare which is useless and more height causes to crack the flare.
2. Always remember to put the flare nut around the tube before making the flare.
Swaging Tool : It's used for swagging the open end of the small diameter copper tube i.e. to
increase the inner dia of the end of the tube to its outer dia. It is a hexagonal bar with two
round steps at the end. The first step is equal to the inner dia of the tube and the dia of the
second step is equal to the outer dia of the tube. The size of the swagging tool depends upon
the dia of the second step. It's forced into the end of the tube with a hammer.
Procedure:
1. Cut two pieces of 1/4" soft copper tube with tube cutter as required in length.
2. Ream and file the ends of both the tubes.
3. Swage one piece of copper tube as follows.
4. Hold the tube in the flaring block leaving the end of the tube equal to outer dia of the
tube plus 1/8" above the surface of the block.
5. Place the flaring block on the edge of a wooden table leaving the tube aside.
6. Put the swagging tool into open end of the tube and force it upto it second step by a
hammer.
7. Remove the swaging tool and free the tube from flaring block.
8. Insert other piece of tube in this swagged tube and clean it properly.
9. Hold the job with plier keeping the joint in vertical position.
10. Heat the joint evenly by a blow lamp or a welding torch.
11. Apply brazing flux on the joint while heating.
12. Feed silver solder into the joint at proper time.
13. After making a fine layer of silver solder on the joint, let it to be cooled.
Precautions:
1. Do not leave the end of the tube less or more than recommended above the surface of
the flare block.
27
2. Do not over heat the job otherwise it will burn the flux and the metal.
3. Make tight fitting of the job and do not feed silver solder in ecxcess otherwise it will
block the interior of tubing.
Tube bender : Tube bender is used for bending small diameter copper tubes. There are so
many types of tube benders like inside spring type tube bender and a pulley type bender. A
pulley type bender is most successful for bending tubes at different angles. Each of these
tubes benders is used with one size of tube. Some pulley type tube benders are also available
which are used for bending different sizes of tubes by changing the pulley of the tube bender.
Procedure:
1. Cut the tube with the tube cutter as required in length.
2. Mark the piece of tube at which it is to be bent.
3. Face your thumbs opposite to the tube meeting each other at the mark on the tube and
hold the tube with fingers.
4. Force out your thumbs against the tube and pull the tube with fingers.
5. Bend the tube slowly by repeating the above process in several operations.
Tube Bending with pulley type tube bender

1. Cut the tube with the tube cutter as required in length.
2. Mark the piece of tube at which it is to be bent.
3. Insert the tube into the bender through the clamp and set the mark of the tubes at an
angle at which it is to be bent.
4. Close the handle of the tube bender at the required angle.
Precautions:
1. Always Bend the tube slowly, donot bend it only in one operation.
28
2. When using spring type tube bender always bend the tube little more than the
required bend, and then back upto the proper angle. This loose the spring for
easy removal.
3. Always bend the tube into as large a radius as possible because it does not
allow the tube to flatten.
Refacing tool : It's used for refacing the seats of different types of connectors.
Flexible Charging Line: It's a flexible rubber tube used for evacuating and charging gas in
the machine.
Charging kit : A charging kit has so many sockets with a charging valve for gas charging in
refrigerating machine equipped with sealed unit.
29
Pinching Tool : Pinching tool is used for closing or sealing the small diameter copper tubes.
It consists of two bars forming jaws and holes of various sizes and are clamped together with
wing nuts and bolts. the tube is pinched off between the two jaws by tightening the wing nuts.
the round holes are used to round up the pinched section, when required.
Vacuum Pump : It's a pump used for evacuating air from a refrigerating system equipped
with sealed unit before charging gas. Sometimes an ordinary open type compressor or sealed
unit is used for this purpose. But a high vacuum pump has a rotary compressor which can pull
few microns of vacuum. The vacuum is measured by micron gauge in micron. A micron is the
unit for the measurement of vacuum which is equal to 1/25000, part of an inch or 00004".
30
Sling Psychrometer : It's an instrument used to measure the percentage of humidity or

moisture present in a refrigerated or air conditioned space.
Types of gauges : The types of gauges used in refrigeration trade are only two, i.e. a high
pressure gauge and a compound gauge.
High Pressure Gauge: It's commonly known as pressure gauge and is used to denote high
side pressure or head pressure of the refrigeration system. It generally has a capacity to
measure up to 300 lbs/sq. inch.
31
Compound gauge : It's also known as low pressure gauge and is used to denote the low side
pressure of the system. It has a scale which is divided into two columns. One shows the low
pressure or vacuum in inches of mercury i.e. from 0 to 30 inches and the other column shows
the pressure 0 to 150 lbs/sq inch. So this gauge can serve two purposes for denoting vacuum
and pressure.
Halide Torch: It's an instrument for finding the refrigerants leaks. It is also called as leak
detector.
32
Compressor Efficiency Test :
Raw Materials Required:

1. Copper tube 1/4".
2. Half union 1/4", two numbers.
3. Flare nuts 1/4", four numbers.
Tools required:
1. Flaring Tool.
2. Tube cutter
3. Double ended spanner
4. Adjustable wrench
5. Ratchet wrench
6. Low pressure gauge
7. High pressure gauge
Procedure:
1. Install high pressure and compound gauge on discharge and suction service shut off
valves respectively.
2. Operate the compressor, note the gauge readings and stop the compressor.
3. If the compressor does not pull sufficient vacuum or does not create sufficient
pressure, it means that the gas or air is leaking back through discharge and suction
reeds or there is more clearance between the piston and cylinder walls than the
normal.
33
4. If the compound gauge reading rises up and head pressure remains constant, it means
that the compressor is leaking from one of the joints in the low side.
5. If the compound gauge reading rises up and head pressure drops, it means that either
the pressure is leaking slightly through the valves or there is an external leak in both
the low and high side of the compressor.
6. If the head pressure drops and compound gauge reading remains constant, it is the
indication that there is an external leakage at one of the joints of the head of the
compressor.
Gas Charging In A Refrigerating Machine Equipped With Sealed Unit
Leak Detection and Repairing :
34
1. Check leakage around all the joints carefully. Presence of oil around any joint
indicates the possibility of leakage.
2. For being sure, connect carbon dioxide cylinder with charging port of sealed unit
through a line valve and high pressure gauge. Fill gas at recommended test pressure.
3. Apply thick soap solution around every joint or where leak is possible. The leaky
joint will form bubbles.
4. If the leak is not easy to detect, close line valve, disconnect the gas cylinder and dip
the entire system into the water tank. The leaky point will form bubbles.
5. Find the leakage and repair it as necessary.
6. Flush the entire system with carbon dioxide and again check its leakage.
7. Disconnect CO2 cylinder, line valve and gauge etc.
Removing air from the system :

1. Connect the suction port of vacuum pump with charging port of sealed unit through a
line valve and compound gauge.
2. Connect one end of the piece of 1/4" copper tube with discharge port of the vacuum
pump and dip the other end of the tube into the container of oil.
3. Operate the vacuum pump for at least 1 to 1 1/2 hour and see if the compound gauge
shows 28 inches of constant vacuum.
4. For being sure see bubbles in the container of oil. No bubble for long period shows a
good vacuum.
5. Heat up the entire system during vacuum in an oven or by a blow lamp.
6. Close line valve and disconnect vacuum pump.
Removing air from the system without vacuum pump.

1. Remove old drier or filter from the system. Connect outlet of a new filter with
capillary tube with the help of flare fitting.
2. Close the other end of the filter with dead nut.
3. Let the condenser outlet open.
4. Connect line valve with the charging line of sealed unit and close the line valve.
5. Start the sealed unit of this system. It will draw air from the capillary tube ,
evaporator, suction line. It will draw air from the capillary tube, evaporator , suction
line, dome and will throw it out through the outlet of the condenser.
6. Heat up the whole system with blow lamp while evacuating the system.
7. For being sure about vacuum, perform oil bubble test at the outlet of condenser.
8. After vacuumizing the system, connect gas cylinder with line valve and charges as
much quantity of gas which may be able to push out the remaining air from
condenser.
9. Connect filter with condenser by opening the dead nut of filter while the gas is
flowing out through the outlet of condenser.
10. Disconnect gas cylinder from line valve, put one injection of anti-moist in the
charging line, connect gas cylinder again with the charging line and charge exact
quantity of gas in the machine.
Gas charging in the machine:

1. Read the name plate of machine and note the refrigerant and its quantity charged in
the machine.
35
2. Take a cylinder full of gas required to charge.
3. Weigh the cylinder and record its weight.
4. Connect the gas cylinder with the line valve through a compound gauge with the help
of charging line. Open cylinder valve slightly and purge the charging line.
5. Open line valve and slowly charge gas in the machine.
6. Operate the machine, maintain its low side pressure as required and charges exact
amount of gas by weight.
7. See if the evaporator and condenser have attained proper temperatures.
8. Check the condition of sealed unit, it should not run over loaded.
9. After full satisfaction, stop the machine, close line valve disconnect gas cylinder,
pinch charging line of sealed unit and seal its end.
10. Again allow the machine to run for hours together and check its performance.
Precautions:
1. Before charging gas always see if the compressor is efficient.
2. Always check oil level in the sealed unit before charging gas.
3. Before charging gas, be sure that there is no leak in the system.
4. Check the leak under recommended test pressure.
5. See that air may not enter after evacuation while connecting gas cylinder and
compound gauge for charging gas.
6. Always purge air from the tubes which have not been evacuated.
7. Always charge exact amount of gas in the system as recommended by the
manufacturer.
PARTS IN REFRIGERATOR INCLUDE:

1) Ice maker or Freezer
2) Chill Tray
3) Shelf
4) Ice Trays
5) Water and Ice dispensers
6) Removable Anti Fungal Gasket
7) Refrigerator Door
8) Compressor
9) Refrigerant
10) Condenser
 Ice Maker or Freezer : It is the most coldest chamber of fridge. You can make ice in
this chamber or you can keep frozen meat as well. Best place to keep the ice cream as
well.
 Chill Tray : Chiller tray temperatures in single-door model refrigerators are usually
colder than the refrigerator fresh food compartment, but not as cold as the freezer
frozen food compartment. Foods will freeze if stored in the chiller tray for extended
periods of time. An example of foods to store in this area would be meats that are to
be prepared in the next few days. Additionally, this is the coldest area in refrigerator.
36
 Shelf : Shelf's are the places where you keep your stuff. Make sure the shelves are of
sufficient height and width to keep the items.
 Ice Trays : Basic single door refrigerator comes with couple of ice trays. High end
refrigerators comes with ice dispensers. Say you have normal fridge and you have
high requirements of ice then you can buy additional ice trays. Look for non
breakable ice trays. Well designed ice trays take significantly less time to form the ice.
‘Absolute buy’ and ‘Agro plast’ are well know brands in ice tray manufacturing. Ice
trays comes in many designs you can have fun choosing different style ice cubes.
 Water and Ice dispensers : Few models of Side-by-side, double door and triple door
refrigerators comes with water dispensers. Water dispensers enables you to drink
water without even opening the refrigerator door. It is very nice to have feature.
 Removable Anti Fungal Gasket : Removable anti fungal gasket is amazing feature.
As the name suggest it is removable so you can remove and clean them easily. The
anti fungal function make sure fungal and bacteria do not grow in the refrigerator.
 Refrigerator Door : Refrigerator door has so much space to keep bottles and other
stuff. It has egg holder and place to hold other accessories to maximize the space in
the fridge. It has exterior plastic rubber seals so that hot air do not leaks out and avoid
any bacteria propagation.
37
 Compressor : Compressor is heart of the refrigerator and it is the actual part which
does the cooling by making changes in pressure. It runs by an electric motor and most
of the electricity is consumed by the compressor. It is located back of the refrigerator.
Without a compressor, refrigerant, condenser your refrigerator is just an almaara. So
all manufactures give good warranty on compressor. While purchasing the refrigerator
make sure you have many years of warranty on compressor.
38
 Refrigerant : Refrigerant is a cooling liquid which flow through the refrigerator and
does the actual cooling. Compressor runs the this Refrigerant with the help of motor.
39
 Condenser : The heat in the refrigerant should be absorbed by something. That is the
condenser job.
40
POSSIBLE CAUSES & SOLUTIONS OF REFRIGERATION UNIT :
1. No supply : Check supply with test lamp and enquire about the cause of non availability
of supply.
2. Fuse Blown : Check fuse , if it is blown replace new one.
3. Broken Circuit : Check continuity and repair the broken circuit.
41
4. Too Low Voltage : Check voltage at power plug and compare it with the voltage stamped
on machine.
5. Thermostat switch in off position : Check thermostat switch and find the cause of
remaining in off position.
6. Overload protector burnt out or in off position : Check overload protector, if burnt
replace it and find the cause of over loading of motor and reduce the load.
7. Defective relay: Start the sealed unit direct without relay, if it runs properly, replace the
relay.
42
8. Motor burnt out : Check the continuity of motor, if it is defective, rewind it.
9. Stuck compressor or motor of sealed unit : Start the sealed unit direct without relay, if it
does not start, dismantle the sealed unit and repair the same as necessary
10. Excessive frost on cooling coil : See if there is an excessive frost on the cooling coil. It
acts as an insulator and does not allow the food stuffs to cool. Switch off the machine and let
the frost melt.
11. Interior light remains always 'on' : Check the door switch and its operation with door.
If it is defective, set it right as necessary.
12. Interior light remains always 'off' : Test bulb, if it is fused, replace new bulb. Check the
electric circuit of bulb-holder and door switch, if it is defective, repair it as necessary.
13. Choking in the system : Not proper cooling in the evaporator and cold condenser will
show choking in the system. In case of choking, evacuate flush and charge new refrigerant in
the machine.
14. Improper level of the cabinet : Check the level of the refrigerator cabinet and if
necessary adjust the level screws at the base or give some solid packing under the base as
necessary.
15. Leak Detection of Refrigerants:
a. Observation Test: Look at all the joints where leak is possible. The leaky joint will show
oil around it.
b. Soap bubble test: Be sure that sufficient gas pressure is present in the refrigeration
system, clean all the joints with a piece of dry cloth and stop the machine. Apply a thick soap
solution around all joints and places having possibility of leakage. The refrigerant will escape
forming bubbles through the leaky joint.
c. Oil Bubble test : For oil bubble test proceed as above. Apply refrigeration oil around every
joint and place having possibility of leakage. In the case of leakage, the refrigerant will again
escape forming bubbles through the leaky point However this test is not sure as small leakage
may be missed.
d. By dipping the system in a water tank: This is very simple and sure test for detecting
even minor leaks of the refrigeration system. With the help of this method the complete
sealed refrigeration unit of a refrigerator can be tested for leaks within no time. For testing
the leak of complete refrigerating unit proceed as follows:
1. Remove the complete refrigerating unit from the refrigerator.
2. Disconnect all the electrical parts from the system.
3. Fill 60 to 75 pounds CO2 pressure in the system through the charging line.
4. Put it in a big water tank.
5. Check its leakage, the gas will escape forming bubbles through the leaky point.
43
44
SCI-TECH ENGINEERING PRIVATE LIMITED

102, Regency, New Link Road, Dahisar (West),
Mumbai 400 068. INDIA. Tel: +91 98202 49238; 99204 42238.
Website: www.sci-tech.biz
E-mail: sci-tech@sci-tech.biz ; scitechenggpvtltd@yahoo.com
45

Domestics Refrigarator Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Domestics Refrigarator Manual

Uploaded by

Copyright:

Available Formats

DOMESTIC REFRIGATOR REPAIRS TRAINER

INSTRUCTION cum REPAIRING MANUAL

Supply of DOMESTIC REFRIGATOR REPAIRS TRAINER

Sr. No. Description Page no.

INSTALLING OF THE SYSTEM: --

1. Remove wooden create and draw out refrigerator.

11. Switch on the machine and check its performance.

REFRIGERATOR WORKING PRINCIPLE

The working principle of a refrigerator (and refrigeration, in general) is very simple: it

TYPES OF DOMESTICS REFRIGERATOR

Distinct classes of refrigerator are common:

Top Freezer Refrigerator :

TOP FREEZER REFRIGERATOR

SIDE BY SIDE REFRIGERATOR

Bottom Freezer Refrigerator :

BOTTOM FREEZER REFRIGERATOR

French Door Refrigerator :

FRENCH DOOR REFRIGERATOR

The inert nature of many haloalkanes, chlorofluorocarbons (CFC) and hydro

India's CFCs / HCFC's Phase out Schedule

HCFC's Phase out management plan

Groups of Refrigerants Based on Carbon And Chlorine

2. HCFC Group (Hydrochloroflurocarbon): This group contains those refrigerants in which

Properties of some important Refrigerants and Blends

INDIVIDUAL LEAK TEST FOR EACH REFRIGERANT

LEAK TEST FOR FREON

LEAK TEST FOR SULPHUR DIOXIDE

LEAK TEST FOR AMMONIA:

REFRIGERATION TOOL MATERIALS:

Tube Bending with pulley type tube bender

Sling Psychrometer : It's an instrument used to measure the percentage of humidity or

Compressor Efficiency Test :

Raw Materials Required:

Gas Charging In A Refrigerating Machine Equipped With Sealed Unit

Leak Detection and Repairing :

Removing air from the system :

Removing air from the system without vacuum pump.

Gas charging in the machine:

PARTS IN REFRIGERATOR INCLUDE:

2. Fuse Blown : Check fuse , if it is blown replace new one.

3. Broken Circuit : Check continuity and repair the broken circuit.

SCI-TECH ENGINEERING PRIVATE LIMITED

You might also like