Marvel 4570105 User manual

Table of contents

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OPERATION

AND

MAINTENANCE

_

ОЕ

MECHANICAL

FIELD

WARD

REFRIGERATOR

NSN

4110-01-291-7046

MARVEL

MODEL

#4570105

-

MODIFIED

-

230/115

VOLT,

60/50

Hz.

CONTRACT

#DLA-120-89-C-8509

MARVEL

INDUSTRIES

DIVISION

OF

NORTHLAND

CORPORATION

P.O.

Box

997

Richmond,

Indiana

47375

Tel.

317-962-2521

P/N

41003786

TABLE

OF

CONTENTS

CHAPTER/PARAGRAPH

PAGE

1

25

.

Maintenance

.

.

Replacement

Parts

List

.

Diagrams

ntroduction

1.

Introduction..

2

Warning

4

Organization

of

the

Manual

5

Purpose

of

the

Refrigerator.

6

Description........

8

Specifications

.

.

..

9

1

ml

1

1

1

1

1

1

1

Required

Tools...

1

Operation

2-1

Introduction

2-3

Unpacking

Procedure

..

2-4

Installation

2-5

Operation

and

Theory

of

Operation

...

3-1

Introduction.....

33

Зав

iia

ee

3-4

Preventive

Maintenance.

.

3-5

Troubleshooting

3-6

Corrective

Maintenance

Procedures.

.

3-7

Fan

Assembly

Replacement

.......

3-8

Transformer

Power

Cord

Replacement

.

3-9

120

Volt

Power

Cord

Replacement.

.

3-10

Door

Gasket

Replacement.

.

3-11

Thermostat

Replacement

.

.

3-12

Front

Glide

Replacement..

3-13 Rear

Glide

Replacement

.

3-14

Freezer

Door

Replacement

3-15

Depot-Level

Repair-or-Replace

Assemblies

.

.

.

316

DERS

um.

ma

a

aa o Pa

rote

see

gua

ate

aerial!

when

АНИ

1.

Utroducton

-<=

8

au

8.4

5M

é

5-1

Introduction

LIST

OF

ILLUSTRATIONS

FIGURE

NUMBER

PAGE

Refrigerator,FrontView...................................l

02

Refrigerator,

Rear

View

Refrigerator

Functional

Block

Diagram........................

06

Mechanical

Assembly

..............

Refrigerator,

Front View.

Refrigerator,

Rear

View

Mechanical

Assembly:

szscaças

een

μα

ο

ας

Refrigerator

Wiring

Diagram

...............................

22

の

で

や

の

い

ーー

SEL

Ss

LIST

OF

TABLES

TABLE

NUMBER

ПИ

ООС

e

ey

ee

ine

am

за бо

ао

ро:

зе

con

1-2

Required

Tools

CHAPTER

1

INTRODUCTION

1-1.

INTRODUCTION.

1-2.

This

Operation

and

Maintenance

Manual

gives

you

the

information

necessary

for

using

and

maintaining

the

Mechanical

and

Biological

Refrigerator,

NSN

4110-01-180-3420.

The

manual

includes

information

for

operation, preventive

maintenance,

and

corrective

maintenance.

WARNING

WHEN

THE

REFRIGERANT

LINE

HAS

BEEN

OPENED,

OR

FOR

ANY

OPERATION

REQUIRING

OPENING

THE

REFRIGERANT

LINE

ONLY

QUALIFIED

MAINTENANCE

PERSONNEL,

USING

PROCEDURES

AND

EQUIPMENT

SPECIFIED

BY

THE

MANUFACTURER

OR

BY

DEPOT-LEVEL

AUTHORITIES,

SHOULD

WORK

ON

THE

REFRIGERATION

SYSTEM.

ANY

MOISTURE

THAT

IS

ALLOWED

INTO

THE

REFRIGERATION

LINES

WILL

COMBINE

WITH

THE

FLUORINE

AND

CHLORINE

REFRIGERANT

TO

PRODUCE

HYDROCHLORIC

ACID,

AN

EXTREMELY

POWERFUL

AND

CORROSIVE

ACID.

1-3.

All

procedures

in

this

manual

refer

to

the

electrical

and

mechanical

elements

of

operation

and

maintenance.

1-4.

Organization

of

the

Manual.

As

shown

in

the

Table

of

Contents,

this

manual

is

organized

as

follows:

Chapter

1:

INTRODUCTION.

Provides

information

on

Organization

of

the

manual,

purpose

of

the

refrigerator,

description

and

specifications

for

the

refrigerator,

list

of

required

equipment,

and

safety

information.

Chapter

2:

OPERATION.

Tells

you

how

to

unpack,

install,

and

operate

the

refrigerator,

with

a

brief

theory

of

operation.

Chapter

3:

MAINTENANCE.

Details

the

procedures

for

preventive

and

corrective

maintenance

of

the

refrigerator.

Chapter

4:

PARTS

LIST.

Lists,

by

assemblies,

the

replacement

parts

for

the

refrigerator,

with

part

numbers

and

illustrations.

Chapter

5:

DIAGRAMS.

Contains

all

illustrations

cited

in

the

text

but

not

otherwise

included.

1-5.

Purpose

of

the

Refrigerator.

The

refrigerator

is

to

be

used

as

a

refrigerator-freezer

at

ward

level

in

field

hospitals

as

designated

by

the

Department

of

Defense.

1-6.

Description.

Refer

to

fig.

1-1

and

1-2.

The

refrigerator

is

light

weight

and portable,

designed

for

field

operations.

Providing

4.5

cubic

feet

of

refrigeration

and

freezing

space,

the

refrigerator

incorporates

three

shelves,

drip

pan,

a

0.7

cubic-foot

freezer

compartment,

adjustable

thermostat,

carrying

handles,

glide-feet,

and

corrosion-resisting

steel

shield

for

mounting

over

rear

mechanism

openings.

The

refrigerator

compartment

operates

over

a

temperature

range

of

34

to

42

degrees

Fahrenheit,

and

the

freezer

compartment

operates

over

a

range

of

12

to

20

degrees

Fahrenheit.

The

refrigerator

has

a

220/110

VAC

step-down

transformer;

it

can

operate

from

either

a

220

or

110

VAC,

60/50

Hz

source.

Fig.

1-2,

No.

1,

2,

3.

1-7.

The

outer

shell

of

the

refrigerator

is

1/32nd

inch

carbon

steel

with

olive

drab

finish.

The

inner

shell

and

door

liner

are

plastic.

The

door

is

trimmed

with

anodized

aluminum

and

has

a

magnetic

latch.

There

is

an

additional

door

-

security

snap

fastener

located

at

the

upper

left

corner

for

use

during

transport.

Fig.

1-1.

Refrigerator,

Front

View

1.

Thermostat

(behind

grill)

2.

Crisper

shelf

3.

Drip

tray

4.

Freezer

door

5.

Hinge

pin

6.

Door

gasket

7.

Door

8.

Wire

shelf

9.

Crisper

tray

10.

Cabinet

assembly

Fig. 1-2.

Refrigerator,

Rear

View

1.

Transformer

220

Volt

line

4.

Cabinet

back

cover

2.

Transformer

120

Volt

outlet

5.

Stainless

steel

backshield

3.

120

Volt

power

cord

(for

mechanical

assembly)

1-8.

Specifications.

Table

1-1

lists

the

complete

specifications

and

parameters

for

the

refrigerator,

NSN

4110-01-291-7046.

Table

1-1

Parameter

Specification

Acceptable

input

voltages

110/220

VAC.

Step-down

transformer

provided

for

use

with

220

VAC

source.

Acceptable

input

freguencies

60/50

Hz.

Power

consumption

240

watts

nominal;

1650

watts

maximum

surge

Line

current

maximum

15

amps

inrush

at

110

V;

7.5

amps

inrush

220

V

Weight

106

Ibs.

Volume,

internal

6.1

cubic

feet

Outer

dimensions

35

1/4”

H

x

25

3/8”

Wx

24

1/16”

D

Internal

volume

Freezer

0.7

cubic

feet,

minimum

Refrigerator

4.5

cubic

feet,

minimum

Pull-down

times

at

ambient

temperature

of

120

degrees

F:

3.0

hours

100

degrees

F.

1%

hour

77

degrees

F.

%

hour

Nominal

weight

and

volume

in

shipping

container

Weight

135

Ibs.

Volume

16.8

cubic

feet

Dimensions

38%"

H

x

28”

W

x

27”

D

Type

of

refrigerant

R-12

Weight

of

full

charge

of

refrigerant

4.7

oz.

(0.29

Ibs.)

1-9.

Required

Tools.

Table

1-2

lists

all

of

the

tools

required

for

normal

use

and

maintenance

of

the

refrigerator.

Table

1-2

Description

No.

Req'd

Phillips

head

screwdriver

(3'’-4”

long)

1

Phillips

head

screwdriver

(8"

long)

Flatblade

screwdriver

(small,

approximately

1/8”

-

wide

blade)

Hand

roller

36”

x

36”

Cardboard

sheet

36”

x

36”

Table

or

bench

Channel-lock

adjustable

pliers

Combination

open

end/box

end

wrenches

Any

standard

multimeter

for

checking

voltages

and

continuity

of

circuits

For

tools

and

associated

equipment

used

in

maintenance

procedures

NOT

described

in

this

manual,

refer

to

Depot-level

maintenance

organization

or

contact

the

manufacturer:

Marvel

Industries,

P.O.

Box

997,

Richmond,

Indiana

47375.

1-10.

Safety.

ALWAYS

observe

the

warning

notice

shown

after

paragraph

1-2,

above.

Additionally,

be

careful

of

power

sources.

110

volts

can

kill

you.

If

your

system

uses

220

volts

with

a

step-down

transformer,

being

very

careful

is

even

more

important.

For

connection

to

a

220

VAC

source,

be

sure

to

use

the

step-down

transformer,

as

detailed

in

par.

2.4f,

below.

1-11.

When

the

refrigerator

is

in

operation,

the

condenser

(radiator)

can

get

hot

enough

to

burn

your

skin.

1-12.

NEVER

use

a

two-wire

cord

or

power

outlet

with

this

refrigerator.

Such

a

practice

can

produce

shocks

and

will

damage

operating

elements

of

the

system.

CHAPTER

2

OPERATION

2-1.

INTRODUCTION.

2-2.

This

chapter

details

unpacking,

installation,

and

operation

of

the

refrigerator,

with

a

brief

explanation

of

the

theory

of

operation.

2-3.

Unpacking.

Unpacking

is

easy.

The

refrigerator

is

shipped

in

a

heavy-duty

cardboard

carton,

with

slip-off

top

and

bottom

covers

held

on

by

steel

straps.

To

unpack:

Stand

the

carton

upright.

With

tin

snips,

cut

the

lower

steel

band.

Pull

all

four

sides

of

the

bottom

cover

away

and

down

from

the

sides

of

the

carton.

Lifting

from

the

top,

pull

the

carton

up

and

off

of

the

refrigerator.

Dispose

of

the

carton,

dust

off

the

refrigerator,

and

it

is

ready

for

installation.

capo»

2-4.

Installation.

Getting

the

refrigerator

ready

to

operate

is

very

simple.

Dispose

of

the

packing

material,

and

position

the

refrigerator

where

you

want

it.

Then:

a.

Be

sure

that

the

cord

provided

is

long

enough

to

reach

a

safely

grounded

three-prong

outlet.

Connect

the

plug

to

the

wall

socket

at

the

end

of

this

installation

procedure.

For

a

wall

outlet

that

is

220

VAC,

the

wall

socket

cord

must

go

to

the

transformer,

located

at

the

back

lower

left

corner,

shown

in

fig.

3-1.

Then

plug

the

output

line

of

the

transformer

to

the

input

line

of

the

refrigerator,

shown

in

fig.

1-2.

b.

The

four

glides

(feet)

of

the

refrigerator

are

non-adjustable.

If

the

refrigerator

is

on

a

level

surface,

the

refrigerator

will

be

level.

c.

At

the

upper

left

front

corner

there

is

a

snap-fastened

safety

strap

which

holds

the

door

closed

during

shipment.

To

open

the

door,

unsnap

the

safety

strap

and

pull

on

the

handle;

the

door

has

a

magnetic

latch.

d.

At

the

lower

left

front

corner,

behind

the

grill,

which

is

held

on

by

two

small

screws,

you

will

find

the

thermostat.

The

aluminum

sensor

line

attached

to

the

thermostat

runs

up

the

back

of

the

refrigerator

to

the

upper

right

rear

corner.

The

sensor

lies

between

the

rear

panel

and

the

insula-

tion.

The

dial

of

the

thermostat

has

an

adjustment

range

of

1

to

7

(7

is

the

coldest

setting.

It

is

pre-

set

at

the

factory

for

3%),

providing

the

normal

operating

temperature.

Varying

ambient

temperatures

may

require

re-setting

the

thermostat

dial

for

your

installation.

e.

Finally,

before

making

the

power

connection,

be

sure

that

the

interior

of

the

refrigerator

is

clean.

f.

Connect

the

power

cord

to

the

appropriate

source:

110

or

220

volts

AC,

nominal.

For

a

220

VAC

source,

plug

the

transformer

inlet

line

into

the

source,

then

connect

the

120

Volt

line

into

the

transformer

outlet.

For

120

VAC

source,

plug

the

120

Volt

line

directly

to

the

source.

2-5.

Operation

and

Theory

of

Operation.

Once

prepared

as

specified

above,

the

refrigerator

func-

tions

automatically.

The following

is

a

brief

explanation

of

how

the

refrigerator

works.

This

explana-

tion

will

enable

you

to

operate

and

maintain

the

refrigerator

most

efficiently.

2-6.

Refer

to

fig.

2-1,

a

functional

diagram

of

the

system,

and

to

figs.

4-1,

4-2, 4-3,

which

show

the

components

and

their

location

in

the

refrigerator.

To

follow

the

explanation,

refer

to

these

figures.

a.

The

thermostat

(located

behind

the

grill

at

the

lower

left

front

of

the

refrigerator)

monitors

temperatures

inside

the

refrigerator.

When

the

sensor

shows

a

temperature

warmer

than

the

adjusted

setting,

the

thermostat’s

contacts

close,

completing

the

circuit

that

operates

the

compressor.

The

compressor

takes

in

the

warm

low

pressure

gas

and

converts

it

to

high

pressure

gas.

Passing

through

the

condenser

(radiator),

the

chlorine/fluorine

refrigerant

gives

off

heat

to

the

air

surrounding

the

condenser,

primarily

through

the

cooling

fins,

like

any

radiator.

During

this

process

the

high

pressure

gas

changes

state

as

it

loses heat,

coming

out

of

the

condenser

as

a

high

pressure

liquid.

The

dryer/

filter

blocks

particles,

and

contains

a

desiccant

to

remove

any

water

from

the

system.

Water

is

a

hazard

because

it

can

combine

with

chlorine/fluorine

refrigerant

to

form

hydrochloric

acid,

a

power-

ful,

toxic

substance.

b.

From

the

output

side

of

the

Filter/Dryer,

the

high

pressure

liquid

flows

through

the

evapor-

ator,

which

in

fact

is

incorporated

into

the

walls

of

the

freezer

compartment

of

the

refrigerator.

In

this

process,

the

refrigerant

lowers

temperatures

by

absorbing

heat

from

the

interior

of

the

refriger-

ator,

changing

in

the

process

to

low

pressure

liquid,

then

to

a

low

pressure

gas.

-5-

c.

On

fig.

2-1,

look

at

the

PTC

Starter

Relay.

This

relay

performs

two

important

functions:

It

brings

both

the

thermostat

and

the

condenser

fan

motor

into

the

compressor-start

circuit,

and

it

Provides

the

required

sequence

for

bringing

the

compressor

to

full

power.

When

the

thermostat

closes,

the

circuit

between

the

120

V

power

cord

high

(black)

line

and

the

P8

of

the

PTC

starter

relay,

the

first

surge

of

power

goes

through

the

relay

to

the

start-up

windings

in

the

compressor.

A

pre-set

time

later,

the

voltage

is

switched

to

the

compressor-run

windings.

Also,

the

relay

completes

the

circuit

through

P2

to

the

condenser

fan

motor.

If

the

fan

does

not

run,

the

refrigerator

system

cannot

function.

Connections

are

as

indicated

in

fig.

2-1.

Notice

that

EITHER

fan

motor

line

can

be

connected

to

either

P8

or

P2.

Looking

at

the

connections

you

will

see

that

two

lines go

to

each

pin,

secured

by

a

spade-lug

connection

covered

with

shrink-wrap

‘‘piggy-back”

connectors.

COVER

FOR

STARTER

RELAY/

RETURN

LINE

TO

TERMINAL

COMPRESSOR

COMPRESSOR

EN

ACCUMULATOR

Low

PRESSURE

LIQUID

(CAP,

TUBE)

LOW

PRESSURE

THERMOSTAT

©

FILTER/DRYER

HIGH

PRESSURE

LIQUID

CONDENSER

FAN

ie0V

MOTOR

CORD

TRANSFORMER

220V

LINE

x

FOR

OPERATION

WITH

120V

SOURCE,

DD

NOT

USE

THE

TRANSFORMER

Fig.

2-1.

Refrigerator

Functional

Block

Diagram

d.

The

element

marked

accumulator

is

a

section

of

the

evaporator

that

acts

as

a

reservoir,

keeping

the

return

line

to

the

compressor

filled

with

low

pressure

gas.

e.

The

refrigeration

system

cannot

function

with

proper

operation

of

the

fan.

f.

Fig.

2-1

shows

a

system

that

uses

a

220

Volt

source.

If

your

system

uses

a

primary

source

of

120

Volts,

the

transformer

is

not

required:

simply

plug

the

120

VAC

power

cord

directly

to

the

source.

g.

Notice

that

the

120

V

power

cord

green

line

and

a

short

green

line

from

one

of

the

com-

pressor’s

mounting

studs

are

attached

to

cabinet

ground.

See

also

fig.

3-1,

No.

13.

h.

Refer

to

fig.

2-1.

It is

important

to

notice

that

a

failure

of

the

PTC

starter

relay

can

appear

to

be

a

failure

of

the

compressor.

When

the relay

functions

as

it

should

in

normal

operation,

closing

of

the

thermostat's

relays

allows

120

VAC

to

flow

from

the

black

lead

of

the

power

cord

through

the

contacts

of

the

thermostat,

along

the

white

return

lead

from

the

thermostat

to

relay

P8.

The

relay

operates

to

start

the

compressor,

then

switches

voltage

to

the

compressor-run

windings.

The

fan

motor

leads

to

the

P8

and

P2

“piggy-backs”

start

the

condenser

fan

motor.

The

white

lead

from

the

power

cord

attaches

to

P2

to

complete

the

circuit.

So,

a

failure

of

the

PTC

relay

can

also

look

like

a

problem

with

the

fan

motor.

CHAPTER

3

MAINTENANCE

3-1.

INTRODUCTION

3-2.

This

chapter

covers

preventive

maintenance

and

corrective

maintenance,

including

a

recom-

mended

schedule

of

maintenance

and

a

brief

trouble

shooting

guide.

3-3.

SAFETY.

In

working

on

this

refrigerator,

be

sure

to

ALWAYS

observe

the

elements

of

safety

cited

in

the

general

introduction,

par.

1-2,

and

at

par.

1-9.

Before

performing

any

of

the

following,

ALWAYS

be

sure that

the

refrigerator

is

unplugged

from

its

power.

3-4.

Preventive

Maintenance.

The

following

lists

periodic

preventive

maintenance

procedures,

to be

completed

daily,

weekly,

monthly,

and

semi-annually

to

insure

continuity

of

operation

and

prompt

discovery

of

problems,

or

potential

problems.

DAILY

Check

door

gasket

for

proper

seal

or

damage.

If

damaged,

see

par.

3-10.

Check

cold

plate

for

heavy

frost

accumulation.

Defrost

if

frost

is

more

than

%”

thick.

For

defrost

procedure,

see

par.

3-16.

Check

that

the

defrost

tray

is

flush

against

rear

cabinet

liner

wall.

If

the

defrost

tray

is

damaged,

see

par.

3-15.

Check

freezer

door

for

correct

operation,

sealing,

and

closure.

If

the

freezer

door

is

damaged,

see

par.

3-14.

Check

commodities

in

the

freezer

and

refrigerator

sections.

If

necessary,

change

the

thermostat

setting

(changes

temperatures

in

both

compartments).

If

the

thermostat

does

not

work,

see

par.

3-11.

WEEKLY

Check

the

refrigerator

for

scratches

or

scrapes

on

outside

painted

surfaces.

Repair

with

touch-up

paint

to

prevent

rusting.

See

parts

list,

Chapter

4.

Check

glass

shelf/crisper

tray

for

cracks

or

other

damage,

replace.

See

parts

list.

MONTHLY

Check

the

refrigerator

door

gasket

for

accumulation

of

dirt

or

possible

damage.

If

dirty,

wipe

clean

with

a

mild

detergent.

If

it is

damaged,

see

par.

3-10.

Check

power

cord

for

damage.

If it

is

damaged,

see

par.

3-8

or

3-9.

Check

electrical

plugs

for

damage.

In

case

of

damage,

see

par.

3-8

or

3-9.

Check

fan

motor/compressor

and

transformer

for

correct

operation.

If

there

is

damage,

see

par.

3-15.

Check

shelves,

crisper

trays,

liner

walls,

and

refrigerator

floor

for

dirt

accumulation

and

damage.

Wipe

clean

with

mild

detergent,

In

case

of

damage,

replace

shelves

and

trays

(see

parts

list,

Chapter

4).

If

liner

walls

or

floor

are

damaged,

return

refrigerator

for

depot-level

repair/replacement.

SEMI-ANNUALLY

Check

the

condenser

coil,

fan

assembly,

compressor,

and

transformer

for

accumulation

of

dirt/dust.

If

necessary,

clean

with

vacuum

cleaner.

For

removal

of

stainless

steel

backshield

to

gain

access

to

the

mechanical

assembly

compartment,

see

par.

3-7c

and

fig.

1-2.