Marvel 4570105 User manual

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

NORTHLAND

CORPORATION

P.O.

Box

997

Richmond,

Indiana

47375

Tel.

317-962-2521

P/N

41003786

TABLE

CONTENTS

CHAPTER/PARAGRAPH

PAGE

Maintenance

Replacement

Parts

List

Diagrams

ntroduction

Introduction..

Warning

Organization

the

Manual

Purpose

the

Refrigerator.

Description........

Specifications

Required

Tools...

Operation

2-1

Introduction

2-3

Unpacking

Procedure

2-4

Installation

2-5

Operation

and

Theory

Operation

...

3-1

Introduction.....

Зав

iia

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.

aa o Pa

rote

see

gua

ate

aerial!

when

АНИ

Utroducton

-<=

8.4

5-1

Introduction

LIST

ILLUSTRATIONS

FIGURE

NUMBER

PAGE

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

Refrigerator,

Rear

View

Refrigerator

Functional

Block

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

Mechanical

Assembly

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

Refrigerator,

Front View.

Refrigerator,

Rear

View

Mechanical

Assembly:

szscaças

een

μα

ας

Refrigerator

Wiring

Diagram

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

の

で

や

の

い

ーー

SEL

LIST

TABLES

TABLE

NUMBER

ПИ

ООС

ine

за бо

ао

ро:

зе

con

1-2

Required

Tools

CHAPTER

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,

FOR

ANY

OPERATION

REQUIRING

OPENING

THE

REFRIGERANT

LINE

ONLY

QUALIFIED

MAINTENANCE

PERSONNEL,

USING

PROCEDURES

AND

EQUIPMENT

SPECIFIED

THE

MANUFACTURER

DEPOT-LEVEL

AUTHORITIES,

SHOULD

WORK

THE

REFRIGERATION

SYSTEM.

ANY

MOISTURE

THAT

ALLOWED

INTO

THE

REFRIGERATION

LINES

WILL

COMBINE

WITH

THE

FLUORINE

AND

CHLORINE

REFRIGERANT

PRODUCE

HYDROCHLORIC

ACID,

EXTREMELY

POWERFUL

AND

CORROSIVE

ACID.

1-3.

All

procedures

this

manual

refer

the

electrical

and

mechanical

elements

operation

and

maintenance.

1-4.

Organization

the

Manual.

shown

the

Table

Contents,

this

manual

organized

follows:

Chapter

INTRODUCTION.

Provides

information

Organization

the

manual,

purpose

the

refrigerator,

description

and

specifications

for

the

refrigerator,

list

required

equipment,

and

safety

information.

Chapter

OPERATION.

Tells

you

how

unpack,

install,

and

operate

the

refrigerator,

with

brief

theory

operation.

Chapter

MAINTENANCE.

Details

the

procedures

for

preventive

and

corrective

maintenance

the

refrigerator.

Chapter

PARTS

LIST.

Lists,

assemblies,

the

replacement

parts

for

the

refrigerator,

with

part

numbers

and

illustrations.

Chapter

DIAGRAMS.

Contains

all

illustrations

cited

the

text

but

not

otherwise

included.

1-5.

Purpose

the

Refrigerator.

The

refrigerator

used

refrigerator-freezer

ward

level

field

hospitals

designated

the

Department

Defense.

1-6.

Description.

Refer

fig.

1-1

and

1-2.

The

refrigerator

light

weight

and portable,

designed

for

field

operations.

Providing

4.5

cubic

feet

refrigeration

and

freezing

space,

the

refrigerator

incorporates

three

shelves,

drip

pan,

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

temperature

range

degrees

Fahrenheit,

and

the

freezer

compartment

operates

over

range

degrees

Fahrenheit.

The

refrigerator

has

220/110

VAC

step-down

transformer;

can

operate

from

either

220

110

VAC,

60/50

source.

Fig.

1-2,

No.

1-7.

The

outer

shell

the

refrigerator

1/32nd

inch

carbon

steel

with

olive

drab

finish.

The

inner

shell

and

door

liner

are

plastic.

The

door

trimmed

with

anodized

aluminum

and

has

magnetic

latch.

There

additional

door

security

snap

fastener

located

the

upper

left

corner

for

use

during

transport.

Fig.

1-1.

Refrigerator,

Front

View

Thermostat

(behind

grill)

Crisper

shelf

Drip

tray

Freezer

door

Hinge

Door

gasket

Door

Wire

shelf

Crisper

tray

10.

Cabinet

assembly

Fig. 1-2.

Refrigerator,

Rear

View

Transformer

220

Volt

line

Cabinet

back

cover

Transformer

120

Volt

outlet

Stainless

steel

backshield

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

amps

inrush

110

7.5

amps

inrush

220

Weight

106

Ibs.

Volume,

internal

6.1

cubic

feet

Outer

dimensions

1/4”

3/8”

1/16”

Internal

volume

Freezer

0.7

cubic

feet,

minimum

Refrigerator

4.5

cubic

feet,

minimum

Pull-down

times

ambient

temperature

120

degrees

3.0

hours

100

degrees

hour

degrees

hour

Nominal

weight

and

volume

shipping

container

Weight

135

Ibs.

Volume

16.8

cubic

feet

Dimensions

38%"

28”

27”

Type

refrigerant

R-12

Weight

full

charge

refrigerant

4.7

oz.

(0.29

Ibs.)

1-9.

Required

Tools.

Table

1-2

lists

all

the

tools

required

for

normal

use

and

maintenance

the

refrigerator.

Table

1-2

Description

No.

Req'd

Phillips

head

screwdriver

(3'’-4”

long)

Phillips

head

screwdriver

(8"

long)

Flatblade

screwdriver

(small,

approximately

1/8”

wide

blade)

Hand

roller

36”

Cardboard

sheet

36”

Table

bench

Channel-lock

adjustable

pliers

Combination

open

end/box

end

wrenches

Any

standard

multimeter

for

checking

voltages

and

continuity

circuits

For

tools

and

associated

equipment

used

maintenance

procedures

NOT

described

this

manual,

refer

Depot-level

maintenance

organization

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,

careful

power

sources.

110

volts

can

kill

you.

your

system

uses

220

volts

with

step-down

transformer,

being

very

careful

even

important.

For

connection

220

VAC

source,

sure

use

the

step-down

transformer,

detailed

par.

2.4f,

below.

1-11.

When

the

refrigerator

operation,

the

condenser

(radiator)

can

get

hot

enough

burn

your

skin.

1-12.

NEVER

use

two-wire

cord

power

outlet

with

this

refrigerator.

Such

practice

can

produce

shocks

and

will

damage

operating

elements

the

system.

CHAPTER

OPERATION

2-1.

INTRODUCTION.

2-2.

This

chapter

details

unpacking,

installation,

and

operation

the

refrigerator,

with

brief

explanation

the

theory

operation.

2-3.

Unpacking.

Unpacking

easy.

The

refrigerator

shipped

heavy-duty

cardboard

carton,

with

slip-off

top

and

bottom

covers

held

steel

straps.

unpack:

Stand

the

carton

upright.

With

tin

snips,

cut

the

lower

steel

band.

Pull

all

four

sides

the

bottom

cover

away

and

down

from

the

sides

the

carton.

Lifting

from

the

top,

pull

the

carton

and

off

the

refrigerator.

Dispose

the

carton,

dust

off

the

refrigerator,

and

ready

for

installation.

capo»

2-4.

Installation.

Getting

the

refrigerator

ready

operate

very

simple.

Dispose

the

packing

material,

and

position

the

refrigerator

where

you

want

it.

Then:

sure

that

the

cord

provided

long

enough

reach

safely

grounded

three-prong

outlet.

Connect

the

plug

the

wall

socket

the

end

this

installation

procedure.

For

wall

outlet

that

220

VAC,

the

wall

socket

cord

must

the

transformer,

located

the

back

lower

left

corner,

shown

fig.

3-1.

Then

plug

the

output

line

the

transformer

the

input

line

the

refrigerator,

shown

fig.

1-2.

The

four

glides

(feet)

the

refrigerator

are

non-adjustable.

the

refrigerator

level

surface,

the

refrigerator

will

level.

the

upper

left

front

corner

there

snap-fastened

safety

strap

which

holds

the

door

closed

during

shipment.

open

the

door,

unsnap

the

safety

strap

and

pull

the

handle;

the

door

has

magnetic

latch.

the

lower

left

front

corner,

behind

the

grill,

which

held

two

small

screws,

you

will

find

the

thermostat.

The

aluminum

sensor

line

attached

the

thermostat

runs

the

back

the

refrigerator

the

upper

right

rear

corner.

The

sensor

lies

between

the

rear

panel

and

the

insula-

tion.

The

dial

the

thermostat

has

adjustment

range

the

coldest

setting.

pre-

set

the

factory

for

3%),

providing

the

normal

operating

temperature.

Varying

ambient

temperatures

may

require

re-setting

the

thermostat

dial

for

your

installation.

Finally,

before

making

the

power

connection,

sure

that

the

interior

the

refrigerator

clean.

Connect

the

power

cord

the

appropriate

source:

110

220

volts

AC,

nominal.

For

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

the

source.

2-5.

Operation

and

Theory

Operation.

Once

prepared

specified

above,

the

refrigerator

func-

tions

automatically.

The following

brief

explanation

how

the

refrigerator

works.

This

explana-

tion

will

enable

you

operate

and

maintain

the

refrigerator

most

efficiently.

2-6.

Refer

fig.

2-1,

functional

diagram

the

system,

and

figs.

4-1,

4-2, 4-3,

which

show

the

components

and

their

location

the

refrigerator.

the

explanation,

refer

these

figures.

The

thermostat

(located

behind

the

grill

the

lower

left

front

the

refrigerator)

monitors

temperatures

inside

the

refrigerator.

When

the

sensor

shows

temperature

warmer

than

the

adjusted

setting,

the

thermostat’s

contacts

close,

completing

the

circuit

that

operates

the

compressor.

The

compressor

takes

the

warm

low

pressure

gas

and

converts

high

pressure

gas.

Passing

through

the

condenser

(radiator),

the

chlorine/fluorine

refrigerant

gives

off

heat

the

air

surrounding

the

condenser,

primarily

through

the

cooling

fins,

any

radiator.

During

this

process

the

high

pressure

gas

changes

state

loses heat,

coming

out

the

condenser

high

pressure

liquid.

The

dryer/

filter

blocks

particles,

and

contains

desiccant

remove

any

water

from

the

system.

Water

hazard

because

can

combine

with

chlorine/fluorine

refrigerant

form

hydrochloric

acid,

power-

ful,

toxic

substance.

From

the

output

side

the

Filter/Dryer,

the

high

pressure

liquid

flows

through

the

evapor-

ator,

which

fact

incorporated

into

the

walls

the

freezer

compartment

the

refrigerator.

this

process,

the

refrigerant

lowers

temperatures

absorbing

heat

from

the

interior

the

refriger-

ator,

changing

the

process

low

pressure

liquid,

then

low

pressure

gas.

-5-

fig.

2-1,

look

the

PTC

Starter

Relay.

This

relay

performs

two

important

functions:

brings

both

the

thermostat

and

the

condenser

fan

motor

into

the

compressor-start

circuit,

and

Provides

the

required

sequence

for

bringing

the

compressor

full

power.

When

the

thermostat

closes,

the

circuit

between

the

120

power

cord

high

(black)

line

and

the

PTC

starter

relay,

the

first

surge

power

goes

through

the

relay

the

start-up

windings

the

compressor.

pre-set

time

later,

the

voltage

switched

the

compressor-run

windings.

Also,

the

relay

completes

the

circuit

through

the

condenser

fan

motor.

the

fan

does

not

run,

the

refrigerator

system

cannot

function.

Connections

are

indicated

fig.

2-1.

Notice

that

EITHER

fan

motor

line

can

connected

either

P2.

Looking

the

connections

you

will

see

that

two

lines go

each

pin,

secured

spade-lug

connection

covered

with

shrink-wrap

‘‘piggy-back”

connectors.

COVER

FOR

STARTER

RELAY/

RETURN

LINE

TERMINAL

COMPRESSOR

ACCUMULATOR

Low

PRESSURE

LIQUID

(CAP,

TUBE)

LOW

PRESSURE

THERMOSTAT

FILTER/DRYER

HIGH

PRESSURE

LIQUID

CONDENSER

FAN

ie0V

MOTOR

CORD

TRANSFORMER

220V

LINE

FOR

OPERATION

WITH

120V

SOURCE,

NOT

USE

THE

TRANSFORMER

Fig.

2-1.

Refrigerator

Functional

Block

Diagram

The

element

marked

accumulator

section

the

evaporator

that

acts

reservoir,

keeping

the

return

line

the

compressor

filled

with

low

pressure

gas.

The

refrigeration

system

cannot

function

with

proper

operation

the

fan.

Fig.

2-1

shows

system

that

uses

220

Volt

source.

your

system

uses

primary

source

120

Volts,

the

transformer

not

required:

simply

plug

the

120

VAC

power

cord

directly

the

source.

Notice

that

the

120

power

cord

green

line

and

short

green

line

from

one

the

com-

pressor’s

mounting

studs

are

attached

cabinet

ground.

See

also

fig.

3-1,

No.

13.

Refer

fig.

2-1.

It is

important

notice

that

failure

the

PTC

starter

relay

can

appear

failure

the

compressor.

When

the relay

functions

should

normal

operation,

closing

the

thermostat's

relays

allows

120

VAC

flow

from

the

black

lead

the

power

cord

through

the

contacts

the

thermostat,

along

the

white

return

lead

from

the

thermostat

relay

P8.

The

relay

operates

start

the

compressor,

then

switches

voltage

the

compressor-run

windings.

The

fan

motor

leads

the

and

“piggy-backs”

start

the

condenser

fan

motor.

The

white

lead

from

the

power

cord

attaches

complete

the

circuit.

So,

failure

the

PTC

relay

can

also

look

problem

with

the

fan

motor.

CHAPTER

MAINTENANCE

3-1.

INTRODUCTION

3-2.

This

chapter

covers

preventive

maintenance

and

corrective

maintenance,

including

recom-

mended

schedule

maintenance

and

brief

trouble

shooting

guide.

3-3.

SAFETY.

working

this

refrigerator,

sure

ALWAYS

observe

the

elements

safety

cited

the

general

introduction,

par.

1-2,

and

par.

1-9.

Before

performing

any

the

following,

ALWAYS

sure that

the

refrigerator

unplugged

from

its

power.

3-4.

Preventive

Maintenance.

The

following

lists

periodic

preventive

maintenance

procedures,

to be

completed

daily,

weekly,

monthly,

and

semi-annually

insure

continuity

operation

and

prompt

discovery

problems,

potential

problems.

DAILY

Check

door

gasket

for

proper

seal

damage.

damaged,

see

par.

3-10.

Check

cold

plate

for

heavy

frost

accumulation.

Defrost

frost

than

%”

thick.

For

defrost

procedure,

see

par.

3-16.

Check

that

the

defrost

tray

flush

against

rear

cabinet

liner

wall.

the

defrost

tray

damaged,

see

par.

3-15.

Check

freezer

door

for

correct

operation,

sealing,

and

closure.

the

freezer

door

damaged,

see

par.

3-14.

Check

commodities

the

freezer

and

refrigerator

sections.

necessary,

change

the

thermostat

setting

(changes

temperatures

both

compartments).

the

thermostat

does

not

work,

see

par.

3-11.

WEEKLY

Check

the

refrigerator

for

scratches

scrapes

outside

painted

surfaces.

Repair

with

touch-up

paint

prevent

rusting.

See

parts

list,

Chapter

Check

glass

shelf/crisper

tray

for

cracks

other

damage,

replace.

See

parts

list.

MONTHLY

Check

the

refrigerator

door

gasket

for

accumulation

dirt

possible

damage.

dirty,

wipe

clean

with

mild

detergent.

it is

damaged,

see

par.

3-10.

Check

power

cord

for

damage.

If it

damaged,

see

par.

3-8

3-9.

Check

electrical

plugs

for

damage.

case

damage,

see

par.

3-8

3-9.

Check

fan

motor/compressor

and

transformer

for

correct

operation.

there

damage,

see

par.

3-15.

Check

shelves,

crisper

trays,

liner

walls,

and

refrigerator

floor

for

dirt

accumulation

and

damage.

Wipe

clean

with

mild

detergent,

case

damage,

replace

shelves

and

trays

(see

parts

list,

Chapter

4).

liner

walls

floor

are

damaged,

return

refrigerator

for

depot-level

repair/replacement.

SEMI-ANNUALLY

Check

the

condenser

coil,

fan

assembly,

compressor,

and

transformer

for

accumulation

dirt/dust.

necessary,

clean

with

vacuum

cleaner.

For

removal

stainless

steel

backshield

gain

access

the

mechanical

assembly

compartment,

see

par.

3-7c

and

fig.

1-2.

Table of contents

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