Service Manual OverHeaD reFriGera TeD MercHanDiSer · and out. Major service to the...

Service Manual

This manual is copyright © 2014 Duke Manufacturing co. all rights reserved. Reproduction without written permission is prohibited. Duke is a registered

trademark of the Duke Manufacturing co.

Duke Manufacturing Co.

2305 N. BroadwaySt. Louis, MO 63102

Phone: 314-231-1130Toll Free: 1-800-735-3853

Fax: 314-231-5074www.dukemfg.com

IMPORTANT WARNING AND SAFETY INFORMATION

WARNING: READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR PERFORMING MAINTENANCE ON THE EQUIPMENT

This document is prepared for trained Duke service technicians. It is not to be used by anyone not properly qualified to perform these procedures.

This Service Manual is not all encompassing. If you have not been trained on servicing this product, be sure to read the manual completely before attempting servicing. Be sure all necessary tools, test equipment and skills are available. Those procedures for which you do not have the proper skills and test equipment must be performed only by a qualified Duke trained service technician.

OverHeaD reFriGeraTeD MercHanDiSerohRm-39

5/29/2014SM-BK-EC-0009

Service Manual for Overhead Refrigerated Merchandiser OHRM-39

25/29/2014 SM-BK-EC-0009

IMPORTANT WARNING AND SAFETY INFORMATIONWARNING

READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR PERFORMING MAINTENANCE ON THE EQUIPMENT.

WARNING

FAILURE TO FOLLOW INSTRUCTIONS IN THIS MANUAL CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH.

WARNING

DO NOT USE OR STORE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

WARNING

DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPERLY PLACING AND SECURING ALL COVER AND ACCESS PANELS.

WARNING

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE

INSTRUCTIONS THOROUGHLY BEFORE INSTALLING THIS EQUIPMENT.

FOR YOUR SAFETY

Electricity and water do not mix. Unplug the unit before cleaning. If repairs are required, use a qualified service agent. While repairs are being made, be sure the unit is not plugged in. Do not store highly combustible substances on or near the unit. Be sure the compressor compartment has adequate ventilation.

CAUTIONObserve the following:

• Provideandmaintainadequateminimumclearancesfromallwallsandcombustiblematerials.

• Provideandmaintainadequateclearanceforairopenings.

• Keeptheequipmentareafreeandclearofcombustiblematerial.

• Operateequipmentonlyonthetypeofelectricityindicatedonthespecificationplate.

• Retainthismanualforfuturereference.


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TABLE OF CONTENTSINSTALLATION...............................................................................................................................................................................5REMOVALANDREPLACEMENTOFPARTS....................................................................................................................................6 ELECTRICALLOCKOUT/TAGOUTPROCEDURE........................................................................................................................6 COVERSANDPANELS............................................................................................................................................................6 LouveredRearCover.....................................................................................................................................................6 RightRearPanel...........................................................................................................................................................7 LeftRearPanel..............................................................................................................................................................7 TopPanel.......................................................................................................................................................................8 ControlPanel.................................................................................................................................................................8 ELECTRICALCOMPONENTS...................................................................................................................................................9 PowerON/OFFSwitch...................................................................................................................................................9 CircuitBreaker...............................................................................................................................................................9 DigitalThermostat–Display........................................................................................................................................10 Controller....................................................................................................................................................................10 ThermocoupleProbe–Evaporator.............................................................................................................................11 ThermocoupleProbe–AirTemperatureSensor.........................................................................................................11 LEDLightPowerSupply...............................................................................................................................................12 LEDLightSticks-Interior.............................................................................................................................................13 LEDLightSticks-BurgerChute....................................................................................................................................14 CompressorMotorCapacitor......................................................................................................................................15 CompressorMotorStartRelay....................................................................................................................................16 CompressorMotorOverloadRelay.............................................................................................................................16 CondenserFanMotor.................................................................................................................................................17 EvaporatorFan............................................................................................................................................................18 REFRIGERATONCOMPONENTS...........................................................................................................................................19 Condenser/CompressorUnit.......................................................................................................................................19 Dryer............................................................................................................................................................................20 Compressor.................................................................................................................................................................20 CondenserCoil............................................................................................................................................................21 EvaporatorCoil............................................................................................................................................................22 CondensateEvaporatorCoil........................................................................................................................................23 DOORPARTS.......................................................................................................................................................................24 Doors...........................................................................................................................................................................24 DoorSprings................................................................................................................................................................24TROUBLESHOOTINGGUIDE........................................................................................................................................................25 SERVICEINFORMATION......................................................................................................................................................26 RECHARGINGREFRIGERATIONSYSTEM..............................................................................................................................26 REFRIGERATIONSYSTEMJOINTMAPPINGDIAGRAM.........................................................................................................27 SERVICEBULLETINNUMBER26–NOVEMBER12,2003....................................................................................................28MAINTENANCE...........................................................................................................................................................................29 STAINLESSSTEELCARE........................................................................................................................................................29 CLEANINGTHECONDENSERCOIL.......................................................................................................................................29WIRINGDIAGRAM......................................................................................................................................................................30CUSTOMERASSISTANCE.............................................................................................................................................................31


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INSTALLATION

LOCATION

Units represented in this manual are intended forindooruseonly.Be sure the locationchosenhasafloororcounterstrongenoughtosupportthetotalweightoftheunits.Reinforcethecounterifnecessarytoprovideformaximumloading.Forthemostefficientoperation,besuretoprovidegoodaircirculationinsideandout.Majorservicetotherefrigerationsystemisdonefromthetopandrearofthecabinet.

39"30"

30"

INSTALLATION – INSIDE UNIT

Takecarenottoblockairflowtothefansandallowspacealongthefront,backandsides.

INSTALLATION – OUTSIDE UNIT

Besurethattheunithasaccesstoampleair;avoidhotcornersandlocationsnearstovesandovens.

CAUTION:

This unit exhausts air to the top and intakes air from the top and back. Do not seal the unit to the wall or block air flow from the top. The ventilation slots must remain open.

Installation Clearances:

12in.topandrear. 0in.sidesandbottom.

Opentothefront.

INSTALLATION – ELECTrICAL WIrINg

The OHRM-39isavailableasa120VAC,60Hzmodel.All electrical connections should be performed byacertifiedelectricianandshouldcomplywith localelectricalcodesforyourmunicipality.

WARNING

REFERTOTHEAMPERAGEDATALISTINTHESPECIFICATIONSORTHESERIALTAGDATAAND

YOURLOCALCODEORTHENATIONALELECTRICALCODETOBESUREUNITISCONNECTEDTOTHEPROPERPOWERSOURCE.APROTECTEDCIRCUITOFTHECORRECTVOLTAGEANDAMPERAGEMUSTBERUNFORCONNECTIONOFTHESUPPLYCORDORPERMANENTCONNECTIONTOTHEUNIT.THE

POWERMUSTBETURNEDOFFANDDISCONNECTEDWHENEVERPERFORMINGMAINTENANCEOR

REPAIRFUNCTIONS.


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REMOVAL AND REPLACEMENT OF PARTS

ELECTRICAL LOCKOUT/TAGOUT PROCEDURE

WARNING

BEFOREPERFORMINGANYSERVICETHATINVOLVESELECTRICALCONNECTIONORDISCONNECTION

AND/ORExPOSURETOELECTRICALCOMPONENTS,ALWAYSFOLLOWTHEELECTRICALLOCKOUT/

TAGOUTPROCEDURE.DISCONNECTALLCIRCUITS.FAILURETOCOMPLYCANCAUSEPROPERTY

DAMAGE,INJURYORDEATH.

TheElectricalLOCKOUT/TAGOUTProcedureisusedtoprotectpersonnelworkingonanelectricalappliance.Beforeperforminganymaintenanceorservicethatrequires exposure to electrical components, followthesesteps:

1. Inelectricalbox,placeappliancecircuitbreakerintoOFFposition.

2. PlacealockorotherdeviceontheelectricalboxcovertopreventsomeonefromplacingthecircuitbreakerON.

3. Placeatagonelectricalboxcovertoindicatethatappliancehasbeendisconnectedforserviceandpowershouldnotberestoreduntiltagisremovedbymaintenancepersonnel.

4. Disconnect the appliance power cord from theelectricaloutlet.

5. Placeatagonthecordtoindicatethatunithasbeendisconnectedforserviceandpowershouldnotberestoreduntiltagisremoved.

COVERS AND PANELS

Louvered Rear Cover

TheLouveredRearPanelgivestopandrearaccesstotheCondenserCoilforcleaningandservice.

1. Placetheunit’sPowerON/OFFSwitchisintheOFFposition and follow the proper Lockout/Tagoutprocedures.

2. Removeandretainthe2thumbscrewsfromtheLouveredRearPanelonthetopoftheunit.

3. SwingthetopoftheLouveredRearPaneloutandliftoffthecover.

4. ReinstalltheLouveredRearPanelbyreversingtheprevioussteps.

5. Restore power to the unit and test for properfunction.


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Right Rear Panel

TheRightRearPanelgivesaccesstotheCompressorandCondenserFanformaintenanceandservice


2. RemovetheLouveredRearPanel.SeeprocedureinCOVERSANDPANELSsection.

3. Removeandretainthe9screws(3ontop,6onrear)fromtheRightRearPanelandremovefromtheunit.

4. SlidetheRightRearPanelouttodisengagelipsonthetopofpanelandremove.

5. ReversethesestepstoreinstallRightRearPanel.


Left rear Panel

TheLeftRearPanelgivesaccesstotheCondensateEvaporatorPanandCondensateEvaporatorCoil.


2. Removeandretainthe10screws(3ontop,7onrear)fromthepanelandremovefromtheunit.

3. ReversethesestepstoreinstallLeftRearPanel.



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Top Panel

The Top Panel gives access to the Controller andEvaporatorcomponentsforcleaningandservice.


2. Removeandretainthe4screwssecuringtheTopPaneltounitandremove.

3. ReversethesestepstoreinstallTopPanel.

Control Panel

TheControlPanelislocatedontherightrearsideoftheunit,undertheRightRearPanel. ItsecuresthePower ON/OFF Switch, Circuit Breaker, and DigitalThermostatDisplaytotheunit.

1. Placetheunit’sPowerON/OFFSwitchinthe“OFF”position and follow the proper Lockout/Tagoutprocedures.

2. RemovetheRightRearPanel.SeeprocedureinCOVERSANDPANELSsection.

3. Removeandretainthe3screwsthatsecuretheControlPaneltotheunit.

4. Reinstall the Control Panel by reversing theprevioussteps.



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ELECTRICAL COMPONENTS

Power ON/OFF Switch

ThePowerON/OFFSwitchislocatedontherightrearsideoftheunitontheControlPanel.



3. Remove the Control Panel. See procedure inCOVERSANDPANELSsection.

4. MarkanddisconnecttheON/OFFSwitchwires.

5. ThePowerON/OFFSwitchissecuredtotheControlPanelwithspringclips.DepressthespringclipsandslidetheON/OFFSwitchoutoftheControlPanel.

6. To install replacement Power ON/OFF Switch,reversethesesteps.

7. Restorepowertounitandtestforproperfunction.

Circuit Breaker

TheCircuitBreakerislocatedintheControlPanelandisusedtopreventtheunitfromshortingoutshouldaleakoccurinsidetheunit.

1. Placetheunit’sPowerON/OFFSwitchisintheOFFposition and follow the proper Lockout/Tagoutprocedures


3. Removeandretainthe3screwsthatsecuretheControlPaneltotheunit.

4. MarkanddisconnecttheCircuitBreakerwires.

5. TheCircuitBreakerissecuredtotheControlPanelwithspringclips.Depressthespringclipsandslidethebreakerfromthepanel.

6. To install replacement Circuit Breaker, reversethesesteps.



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Digital Thermostat – Display

TheDigitalThermostatislocatedintheControlPanelattherightrearoftheunit.Itdisplaysandcontrolsthecurrenttemperatureinsidetheunit.


2. RemoveRightRearPanel.SeeprocedureinCOVERSANDPANELSsection.

3. Remove the Control Panel. See procedure inCOVERSANDPANELSsection.

4. Remove the ribbon cable from thebackof theDigitalThermostatDisplay.

Spring clips (4)

5. TheDigitalThermostatDisplayissecuredtotheControlPanelwithspringclips.Depressthespringclipsandslidethedisplayfromthepanel.

6. ToinstallreplacementThermostatDisplay,reversethesesteps.

NOTE: Theribboncableispolarized(redwire)andmustbepluggedincorrectly


Controller

TheControllerislocatedundertheTopPanelandisusedtocontrolandprovideinformationtotheDigitalThermostatDisplayandThermocoupleProbes.


2. RemoveTopPanel.SeeprocedureinCOVERSANDPANELSsection.

3. Markanddisconnectthe4ThermocoupleProbewires,DigitalThermostatDisplaycable,andthe3powerwiresfromtheController.

4. RemovetheControllercoverbypullingitoffitsbase(whichremainssecuredtotheunit).

NOTE: The control board inside the Controller is notattachedtothebase.

Control Board

5. InstallthereplacementControllercontrolboard into thebaseandsecurebyreplacingthecover.

6. Reattachallofthewires: Thermocouple Probe–Evaporatorsensorwiresat

terminals29and30 Thermocouple Probe – Air Temperature sensor

wiresatterminals27and28 Power–Blacktoterminals9and10;Neutral(white)

toterminal14 Digital Thermostat Display cable

NOTE: Theribboncable ispolarized (redwire)andmustbepluggedincorrectly

7. ReinstallTopPanelbyreversingtheprevioussteps.


9. Consult the operations manual (P/N 229240) foroperationandprogramminginstructions.


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Thermocouple Probe – Evaporator

TheThermocoupleProbe–EvaporatorisattachedtothefrontoftheEvaporatorCoil,undertheTopPanel.ItmonitorsthetemperatureattheEvaporator.



3. DisconnecttheEvaporatorThermocoupleProbesensorwiresatControllerpins29and30.Theyaremarkedas“EVP”.

4. Remove the foil tape securing thewires to theEvaporatorCoil.

5. CarefullyopentheEvaporatorfinscrimpedaroundtheEvaporatorThermocoupleProbeandremoveit.

6. RemoveThermocouplefromEvaporatorCoil.

7. To install replacement Thermocouple, reversethesesteps.


Thermocouple Probe – Air Temperature Sensor

TheAirTemperatureThermocoupleProbemonitorstheairtemperatureinsidetheunit.



3. Disconnect the Air Temperature ThermocoupleProbesensorwiresatControllerpins27and28.Theyaremarkedas“AIR”.

4. Fromthefrontoftheunit,removebothdoorsbyliftingupandpullingoutattheirbottom.

5. Removeallequipmentfromtheinteriorofunit.

6. Removethe4thumbscrewssecuringeachrackrailandremove.


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7. Removetheinteriorcompartmentbottompanelbyliftingupandoutoftheunit.

8. Removethe8screwssecuringinteriorcompartmentbackpanelandremovethepanel.

9. Removethescrewfromthehold-downloopandremovetheAirTemperatureThermocoupleProbe.

10. To install replacement Thermocouple, reversethesesteps.


LED Light Power Supply

TheLEDLightPowerSupplypowersthe12LEDLightSticks (9 inthe interior,3 intheburgerchute). It islocatedinsidetheinterioroftheunit,belowtheinteriorcompartmentbottompanel.


2. Removebothdoorsbyliftingupandpullingoutattheirbottom.

3. Removeall equipment from the interiorof theunit.

4. Removetheinteriorcompartmentbottompanelbyliftingupandoutoftheunit.


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5. MarkanddisconnectallwiresfromtheLEDLightPowerSupplyandremove.

6. To install replacement LED Light Power Supply,reversethesesteps.


LED Light Sticks - Interior

There are 9 LED Light Sticks, connected togetherin groups of 3 (3 in top-front, 3 in top-rear, 3 inbottom-front),thatareusedtoilluminatetheinteriorcompartmentoftheunit.


2. Removebothdoorsbyliftingupandpullingoutattheirbottom.

3. The LED Light Sticks are connected together ingroupsofthree(3intop-front,3intop-rear,3inbottom-front)andareheldinplacebyclips.Snapout theentiregroup that contains theeffectedlightstick(s)fromtheirrespectiveclips.

LED for Burger Chute under OHRM

4. IfreplacinganyLEDLightSticksintherear,removeallequipmentfromtheinterioroftheunittoallowforeasieraccess.

5. RemovethefaultyLEDstick(s)byunpluggingfromitsgroup.

6. Install thereplacementLEDstick(s)bypluggingthegroupof3LEDLightSticksbacktogetherandreinstallingintotheirrespectiveclips.


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7. Ifnecessary,reinstalltheinteriorequipment.

8. Reinstallthedoors.


LED Light Sticks - Burger Chute

There are 3 LED Light Sticks located in the BurgerChute,nearthefrontoftheunit,whichareusedtoilluminatetheBurgerChute.


2. TheBurgerChuteLEDLightSticksareconnectedtogether inagroupof3,held inplacebyclips.Removethescrewssecuringtheclipsandsnapouttheentiregroupfromitsclips.

3. RemovethefaultyLEDstick(s)byunpluggingfromitsgroup.

4. Install the replacementBurgerChute LED LightStick(s) by plugging the LED light sticks backtogetherandreinstallingintoitsclips.



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Compressor Motor Capacitor

The Compressor Motor Capacitor is attached to amountingbracketonthetopoftheelectricalboxcoverattherearoftheCompressor.ItisusedtokeeptheCompressorMotorrunningmoreefficientlyandcooler.


2. EventhoughtheCompressorMotorCapacitorisphysicallylocatedbehindtheRightRearPanel,itiseasilyaccessedviatheLeftRearPanel.RemoveLeftRearPanel.Seeprocedure inCOVERSANDPANELSsection.

WARNING

CAPACITORSSTOREANELECTRICALCHARGEEVENAFTERTHEPOWERSOURCEHASBEENREMOVED.

HANDLEWITHExTREMECAUTION.

3. Withapairofelectrically insulatedpliers,markanddisconnect thewires fromtheCompressorMotorCapacitor.

4. With a short length of insulated, large gaugewirestrippedoneachend,bridgebetweeneachterminalandfromeachterminaltothecaseoftheCompressorMotorCapacitor.

5. Repeat3times.Ifcorrectlydone,theCompressorMotor Capacitorwill be completely dischargedandsafetohandle.

6. RemovetheelectricalboxcoverbypryingitfromitsbaseatthebottomandpullingitawayfromtheCompressor.

7. RemovetheCompressorMotorCapacitorfromitsmountingbracketontopofelectricalboxcover.

8. Attach the replacement Compressor MotorCapacitortothemountingbracketontopoftheelectricalboxcover.

9. Reinstalltheelectricalboxcover.

10. ReconnecttheCompressorMotorCapacitorwires.

11. Reinstall the Left Rear Panel by reversing theprevioussteps.



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Compressor Motor Start Relay

The Compressor Motor Start Relay is inside theelectricalboxcoverattherearoftheCompressor.


2. TheCompressorMotor StartRelay isphysicallylocatedbehindtheRightRearPanel,butisaccessedviatheLeftRearPanel.RemovetheLeftRearPanel.SeeprocedureinCOVERSANDPANELSsection.

3. Remove the electrical box cover at the rear oftheCompressorbypryingitfromitsbaseatthebottomandpullingitaway.

4. Mark and disconnect all wires attached toCompressorMotorStartRelay.

5. RemovetheCompressorMotorStartRelay(thelowerone)bypulling itawayfromitselectricalpin.

6. To install replacement CompressorMotor StartRelay,reversethesesteps.


Compressor Motor Overload Relay

TheCompressorMotorOverloadRelayisinsidetheelectricalboxcoverattherearoftheCompressor.


2. TheCompressorMotorOverloadRelayisphysicallylocatedbehindtheRightRearPanel,butisaccessedviatheLeftRearPanel.RemoveLeftRearPanel.SeeprocedureinCOVERSANDPANELSsection.

3. Remove the electrical box cover at the rear oftheCompressorbypryingitfromitsbaseatthebottomandpullingitaway.

4. Mark and disconnect all wires attached toCompressorMotorOverloadRelay.

5. RemovetheCompressorMotorOverloadRelay(theupperone)bysimplypullingitawayfromitselectricalpin.

6. To install replacement Compressor MotorOverload,reversethesesteps.



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Condenser Fan Motor

TheCondenserFanMotorisattachedtoamountingbracketbetweentheCompressorandCondenserCoil.ItisusedtocirculateairacrosstheCondenserCoiltoincreasethetransferofheat.



3. Remove and retain the 4 bolts securing theCondenserFanMotortoitsmountingbracketandremovefromtheunit.

NOTE: Fan blade clearance is important.Measureandrecorddistanceoffantocondensercoil.

4. Removethefanmotorfromitsmountingbracket.

5. Markanddisconnectwiringtothemotor.

6. Removethefanbladefromitsmotorshaft.

7. Reattach the fan blade to the replacementCondenserFanMotor.

8. Attach the replacementmotor to itsmountingbracket.

9. To install replacement Compressor MotorCapacitor,reversethesesteps.



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Evaporator Fan

TheEvaporatorFan is locatedbetweenthe interiorcompartment and the top compartment. It is usedtoprovidechilledairfromtheEvaporatorCoiltotheinteriorcompartment.



3. MarkanddisconnectthewirestotheEvaporatorFanmotor.

4. Fromthefrontoftheunit,removebothdoorsbyliftingupandpullingoutattheirbottom.

5. Remove all equipment from the interiorcompartmentoftheunit.

6. Removeandretain the12screws (5across thefront,2oneachangledside,and3acrosstheback)securingtheinteriorcompartmenttoppaneltotheunit.

NOTE: BecarefulofthetopinteriorLEDlightsaseventhoughthereisenoughslackforthemtonotneedtoberemoved,theirclipsareattachedtothetoppanelandthewirestothefrontLEDlightspassthroughanaccessholeinthetoppanel.

7. Frominsidetheinteriorcompartment,carefullyremovetheEvaporatorFanbladebypullingstraightdownwithequalpressureontosidesasclosetotheshaftaspossible.

8. Fromthetopoftheunit,removeandretainthe2screwssecuringtheEvaporatorFantoitsmountingbracket.

9. Attach the replacement Evaporator Fan to itsmountingbracketusingitsscrews.

10. To install replacement Evaporator Fan, reversethesesteps.



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REFRIGERATON COMPONENTS

Condenser/Compressor Unit

The Condenser/Compressor Unit is located behindthe Right Rear Panel. It contains the Compressor,Condenser Coil, Condenser Fan,Dryer, CompressorMotor Capacitor, and CompressorMotor Relays oftheOHRMinasingleunit.



3. EvacuatetherefrigerantsystemaccordingtoDukeManufacturingServiceBulletin#26(page28).

4. Cut refrigeration lines close to Compressor/CondenserUnit.

5. Markanddisconnectallwiring toCompressor/CondenserUnit.

6. Remove and retain the hex nuts securing theCompressor/CondenserUnitbaseplate.

7. LiftandremovetheCompressor/CondenserUnit.

8. SetthereplacementCompressor/CondenserUnitinplaceonitsstudsandsecurewithitshexnuts.

9. Brazetherefrigerantlinestoconnecttoexistinglines.Addtubingasneeded.


11. Rechargetherefrigerantsystemaccordingtothedataplate.

12. Replaceallpanels.

13. Restore power to unit and check for properfunction.


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Dryer

TheDryerislocatedbehindtheRightRearPanel.Itisusedtoproviderefrigerationsystemfiltrationandadsorbsystemcontaminants.




4. Cut refrigeration lines close to the Dryer andremovefromtheunit.

5. BrazeareplacementDryerinplace.





Compressor

TheCompressorislocatedbehindtheRightRearPanel.It isused topressurize,heat, andmove refrigerantthroughtherefrigerationsystem.




4. CuttherefrigerationlinesclosetotheDryer.

5. CuttherefrigerationlinesclosetotheCompressor.

6. MarkanddisconnectallwiringtotheCompressor.

7. Remove and retain the hex nuts securing theCompressortoitsbase.

8. RemovetheCompressorfromtheunit.

9. Set the replacement Compressor in place andsecurewithitshexnuts.

10. BrazetherefrigerantlinestoconnectareplacementDryer and existing lines to the replacementCompressor.Addtubingasneeded.




14. Restorepowertounitandcheckforproperfunction


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Condenser Coil

TheCondenserCoilislocatedbehindtheLouveredRearPanel.Itisusedtoremoveheatfromtherefrigerationsystem.




4. CuttherefrigerationlinesclosetotheDryerandremovefromtheunit.

5. CuttherefrigerationlinesclosetoCondenserCoil.

6. Removethe4boltsmountingtheCondenserCoiltoitsmountingplateandremovethecoil.

7. Remove and retain the screws securing theCondenserFanshroud.

8. SetreplacementCondenserCoilinplaceandsecurewithitsbolts.

9. Braze the refrigerant lines to connect thereplacementCondenserCoiltoexistinglines.Addtubingasneeded.

10. ReinstalltheCondenserFanshroud.







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Evaporator Coil

The Evaporator Coil is located inside the topcompartmentundertheTopPanel.Itisusedtocoolandconditiontheairthatflowsthroughtheinteriorcompartmentbydrawingoutheatandmoisture.




4. De-brazethecapillarytubeandremovefromtheEvaporatorCoil.

5. CuttheremainingrefrigerationlineclosetotheEvaporatorCoil.

6. Remove the foil tape securing thewires to theEvaporatorCoil.

7. CarefullyopentheevaporatorfinscrimpedaroundEvaporator Thermocouple Probe and carefullyremoveitfromtheEvaporatorCoil.

8. Removeandretain4screwssecuringtheEvaporatorCoiltotheunitandremovefromtheunit.




12.MountthereplacementEvaporatorCoilinplaceusingitsscrews.

13. Brazethecapillary tubeandsuction line to thereplacementEvaporatorCoil.

14. ReinstallreplacementEvaporatorThermocoupleProbebycarefullycrimpingtheprobeandwireintotheEvaporatorCoilandreplacingfoiltape.




18. Restorepowertounitandtestforproperfunction


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Condensate Evaporator Coil

The Condensate Evaporator Coil is located behindtheLeftRearPanel.ItisusedtoassistinevaporatingtheexcessmoisturefromtheEvaporatorCoilinthedrippan.

WARNING

BEFOREPERFORMINGANYSERVICETHATINVOLVESELECTRICALCONNECTIONORDISCONNECTION

AND/ORExPOSURETOELECTRICALCOMPONENTS,ALWAYSFOLLOWTHEELECTRICALLOCKOUT/

TAGOUTPROCEDURE.DISCONNECTALLCIRCUITS.FAILURETOCOMPLYCANCAUSEPROPERTY

DAMAGE,INJURYORDEATH.


2. RemoveLeftandRightRearPanels.SeeprocedureinCOVERSANDPANELSsectionat.


4. CuttherefrigerationlinesclosetotheCondensateEvaporatorCoil.

5. Removeandretainthe2hexnutsandhold-downbracketssecuringtheCondensateEvaporatorCoil.

6. Removeandretaintheadjustablehoseclamp,hoseandcopperdrainpipeattachedtothestainlessoutletpipe.

7. RemovetheCondensateEvaporatorCoil.

8. SetthereplacementCondensateEvaporatorCoilinplaceandsecuretotheunitwiththehold-downbrackets.

9. Trimthelinestoproperdimensionandbrazethelines to connect the replacement CondensateEvaporatorCoil.








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DOOR PARTS

Doors

Thespring-loadeddoorsareeasilyremovedforrepairandaccesstotheinteriorcompartmentcomponentsoftheunit.

1. Slidetheoutermostdooropenslightly.

2. Graspwithbothhandsandliftup.

3. Swingtheloweredgeoutandremovedoor.

4. Repeatforinnermostdoor.

5. Reinstall thedoors, innermostfirst,bygraspingtheinnerdoorwithbothhands.

6. Usetheuppercorneroftheinnerdoortopushthespringslideuntilenoughclearanceismadetoslidethedoorintotheupperdoortrack.

7. Slidetheupperedgeoftheinnerdoorintotheuppertrack.

8. Swingthebottomoftheinnerdoorintothebottomdoortrack.

9. Testforproperoperation,slidingback-and-forthacrosstheentirelengthofthetrack.

10. Repeatthepreviousstepsfortheouterdoor.

Door Springs

1. RemoveDoors.SeeDoorssectionabove.

2. RemovethePhillipsheadscrewsecuringthespringendintheaffectedupperdoortrack.

3. Pull thespringandslidemechanismoutof theeffectedupperdoortrack(s).

4. Slidethereplacementdoorspringassemblyintotheaffectedupperdoor track,makingsure thespringeyeletisinstalledasshown.

CAUTION: Inverting the spring eyelet will cause the door to catch when opened or closed.

5. ReinstallthePhillipsheadscrewsecuringthespringendofthespringassemblyintotheeffecteddoortrack(s).

6. Reinstallthedoors.SeeDoorssectionabove.


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TROUBLESHOOTING GUIDE

Symptom Possible Cause Remedy

Cabinettoowarm Unitnotpluggedin Plugunitin

Thermostatsettoohigh SetThermostattoalowersettingforacoldertemperature

Thermostatfaulty ReplaceThermostat

CondenserFanMotornotrunning

CheckandrepairorreplaceCondenserFanMotor

DirtyCondenserCoil CleanCondenserCoil

Refrigerantleak Findleak,repairandrecharge

Doorsnotclosingfully Ensuredoorsarefullyclosed

Productnotpre-chilled Ensureonlypre-chilledproductisplacedinside.

Cabinettoocold Thermostatsettoolow SetThermostattoahighersettingforawarmertemperature

Thermostatfaulty ReplaceThermostat


265/29/2014 SM-BK-EC-0009

SERVICE INFORMATIONRECHARGING REFRIGERATION SYSTEM

General

Toanalyzetheperformanceofarefrigerationsystem,temperature readings are recorded and convertedto pressure readings using a standard pressure/temperaturechart.

When it is necessary to service a factory sealedrefrigerationsystemandreturnittoitsproperlysealedcondition,strictlyadheretothefollowingapprovedprocedure.

Tools

Standardhandandrefrigerationtools

RefrigerantType:134a

Charging Procedure

NOTE: Priortorefrigerationsystemservice,specialcare must be taken during the evacuationprocess to remove air, moisture and othernon-condensables from the system. DukeManufacturing recommends the followingtriple evacuationmethod. Failure to followthisproceduremayresultinpoorrefrigerationsystemperformance.

1. Evacuatesystemto1500microns

2. Break vacuum to 2 psig with dry nitrogen. Ifdry nitrogen is unavailable, use same type ofrefrigerantasusedinsystem.

3. Evacuatesystemto1500microns.

4. Break vacuum to 2 psig with dry nitrogen. Ifdry nitrogen is unavailable, use same type ofrefrigerantasusedinsystem.

5. Evacuatesystemto500microns.

Thesystemisnowreadytoreceiverefrigerantchargeaccordingtoinformationondataplate.

CAUTION: Never use oxygen or acetylene in place of dry nitrogen or refrigerant for leak testing. A violent explosion may result causing property damage, personal injury or death. When using nitrogen to pressure test, always use a pressure regulator. Failure to do so will result in extremely high pressure of the compressor or other system components and result in property damage, personal injury or death.

NOTICE:Priortorepair;ensurethereisenoughprocesshose (approximately 12”) present to complete therepairusingtheaboveprocedure.Ifnot,installanewprocesshosebeforerepairsequence.

1. Installatemporaryaccessvalveonthehighandlowsideofprocesshosesasclosetofactorycrimpsaspossible.

2. Use temporary valves to perform repair. DukeManufacturing will not reimburse the cost ofpermanentlyinstalledvalves.

3. After completing repair, evacuate system usingthetripleevacuationmethoddescribedinDukeManufacturingServiceBulletinNumber26.

4. After completing proper evacuation method,recharge system, using proper refrigerantaccordingtoinformationondataplate.

5. Continue crimping process hose just belowtemporaryvalveandagain2”belowcrimp.

6. Withcrimptoolinplace,removetemporaryvalve.

7. Brazeshutendofprocesshose.

8. Allowtocoolforabout5minutes.

9. Removecrimptool.

10. Checkbrazedendforleaks.


27 5/29/2014SM-BK-EC-0009

REFRIGERATION SYSTEM JOINT MAPPING DIAGRAM

19 17

23

18

9

4

5

1

78121320

10

6

21

11

15

16 14

Intheeventaleakisfound,usethefollowinglisttodocumentthejointrepaired.

1. Outletfromcompressortowardcondenser.

2. Outletfromcompressortocondensationpancoil.

3. Condensationevaporationpancoil.

4. Inlettocondenser–A.

5. Inlettocondenser–B.

6. Outletfromcondenser–A.

7. Outletfromcondenser–B.

8. Inlettofilter/drierfromcondenser.

9. Highpressureprocesstubetermination.

10. Highpressureprocesstubeinletto filter/drier–A.

11. Highpressureprocesstubeinletto filter/drier–B.

12. Outletfromfilter/driertocapillarytube–A.

13. Outletfromfilter/driertocapillarytube–B.

14. Captubeinlettoevaporator.

15. Evaporatorcoilelbows(multiple).

16. Outletfromevaporatortocompressor–A.

17. Outletfromevaporatortocompressor–B.

18. Inlettocompressorfromevaporator.

19. Lowpressureprocesstubetermination.

20. Inlettocompressorfromlowpressureprocesstube.

21. Condensercoilelbows(multiple).


285/29/2014 SM-BK-EC-0009

SErVICE BULLETIN NUMBEr 26 – NOVEMBEr 12, 2003

refrigeration System Evacuation Process

Whenserviceoftherefrigerationsystemisnecessary,caremust be giving during the evacuation processtoensure removalof air,moisture, andothernon-condensablesfromthesystem.Toevacuateasystemproperly,DukeManufacturingrecommendsa tripleevacuationprocedureoutlinedbelow.Failuretofollowthis process could cause poor performance of therefrigerationsystem.

• Evacuatesystemto1500microns

• Breakthevacuumto2psigwithdrynitrogen,ifdrynitrogenisunavailableusethesametypeofrefrigerantasusedinthesystem


• Breakthevacuumto2psigwithdrynitrogen,ifdrynitrogenisunavailableusethesametypeofrefrigerantasusedinthesystem


• Thesystemisnowreadytoreceivetherefrigerantchargeperthedataplateinformation.

CAUTION: NEVER USE OXYGEN OR ACETYLENE IN PLACE OF REFRIGERANT AND DRY NITROGEN FOR LEAK TESTING. A VIOLENT EXPLOSION MAY RESULT, CAUSING PERSONAL INJURY OR DEATH.

ALWAYS USE A PRESSURE REGULATOR WHEN USING NITROGEN TO PRESSURE TEST. FAILURE TO DO SO WILL RESULT IN EXTREMELY HIGH PRESSURE, WHICH COULD EXCEED THE BURST PRESSURE OF THE COMPRESSOR OR OTHER SYSTEM COMPONENTS AND RESULT IN PERSONAL INJURY OR DEATH.


29 5/29/2014SM-BK-EC-0009

MAINTENANCE

STAINLESS STEEL CARE

Cleaning

Stainlesssteelcontains70-80%iron,whichwillrustifnotproperlymaintained. It also contains12-30%chromium,whichformsaninvisiblepassive,protectivefilmthatshieldsagainstcorrosion.Ifthefilmremainsintact,thestainlesssteelwillremainintact.However,ifthefilmisdamaged,thestainlesssteelcanbreakdownandrust.Topreventstainlesssteelbreakdown,followthesesteps:

CAUTION: Never use any metal tools. Scrapers, files, wire brushes or scouring pads (except for stainless steel scouring pads) will mar the surface.

CAUTION: Never use steel wool, which will leave behind particles that rust.

CAUTION: Never use acid-based or chloride-containing cleaning solutions, which will break down the protective film.

CAUTION: Never rub in a circular motion.

CAUTION: Never leave any food products or salt on the surface. Many foods are acidic. Salt contains chloride.

Forroutinecleaning,usewarmwater,mildsoapordetergentandaspongeorsoftcloth.

Forheavy-dutycleaning,usewarmwater,adegreaserandaplastic,stainlesssteelorScotch-Britepad.

Always rinse thoroughly. Always rub gently in thedirectionofthesteelgrain.

Preserving & Restoring

Specialstainlesssteelpolishingcleanerscanpreserveandrestoretheprotectivefilm.

Preserve the life of stainless steel with a regularapplicationofahighqualitystainlesssteelpolishingcleanerasafinalsteptodailycleaning.

If signs of breakdown appear, restore the stainlesssteel surface. First, thoroughly clean, rinse anddrythesurface.Then,onadailybasis,applyahigh-qualitystainless steel polish according to manufacturer’sinstructions.

CLEANING THE CONDENSER COIL

WARNING

THEPOWERMUSTBETURNEDOFFANDDISCONNECTEDATALLTIMESDURINGMAINTENANCEORREPAIRFUNCTIONS.

Failuretomaintainacleancondensercoilcancausehightemperaturesandexcessiveruntimes.Continuousoperationwithdirtyorcloggedcondensercoilscanresultincompressorfailure.Neglectingthecondensercoil cleaning procedures will void the compressorwarranty.

CAUTION:Neverusehigh-pressurewatertocleanthecondenser.High-pressurewatercandamageelectricalcomponentslocatedatornearthecondensercoil.

Thecondensercoilislocatedatandaccessedtotherearoftheunit.ALouveredPanelallowsaccess.Thecondensercoilrequiresregularcleaningandshouldbedoneevery60days.However,iflargeamountsofdust and grease accumulatemore often, clean thecondenser coil every 30 days. For light dust, use asoft,non-wirebrush.Forheavierdust,useavacuumcleanerorblowwithcompressedair.

For heavy grease, use a degreasing agent madespecificallyforcondensercoilsonrefrigerationunits.Spraythedegreasingagentonthecoilandthenblowwithcompressedair.Neverwashthecondenserwithhigh-pressurewater.Highpressurewatercandamageorbendthecoolingfinsonthecondenser,reducingitsefficiency.

Water can also damage the electrical componentslocatednearthecondensercoil.


305/29/2014 SM-BK-EC-0009

WIRING DIAGRAM

CONDENSER

CONTROLLER

T1 P

ROBE

AIR

T2 P

ROBE

EAP

ORAT

OR

LIGHTS

L1 N120 VAC

G

HEATER EVAP FAN

4 AMPCIRCUITBREAKER

MAINPOWERSWITCH

229932 Rev. B

RECEPTACLE


31 5/29/2014SM-BK-EC-0009

CUSTOMER ASSISTANCEToaidinreportingthisunitincaseoflossortheft,pleaserecordbelowthemodelnumberandserialnumberlocatedontheunit.Wealsosuggestyourecordalltheinformationlistedandretainforfuturereference.

MODEL NUMBER: SERIAL NUMBER:

DATE OF PURCHASE:

DEALER: TELEPHONE:

SERVICER: TELEPHONE:

FOR WARRANTY, PARTS & SERVICE:

DUKE CORPORATE,CANADA, LATIN AMERICA

2305 N. BroadwaySt. Louis, MO 63102

Phone: 314-231-1130Toll Free: 800-735-3853

Fax: [email protected]

DUKE ASIA PACIFIC

Duke ManufacturingNo.3 Building

Lane 28, Yu Lv RoadMalu Town, Jiading District

Shanghai 201801, ChinaPhone: +86 21 59153525 / 59153526

Fax: +86 21 [email protected]

DUKE EMEA - EUROPE,MIDDLE EAST, AFRICA, RUSSIA

Duke Manufacturing CR, s.r.o.Na Dlouhem 86Jazlovice, Ricany

Building number DC 4 on theProLogis Park Prague D1 West

Prague 251 01Czech Republic

Phone: +420 323 608 193Fax: +420 323 608 144

[email protected]

DUKE EMEA – UK, IRELAND

Phone: +44 (0) 1395 234140Fax: +44 (0) 1395 234154

[email protected]

TO ACCESS INTERNET: www.dukemfg.com

Pleaseprovidethefollowinginformationwhenyouwriteorcall:modelnumber,serialnumber,dateofpurchase,yourcompletemailingaddress(includingzipcode),anddescriptionoftheproblem.


325/29/2014 SM-BK-EC-0009

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