Fisher & Paykel 635 Active Smart Service Manual Download

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13.8 Evaporator Replacement

The evaporator is located in the FC compartment mounted on the back wall on its own carrier, with a grill
covering a fan motor that is housed in the front cover.

Having determined that the evaporator needs replacing:
1.  Recover the refrigerant.
2.  Remove the FC door.
3.  Remove the evaporator coil cover.
4.  Clean both suction and capillary pipes with emery cloth.
5.  With the tube cutter, cut the suction pipe as close as possible to the induction brazed joint (cutting the

suction capillary side of the joint).

6.  With a file or knife cut the capillary where it enters the transition joint on the evaporator.
7.  With the element wiring disconnected, the evaporator can be removed.
8.  Take the replacement evaporator and fit it to the carrier, fitting the defrost element assembly and fitting

the heat shrink sleeving onto the pipes.

9.  Align the evaporator and joints ready to be soldered into position.
10.  Lay the product on its back.
11.  Place a protective covering over the back of the liner to protect it should solder drop onto it while the

joint connections are being made.

12. Fit the suction and capillary lines together, with a protective heat shrink sleeving first being placed on

the pipe clear of the heated area. Care must be taken when brazing near the plastic liner.

13. The same applies for the capillary, applying more heat to the transition joint as it is heavier in material

than the capillary.

14. Pressure test both joints.
15. Slide the heat shrink sleeving over the joint and heat, having placed damp rags around the area of the

ABS liner as heating the heat shrink can cause the liner to be overheated. It is also important to keep
the thermal fuse in the element circuit away from the heat gun, as heat from the heat gun can cause the
thermal fuse to go open circuit.

13.9 Refilling A Void In Foam Insulation After System Service

Or Adjustment

When 50ml of each foam component is mixed together, sufficient insulation will be formed to fill a space of
approximately 25cm x 25cm x 5cm deep (3 litres volume). "Freefoam" means that the space being filled is
not fully enclosed.

The foam is handled as follows:

1. Roughly determine the volume of the void to be foamed and then determine how much activator and

resin is required. Do a test run mixing a ¼ cup of each to estimate your requirement (on waste
cardboard).

2. Measure equal quantities of activator and resin into a large wax cup or similar and mix briskly with a

wooden spatula for 10-15 seconds. The mixture will start to feel warm and this indicates that mixing is
complete.

3. Pour the mixture into the void and allow to foam. More can be added if necessary.
4. When the foam is firm, remove any excess with a sharp knife, apply a film of wax to the foam, apply a

vapour seal to the triple fold, then refit the back panel, making sure the panel is perfectly vapour sealed.

DO NOT OPERATE THE APPLIANCE FOR AT LEAST FOUR HOURS AFTER FOAMING.

6. Foam solvent for cleaning while the foam is still in a liquid state is methylated spirits.

CAUTION

1. Avoid splashing the mixture onto the cabinet. Once set, foam is almost impossible to remove.
2. When clearing a pocket for foaming it is recommended to leave a layer of old foam against the ABS

plastic liner for support and to prevent pressure of the foam causing a bulge on the PC inside surface.