Haier BD-388A, Service Manual

Page 1: ... foam cover for efficient Temperature preservation Adjustable thermostat Superior insulation Efficient defrosted storage Designed for cafeterias restaurants and hotels Haier Group Manual No BD 478A Edition 20051201 BD 478A PDF created with pdfFactory trial version www pdffactory com ...

Page 2: ...Circuit Diagram 15 12 Maintenance Service and Trouble Shooting 1 System Troubleshooting 16 2 Common freezer problems 28 3 Service and technical requirements of R134a freezer 30 4 Application and maintenance of freezer 33 5 Procedure and tools required for evacuation and Charging 38 6 Freezers Noise 40 7 National Standard for noise 49 8 Measuring technology of freezer performance parameter 51 13 Ex...

Page 3: ... Code Illumination and Series Introduction B D A B C D A The first letter of FREEZER in Chinese spelling B The first letter of FREEZER in Chinese spelling C Capacity Unit litre D Improve Series Number PDF created with pdfFactory trial version www pdffactory com ...

Page 4: ...sted storage Designed for cafeterias restaurants and hotels Low power consumption 20 less than the other similar freezers Imported high quality compressor and condenser large freezing capacity 1 5 times more then regular freezers Freezing quick and deep freeze functions are 2 times faster then regular freezers PDF created with pdfFactory trial version www pdffactory com ...

Page 5: ...8 478 Power Supply V Hz 220V 50Hz 220V 50Hz Unit Dimension W D H 1420 715 810 1690 715 810 Unit Weight Kg 72 78 Box Dimensions W D H 1495 765 870 1765 765 870 Box Weight Kg 84 91 Container Quantity 40HC 66 57 PDF created with pdfFactory trial version www pdffactory com ...

Page 6: ...power cord Always grasp the plug firmly and pull straight out from the outlet 4 Repair or replace immediately all electric service cords that have become frayed or otherwise damaged Do not use a cord that shows cracks or abrasion damage along its length the plug or the connector end 5 Unplug your freezer before cleaning or before making any repairs Note If for any reason this product requires serv...

Page 7: ...s designed for freestanding installation only 8 Do not operate your freezer in the presence of explosive fumes 9 Do not refreeze foods which have been thawed completely 10 Do not use any electrical device or any sharp instrument in defrosting your freezer PDF created with pdfFactory trial version www pdffactory com ...

Page 8: ...MENSION Net Dimension H a L W H Model BD 388A BD 478A Unit Dimension W D H 1420 715 810 1690 715 810 Dimension Door open 1420 715 1470 1690 715 1470 PDF created with pdfFactory trial version www pdffactory com ...

Page 9: ...strong enough to support it fully loaded 3 When moving the freezer never tilt it more than a 45 degree angle This could damage the compressor and the sealed system 4 If the freezer is tilted let it stand in an upright position for at least 24 hours prior to plugging This is to allow the refrigerant to settle Proper Air Circulation l To assure your freezer works at the maximum efficiency it was des...

Page 10: ... this is a dangerous practice since it provides no effective grounding for the freezer and may result in shock hazard Install Limitations l Do not install your freezer in any location not properly insulated or heated e g garage etc l Select a suitable location for the freezer on a hard even surfaces away from direct sunlight or heat source e g radiators baseboard heaters cooking appliances etc Any...

Page 11: ...r freezer or experience an electrical outage allow 5 Minutes before plugging it back in Note If the freezer has been placed in a horizontal or tilted position for any period of time wait 24 hours before plugging the unit in Adjustable temperature dial Your freezer will automatically maintain the temperature level you select The temperature level you select The temperature control dial has 6 settin...

Page 12: ...draining place a tray beneath the outer drain plug Pull out the drain dial and rotate it so that the arrow points down ward This will let the water flow out into the tray Remove the drain plug from the inside of the freezer Defrosting usually takes a few hours To defrost faster keep the freezer door open When done push the drain dial in and turn the arrow to the up position Re plug the drain plug ...

Page 13: ... of direct cooling single system freezers belongs to the category of a single temperature and single control refrigerating system with only one evaporator and is controlled by a single temperature control PDF created with pdfFactory trial version www pdffactory com ...

Page 14: ...ging it back in Note If the freezer has been placed in a horizontal or tilted position for any period of time wait 24 hours before plugging the unit in Adjustable temperature dial Your freezer will automatically maintain the temperature level you select The temperature level you select The temperature control dial has 6 settings plus 01 1 is the warmest 6 is the coldest Turning the dial to 0 stops...

Page 15: ...starting the machine the thermostat will be closed the compressor will run When the temperature in the freezer is lower and reaches the value for closing the machine the thermostat will be open thus the compressor will be stop running MAINTENANCE SERVICE AND TROUBLE SHOOTING Maintenance Service and Trouble Shooting 12 1 System Trouble shooting PDF created with pdfFactory trial version www pdffacto...

Page 16: ...dometer The normal value is several Ohm to tens of ohm If the resistance is zero means that there is a short in the freezer circuit or there is a short caused by a bad compressor or fan motor The reason should be found out and repaired If the resistance is too big or infinite this means that there is broken circuit please check and solve it After the above checks the freezer will not have any elec...

Page 17: ...kage of motor connection terminals the connection terminals of fully enclosed compressor are made from high temperature soda glass sintered ceramics around the terminals are filled with a high polymer The terminals and insulation material must have the same linear expansion coefficient the for requirement between terminals and the shell is more than 0 5 million ohm The reason of terminal leakage i...

Page 18: ...k it If there is leakage please make the connections again and leave a piece of insulation paper under the screw 5 Leakage of fan because of too high humidity of freezer environment or a bad fan controlling unit the fan is burned after long time operation and thus causes leakage Using voltammeter to measure the insulation resistance between each respective connection terminal and the freezer body ...

Page 19: ...tle refrigerant oil If there is leak there will be traces of oil at the leak points 12 1 4 Troubleshooting by sounds 1 When the freezer is working normal high pressure liquid refrigerant flows into the low pressure evaporator via acapillarytube a gas flowing sound and water flowing sound can be heard Open the freezer door and access to the evaporator you can hear the sound If there is no sound or ...

Page 20: ...nd the condenser s temperature is low too and there is only a small part warm In summer the temperature is high and the temperature of condenser cover is high too and the whole condenser is warm 2 The temperature of high pressure exhaust pipe is high when touching with your hand in summer it is hot in winter it is also hot The temperature of low pressure gas inlet pipe is low In summer there is de...

Page 21: ...ther decision should be made 12 1 6 System noise repair Normally there are two kinds of freezer noise one is the natural noise of compressor and fan and the other is the resonance noise or structural noise The natural noise of compressor and fan is controlled within a standard range if the range is exceeded the compressor or fan needs to be repaired or changed The resonance or structural noise can...

Page 22: ... noise please clear the obstacles around the fan or adjust fan blades 6 If the fan supporter is loose and noise is caused please tighten 12 1 7 Poor freezing effect analysis and solutions 1 Check the position of temperature control dial if it is set at weak position please change to middle or close to strong position MAINTENANCE SERVICE AND TROUBLE SHOOTING Maintenance Service and Trouble Shooting...

Page 23: ...cannot be sealed well Remove dirt and put on a little talcum powder 5 Frequent opening and extended opening of freezer door will reduce refrigeration ability 12 1 8 How to handle the seal bar for poor sealing If there is too much dirt and the sealing effect is not well please take a rag and dip in warm water and clean the seal bar After cleaned put on a little talcum powder If there is still seam ...

Page 24: ...ed or Compressor damage may occur 12 1 10 How to know there is problem with compressor motor It is easy to find out motor problem by checking the resistance of coil The method is to connect the terminals of common and run using ohm meter the coil resistance can then be determined Using terminals common and start can measure the resistance of starting coil If the value is infinite the coil must be ...

Page 25: ...ood stuffs in the freezer too much door opens too frequent and open time too long 4 The environment temperature is too high humidity too high airflow is impeded 5 The frost layer at the evaporator is too thick 6 The refrigerant is insufficient or leakage 7 Compressor efficiency is reduced 8 The drying filter is blocked 1 Adjust and make it close to evaporator cover 2 Change the temperature control...

Page 26: ...l refrigerant again 2 Clean the capillary or change filter Frost at evaporator is not full 1 There is some leakage of refrigerant 2 There is dirt block but not serious 3 Refrigeration quantity of compressor is reduced 1 Check leakage make welding repair and fill refrigerant again 2Clean the capillary and filter 3 Change compressor Evaporator frosts too rapid frost layer too thick or frozen to ice ...

Page 27: ...ot been mounted to position or changed during transportation Mount it again 12 1 12 Procedure for fan change 1 Switch off power and open the fan protection cover 2 Remove the fan bolts by using fork wrench or universal tool 3 Loose the fan blade and take it out 4 Take the fan out from the space between compressor and tubes 5 Mount new fan from the space between the compressor and tubes put blade o...

Page 28: ...he contact of plug and socket is not well or the voltage is too low The knob of temperature controller is set to off position 2 In side factors Electrical problem of freezer normally caused by connection terminals coming off or not in good contact Temperature controller out of order contact point are burned or switch element is damaged etc The start capacitor is bad MAINTENANCE SERVICE AND TROUBLE...

Page 29: ...onnection state for a long time and cannot be released in time at normal situation the motor starting coil will cut off in about 1s after starting This will make the coil temperature rising rapidly and then the thermal protection unit cuts off the circuit and stop operation When power is cut off the temperature of thermal protection unit reduces quickly and will switch power on when reaching the r...

Page 30: ... bad The reason is that the insulation around the motor windings bad 12 3 Service and technical requirements of a R134a freezer 12 3 1 Refrigeration equipment requirements The compressor condenser evaporator drying filter must be special for R134a freezer and not be confused 12 3 2 Repair equipment Requirements 1 The evacuation and fill machine is special only for R134a use 2 Other equipment such ...

Page 31: ...akage occurs at low pressure end Check system pressure if the system has no pressure the freezer has to be scrapped and change with new one if there is pressure it is repairable 12 3 4 Changing procedure of R134a compressor 1 Switch power off Open the protection cover by using cross screwdriver or universal 2 Screwdriver 3 Remove electrical parts of compressor MAINTENANCE SERVICE AND TROUBLE SHOOT...

Page 32: ...ze to wipe away welding powder and flux 11 Connect the electrical controlling unit of compressor 12 Mount and adjust temperature controller 13 Switch on power for test run check unit operation 12 3 5 Compressor installation and brazing procedures 1 Install new compressor 2 Compressor is not allowed to suck in air directly for check or other test MAINTENANCE SERVICE AND TROUBLE SHOOTING Maintenance...

Page 33: ...uses R134a as the refrigerant which is recognized internationally It has an ozonosphere depletion coefficient ODP 0 New climate type design commercial freezer uses wide temperature zone design At 38 100 F high temperature the freezer can start and stop freely 2 New refrigeration system design it takes dual direction refrigeration system thus increases refrigeration speed and prolongs compressor li...

Page 34: ...w then you can put food in If food is put in too early it may get damaged as the temperature is still high 6 Do not over pack refrigerator 7 Place food by reasonable sorts try to power open door frequency and time so as to reduce the loss of refrigeration and reduce consumption 8 There are four wheels at the bottom of freezer but it can only be used for short distance and on level road movement If...

Page 35: ...le ground connection for the freezer ground line is not allowed to connect to water pipe gas pipe etc 4 Once the freezer is cut off at least 5 minute must be waited for starting again otherwise the compressor or refrigeration system will be damaged 5 Explosive flammable and volatile substance liquid filled glass containers alkalis or corrosive acids are not or be stored in freezer 6 Do not let chi...

Page 36: ...ater or soap water non corrosive neutral detergent is available After cleaning please make it dry by using cloth so as to avoid rust 6 Please clean the condenser compressor in the cabin and dust proof element by using soft brush regularly so as to keep good refrigeration effect Dust proof element 2 3 days 7 Down time If the freezer has extended down time please disconnect power supply and wipe uni...

Page 37: ...f there is any damage 5 Check the power cord if there is any wear or damage please change 6 Take an avometer and check if the resistance of ground resistor is normal 7 Check the insulation by using if it is abnormal please check the circuit and various components 8 If the trademark is damaged or lost please change with new Haier trademark 9 Wipe the inside and outside of freezer clean If freezer w...

Page 38: ...iver 8 Philip screwdriver 9 Needle nose pliers notch pliers sealing pliers 10 Hansen valve 11 Tube cutters 12 5 2 Notice for use R134a filling equipment can only be used specially for R134a refrigerant MAINTENANCE SERVICE AND TROUBLE SHOOTING Maintenance Service and Trouble Shooting 1 It is not allowed to fill R134a by R12 filling equipment PDF created with pdfFactory trial version www pdffactory ...

Page 39: ...uipment until really to proceed 2 Evacuation Connect recovery machine hoses to system fittings Switch on power Switch on motor Open all related valves Observe the pointer of vacuum meter when it is accessing the mark 1 Evacuation time shall not be less than 45 min After evacuation close valves MAINTENANCE SERVICE AND TROUBLE SHOOTING Maintenance Service and Trouble Shooting Switch off motor PDF cr...

Page 40: ...Observe the unit operation Switch off power 12 6 Freezer noise 12 6 1 Freezer noise sources Freezer noise comes from the expanding with heat and contracting with cold of compressor evaporator or condenser from the contacting or resonance of pipes from the flowing of refrigerant or from the vibration of freezer because the floor is not level etc MAINTENANCE SERVICE AND TROUBLE SHOOTING Maintenance ...

Page 41: ...ake sound The continuous buzz we heard is this kind of sound 2 When compressor is produced there must be clearance between components When freezer is running the existing of clearance will make some components touch and gives out sound Especially at starting and stopping the forces acted on compressor components changes greatly and bigger sound will be generated 3 Noise of flowing liquid The runni...

Page 42: ...netic sound a hermetically sealed motor is relatively small 12 6 3 How is the sound of water flowing generated Answer When liquid refrigerant is flowing especially through the evaporator there will sound like water flowing This sound is different for the evaporator used and assembly technologies during producing are different If there is not this sound at freezer operation and evaporator cannot ma...

Page 43: ...und may occur at the following situations 1 Newly bought freezer the internal stress of materials has not been eliminated With time going on the stress of materials will disappear and it is less possible to make this sound 2 Temperature in the freezer is not uniform just after frost melting 3 When open door and take out food the evaporator feels hot suddenly 4 Temperature changes greatly of conden...

Page 44: ...ressor cannot be started or noise will increase after starting and the wear of crankshaft will increase too It is better that freezer doesn t stop use Sometimes newly bought freezer also has this characteristic After a period operation it will get normal 12 6 8 How to reduce freezer s noise At present all kinds of freezers have the problem of noise Scientists have been seeking a method to solve it...

Page 45: ...r freezer noise is made in national standard GB8059 1 87 family use freezer with the volume below 250L noise 52 dB A sound power level The noise at offices we stay everyday or other public places is much higher than this freezer noise 12 6 11 Why freezer noise measured at home is incorrect Answer Because at home there is not the environment conditions for freezer noise measuring and the value meas...

Page 46: ...ard is the sound power level Under the measuring conditions stipulated in national standard measure the freezer noise at four points take the average of indicated reading at greater noise situation calculate the arithmetic average value of the four points This value is the average sound pressure level of noise the calculation formula is Lw LPA 2 10LgS where LW sound power level dB LPA average soun...

Page 47: ...her and so their noises are different Even for same type freezers as the noise of compressors are different their differences to national standard 52dB A are not the same and the noises are different 12 6 14 Why there are greater noises at starting and stopping of freezer Answer 1 At the starting of freezer starting relay will make sound The acceleration of motor will cause vibration of compressor...

Page 48: ...the previous reasons freezer makes sound at starting and stopping 12 6 15 Why sometimes noise at far distance is greater than at near distance Answer Because the transfer of freezer noise has relations with freezer position room space etc The sound wave giving out at freezer operation will reflect when it touches wall or furniture So it is possible that at a far distance it is noisier than near di...

Page 49: ...e of sound power level of freezer with the volume 250L and below measuring according to the stipulations in item 6 3 6 1 will not greater than 52dB A Sound power level noise of freezing freezer with fan 300L below 55dB A 300 400L including 400L 60dB A 401 500L including 500L 63dB A MAINTENANCE SERVICE AND TROUBLE SHOOTING Maintenance Service and Trouble Shooting 12 7 2 Noise test At the geometrica...

Page 50: ...o measurement point 1 2 3 4 measure the sound level by sound level meter A weighted Take the greater readings and calculate the average value The arithmetic average value of these four points is taken as the average sound pressure level noise According to the testing result sound power level of the freezer being measured can be calculated out LW LPA 2 10LgS Where LW A sound power level dB datum va...

Page 51: ...ulation resistor cool state 5 electrical intensity 6 starting performance 7 ground resistor 8 sealing performance of refrigeration system 9 documents and accessories Spot tests for ex factory are 10 store temperature 11 insulation resistor wet state and hot state 12 electrical intensity wet state and hot state MAINTENANCE SERVICE AND TROUBLE SHOOTING Maintenance Service and Trouble Shooting 13 Ele...

Page 52: ...s set to 0 5g of yearly leakage check every position of refrigeration system Leakage at any point shall not greater than 0 5g Leakage inspection instrument normally used includes H 25 of American GE product and Halogen instrument HLD4000 made by a German company 12 8 2 2 Insulation resistor This test is to check the insulation performance of freezer The resistance is measured with a voltage of 500...

Page 53: ...ument is made in accordance with the stipulations The leakage current measured shall not exceed 1 5mA 12 8 2 6 Noise test This test is carried out at semi sound eliminating room The freezer is put to the geometrical center of room on a 5 10mm thick elastic cushion The freezer should be empty when testing Turn the knob of temperature controller to middle or near to strong position and close the doo...

Page 54: ... the stipulated environment temperature the fluctuation range is 0 5K Within the range of 2m heights away from the test platform the vertical temperature gradient shall not exceed 2K m Table 6 1 Different climate sorts for freezers Climate types Symbols Suitable temperature Measuring temperature Sub temperate zone Temperate zone Sub tropical zone Tropical zone SN N ST T 10 32 16 32 18 38 18 43 25 ...

Page 55: ...tinum resistor There are two types Put the platinum resistor directly into test pack M pack when measuring a Its temperature b Insert the platinum resistor into the center of four tin electroplated copper columns the diameter and height of column is the same 15 2mm The measuring equipment is temperature measuring bridge with the accuracy of 0 3K MAINTENANCE SERVICE AND TROUBLE SHOOTING Maintenance...

Page 56: ...or and let the freezer running continuously Record the time needed for storage temperature tm to reach tm max in accordance with table 13 3 cooling temperature tm to reach 14 and the time the freezing temperature reaches the corresponding star level According to standard 250L below freezer will not exceed 2h 250L 500L freezers will not exceed 3h 8 Freezing ability The freezing ability of freezer s...

Page 57: ... test of storage temperature ice producing ability etc Table 6 3 Storage temperature of freezer Storage Cabin Climate type Climat e type Environme nt temp t1 t2 t3 tm max Cooling cabin Freezing cabin 10 Sub temp erate SN 32 1 t1 t2 t3 10 7 16 Temperat e N 32 0 t1 t2 t3 10 5 8 tcm 14 18 Sub tropical ST 38 18 Tropical T 43 0 t1 t2 t3 12 7 Complies with One star 6 Two stars 12 three stars 18 EXPLODED...

Page 58: ...５７ Marketing model BD 388A 478A Exploded View Edition 2005 12 01 CARTON USER MANAUL LIST OF PARTS Parts list PDF created with pdfFactory trial version www pdffactory com ...

Page 59: ...7 0 007 X BD 388A 1 0 189 0 189 X 12 0070810205 Outer cabinet BD 478A 1 0 189 0 189 X 13 0070201812 Insolution fill cap large BD 388A 478A 1 0 0 X 14 0070800197 Castor BD 388A 478A 6 0 168 0 200 15 0070503876 Use manual BD 388A 478A 1 0 0 X 16 0070401608 power Wire BD 388A 478A 1 0 056 0 056 17 0071150025 Lock nose BD 388A 478A 1 0 0 010 X 18 0077050051 Screw BD 388A 478A 2 0 0 X 19 0070200676 Dra...

Page 60: ...20010 Ground screw BD 388A 478A 4 0 0 X 44 0074090308 Fan BD 388A 478A 1 0 063 0 100 45 0071210004 Engine room cover BD 388A 478A 1 0 0 X 46 0072130038 Screw BD 388A 478A 1 0 0 X 47 0077010036 Screw BD 388A 478A 1 0 0 X 48 0074180001 Filter drier BD 388A 478A 1 0 119 0 200 49 0079020006 Hot shorten tube BD 388A 478A 1 0 0 X 50 0070804041 Condensor BD 388A 478A 1 0 056 0 056 51 0077070006 spring wa...

Page 61: ...the spare parts warehouse and should be marked with 3 possible damaged The spare part which is not often damaged like the easy damaged one and the customer may stock in the spare part warehouse accord with the actual case should be marked with 4 not need provided The spare part which is seldom damaged or the maintenance man could not maitmains The spare parts may be air freighted by the factory if...