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INSTRUCTION SHEET
! IMPORTANT

FSP
INSTRUCTION SHEET

Part No. 4388020

R12 Conversion to R134a Refrigerant

R134a COMPRESSOR CONVERSION KITS ARE MODEL SPECIFIC AND SHOULD NOT BE USED FOR ANY APPLICATION THAT IS NOT SPECIFIED. MAKE SURE THE CONVERSION KIT HAS BEEN ODERED BY PRODUCT MODEL NUMBER.
This Instruction Sheet provides procedures for converting specific R12 refrigerator sealed systems to R134a. The conversion requires replacing the compressor with an R134a replacement compressor with an oil charge that is tolerant of residual R12. These compressor kits can only be used for conversion of R12 systems and only those that are specified.

GENERAL INFORMATION
INCLUDES: - Most Free Standing Refrigerators with Reciprocating Compressors. - 20 TM Horizontal Rotary Compressor Refrigerators that use a Reciprocating Replacement EXCLUDES: - Undercounter Ice Makers - Built-In Refrigerators - All Freezers - Rotary Compressor Products - R134a Production Refrigerators - Refrigerators with Serial Numbers beginning with * EC - EAD 25 SxS models built in 1976-77 * EF - RT18DK T-M models built in 1994-95 Current sweep charge procedures apply to this sealed system conversion to R134a. Backflushing is only required for contaminated systems. (Same as current sweep procedure). The replacement compressor uses alkyl-benzene oil and will tolerate a minimal amount of chlorine and original compressor oil. It does not have the extreme hydroscopic tendencies of ester oil. Uses less refrigerant in the system (25% less).

SPECIAL LABELING
Three special labels are provided in the compressor kit. Label 1 (Fig. 1): Make sure this label is already afixed to the new conversion replacement compressor just above the weld seam. If it is not, place it there. These labels are specific to the service replacement kit ordered.
This Sealed System Has Been Converted to R134a.
Use the following part numbers to order compressor components. XXXXXXX Compressor Kit XXXXXXX Over load Relay Assembly XXXXXXX Run Capacitor XXXXXXX Drier

R134a charge amount located below Model / Serial label.

XXXXXXX

Fig. 1 Label 2 (Fig. 2): This label is to be afixed to the back of the cabinet just above the compressor compartment access cover. The charge amount must be written on this label. Fig. 2
This Sealed System Has Been Converted to

R134a.
See label on the compressor for electrical component information. Use sweep charge procedures to service the sealed system. This Sealed System has been converted to R134a. The new refrigerant charge is

SERVICE CONSIDERATIONS
It is important not to introduce trace amounts of foreign substances, chemical contamination or moisture into the sealed system. R134a service equipment can be used to convert R12 sealed systems to R134a refrigerant. Use new servicing equipment. Old equipment (hoses, coupler/valve seals and O-rings) are not compatible with R134a. Check service replacement compressor to make sure the stubs seals are in place and not tampered with. Always replace the filter-drier in ALL sealed system repairs.

______ ounces.

4388013

Lable 3 (Fig. 3): This label is to be afixed to the inside of the refrigerator just below the model/serial number plate. The charge amount must be written on this label.
This Sealed System Has Been Converted to R134a. The New Refrigerant Charge is _______ Ounces.
4388014

Fig. 3

INSTRUCTION SHEET 4388020 AUG. 97

PROCEDURES NON-CONTAMINATED SEALED SYSTEM REPAIRS

NOTE: Use separate recovery bags to capture R12 and R134a refrigerants. PURGING PROCEDURE AND REPAIR Diagnose failure. Purge R12 refrigerant from the sealed system. (Fig. 4) (Operating Compressor) 1. Attach temporary access valve to inlet end of filterdrier. 2. Turn compressor ON and purge into Ozone Saver Recovery Bag for 8 minutes. (Fig. 4) (Non-Operating Compressor) 1. Attach temporary access valve to inlet end of filterdrier. 2. Install additional temporary access valve on low-side of system (compressor or suction line process stub). Purge refrigerant into Ozone Saver Recovery Bag for 15 minutes. (Fig. 4) 3. Heat compressor during entire purge. 4. Sharply wrap with mallet several times after heating and purging for 12 minutes. 5. Continue heating and purging for 3 more minutes. 6. Remove temporary access valve(s). 7. Perform repairs. 8. Replace filter-drier. 9. Replace the compressor. 10. Leak check, sweep and recharge the system with R134a. (See Leak Checking, Sweeping and Charging below.) Second Hose for Non-Operating Systems

CONTAMINATED SEALED SYSTEM REPAIRS

NOTE: Use separate recovery bags to capture R12 and R134a refrigerants. COMPRESSOR BURN OUT 1. Purge R12 refrigerant from the system. (Fig. 4) 2. Backflush the high-side of the system with R134a refrigerant. (Refer to backflushing the high side-page 3.) 3. Replace the filter-drier. 4. Replace the compressor. 5. Leak check, sweep and recharge the system with R134a refrigerant. (See Leak Checking, Sweeping and Charging below.) LOW-SIDE LEAKS/EXCESSIVE MOISTURE 1. Heat the evaporator for 5 minutes before purging refrigerant. 2. Purge R12 refrigerant from the system. (Fig. 4) 3. Repair the leak. 4. Backflush the high-side of the system with R134a refrigerant. (See page 3.) 5. Replace the filter-drier. 6. Replace the compressor. 7. Leak check, sweep and recharge the system with R134a. (See Leak Checking, Sweeping and Charging below.) RESTRICTION IN THE SYSTEM 1. Purge R12 refrigerant from the system. (Fig. 4) 2. Determine location of restriction and repair if possible. a. If restriction is in capillary tube inlet, cut 1 to 2 off of tube. Then go to step 3. b. If restriction is beyond the inlet to the capillary tube and the heat exchanger is accessible, replace the heat exchanger. Then go to step 3. c. If the restriction is beyond the inlet to the capillary tube and the heat exchanger is not accessible, the unit is not repairable. 3. Backflush the high-side of the system with R134a refrigerant. (See page 3) 4. Replace the filter-drier. 5. Replace the compressor. 6. Leak check, sweep and recharge the system with R134a. (See Leak Checking, Sweeping and Charging below.)

REPLACING THE COMPRESSOR

PURGING EQUIPMENT AND HOOKUP Fig. 4 NOTE: Never open replacement compressor stubs to the air any longer than necessary. 1 . Carefully inspect rubber plugs in the service replacement compressor stubs. If the plug appears to have been removed or tampered with, DO NOT USE THE COMPRESSOR. Get another one. 2. Clean compressor stubs with plugs still in them. 3. Install into system last.

INSTRUCTION SHEET 4388020 AUG. 97

LEAK CHECKING, SWEEPING & CHARGING

1. Warm refrigerant tank or charging cylinder. 2. Charge with 4 oz. of R134a refrigerant into access valve at replacement filter-drier or condenser inlet. (Fig. 5) 3. Leak check system with bubble solution. 4. Run compressor for 3 minutes to sweep system. 5. Check evaporator for frost pattern. 6. Purge refrigerant into a different Ozone Saver Recovery Bag for 5 minutes. (Fig. 4) 7. Leave compressor running and charge system with new specified charge. (75% of R12 system charge.) (Fig. 5) 8. Remove charging hose/valve. 9. Securely tighten the cap on the access valve.

BACKFLUSHING THE HIGH-SIDE

Servicer has the choice of backflushing the entire high-side of the system or the condenser and heat loop separately. (Use no more than 20 oz. of R134a refrigerant for each backflush.) Use a charging scale or charging cylinder to monitor the required amount of refrigerant. Backflush highside or components in reverse direction from normal flow of refrigerant. Use R134a ONLY to backflush system. Do not overfill the recovery bag during backflushing. Put no more than 20 oz. of R134a in an Ozone Saver Recovery Bag. Use a separate recovery bag to capture R134a refrigerant used for backflushing.

COMPRESSOR REPLACEMENT KIT PARTS LIST Quantity 1 1 1 1 4 4 1 1 1 1 1 1 1 Description Compressor Overload/Relay Asy Cover, Terminal Run Capacitor Grommets Sleeves Drier Capacitor Wire Label Label Label Instruction Sheet Instruction Sheet

CHARGING EQUIPMENT AND HOOKUP

Fig. 5 10. Check for heat at the condenser inlet.

PLACING LABELS AFTER SERVICING UNIT

Label 1 (Fig. 1): Make sure this label is already afixed to the new conversion replacement compressor just above the weld seam. If it is not, place it there. These labels are specific to the service replacement kit ordered. Label 2 (Fig. 2): This label is to be afixed to the back of the cabinet just above the compressor compartment access cover. The charge amount must be written on this label. Lable 3 (Fig. 3): This label is to be afixed to the inside of the refrigerator just below the model/serial number plate. The charge amount must be written on this label.

USING THE CONVERSION CHARTS

Scales that measure only in (.25) or (.5) ounce increments - charge the system to the next highest quantity of R134a. EXAMPLE: Chart Reads: R12 3.5 oz. R134a 2.6 oz.

Scales reading in (.25) oz. increments - Charge system with 2 (2.75) ounces of R134a. Scales reading in (.5) oz. increments - Charge system with 3 ounces of R134a.

INSTRUCTION SHEET 4388020 AUG. 97

CONVERSION CHARTS
These charts show the conversion values from the original R12 charge to the new R134a charge. The conversion is determined by multiplying the R12 charge value by .75 (R12 charge x .75 = R134a charge). Chart 1: R12 ounces to R134a ounces. REFRIGERANT CHARGE CONVERSION TABLE IN OUNCES R12 R134a R12 R134a R12 R134a R12 R134a R12 R134a R12 R134a R12 R134a
3.0 3.1 3.2 3.25 3.3 3.4 3.5 3.6 3.7 3.75 3.8 3.9 4.0 4.1 4.2 4.25 4.3 4.4 4.5 4.6 4.7 4.75 4.8 4.9 2.3 2.3 2.4 2.4 2.5 2.5 2.6 2.7 2.8 2.8 2.9 2.9 3.0 3.1 3.2 3.2 3.2 3.3 3.4 3.4 3.5 3.6 3.6 3.7 5.0 5.1 5.2 5.25 5.3 5.4 5.5 5.6 5.7 5.75 5.8 5.9 6.0 6.1 6.2 6.25 6.3 6.4 6.5 6.6 6.7 6.75 6.8 6.9 3.8 3.8 3.9 3.9 4.0 4.0 4.1 4.2 4.3 4.3 4.4 4.4 4.5 4.6 4.7 4.7 4.7 4.8 4.9 5.0 5.0 5.0 5.1 5.2 7.0 7.1 7.2 7.25 7.3 7.4 7.5 7.6 7.7 7.75 7.8 7.9 8.0 8.1 8.2 8.25 8.3 8.4 8.5 8.6 8.7 8.75 8.8 8.9 5.3 5.3 5.4 5.4 5.5 5.6 5.6 5.7 5.8 5.8 5.9 5.9 6.0 6.0 6.1 6.2 6.2 6.3 6.4 6.5 6.5 6.6 6.6 6.7 9.0 9.1 9.2 9.25 9.3 9.4 9.5 9.6 9.7 9.75 9.8 9.9 10.0 10.1 10.2 10.25 10.3 10.4 10.5 10.6 10.7 10.75 10.8 10.9 6.8 6.8 6.9 6.9 7.0 7.0 7.1 7.2 7.3 7.3 7.4 7.4 7.5 7.6 7.7 7.7 7.7 7.8 7.9 8.0 8.0 8.1 8.1 8.2 11.0 11.1 11.2 11.25 11.3 11.4 11.5 11.6 11.7 11.75 11.8 11.9 12.0 12.1 12.2 12.25 12.3 12.4 12.5 12.6 12.7 12.75 12.8 12.9 8.3 8.3 8.4 8.4 8.5 8.6 8.6 8.7 8.8 8.8 8.9 8.9 9.0 9.1 9.2 9.2 9.2 9.3 9.4 9.5 9.5 9.6 9.6 9.7 13.0 13.1 13.2 13.25 13.3 13.4 13.5 13.6 13.7 13.75 13.8 13.9 14.0 14.1 14.2 14.25 14.3 14.4 14.5 14.6 14.7 14.75 14.8 14.9 9.8 9.8 9.9 9.9 10.0 10.0 10.1 10.2 10.3 10.3 10.4 10.4 10.5 10.6 10.7 10.7 10.7 10.8 10.9 11.0 11.0 11.1 11.1 11.2 15.0 15.1 15.2 15.25 15.3 15.4 15.5 15.6 15.7 15.75 15.8 15.9 16.0 16.1 16.2 16.25 16.3 16.4 16.5 16.6 16.7 16.75 16.8 16.9 11.3 11.3 11.4 11.4 11.5 11.6 11.6 11.7 11.8 11.8 11.9 11.9 12.0 12.1 12.2 12.2 12.2 12.3 12.4 12.5 12.5 12.6 12.6 12.7

Chart 2: R12 ounces to R134a Kg. REFRIGERANT CHARGE CONVERSION TABLE IN KILOGRAMS R12 R134a R12 R134a R12 R134a R12 R134a R12 R134a R12 R134a R12 R134a
3.0 3.1 3.2 3.25 3.3 3.4 3.5 3.6 3.7 3.75 3.8 3.9 4.0 4.1 4.2 4.25 4.3 4.4 4.5 4.6 4.7 4.75 4.8 4.9 0.06 0.07 0.07 0.07 0.07 0.07 0.07 0.08 0.08 0.08 0.08 0.08 0.09 0.09 0.09 0.09 0.09 0.09 0.10 0.10 0.10 0.10 0.10 0.10 5.0 5.1 5.2 5.25 5.3 5.4 5.5 5.6 5.7 5.75 5.8 5.9 6.0 6.1 6.2 6.25 6.3 6.4 6.5 6.6 6.7 6.75 6.8 6.9 0.11 0.11 0.11 0.11 0.11 0.12 0.12 0.12 0.12 0.12 0.12 0.13 0.13 0.13 0.13 0.13 0.13 0.14 0.14 0.14 0.14 0.14 0.15 0.15 7.0 7.1 7.2 7.25 7.3 7.4 7.5 7.6 7.7 7.75 7.8 7.9 8.0 8.1 8.2 8.25 8.3 8.4 8.5 8.6 8.7 8.75 8.8 8.9 0.15 0.15 0.15 0.15 0.16 0.16 0.16 0.16 0.16 0.17 0.17 0.17 0.17 0.17 0.17 0.18 0.18 0.18 0.18 0.18 0.19 0.19 0.19 0.19 9.0 9.1 9.2 9.25 9.3 9.4 9.5 9.6 9.7 9.75 9.8 9.9 10.0 10.1 10.2 10.25 10.3 10.4 10.5 10.6 10.7 10.75 10.8 10.9 0.19 0.19 0.20 0.20 0.20 0.20 0.20 0.20 0.21 0.21 0.21 0.21 0.21 0.22 0.22 0.22 0.22 0.22 0.22 0.23 0.23 0.23 0.23 0.23 11.0 11.1 11.2 11.25 11.3 11.4 11.5 11.6 11.7 11.75 11.8 11.9 12.0 12.1 12.2 12.25 12.3 12.4 12.5 12.6 12.7 12.75 12.8 12.9 0.23 0.24 0.24 0.24 0.24 0.24 0.25 0.25 0.25 0.250 0.25 0.25 0.26 0.26 0.26 0.26 0.26 0.26 0.27 0.27 0.27 0.27 0.27 0.27 13.0 13.1 13.2 13.25 13.3 13.4 13.5 13.6 13.7 13.75 13.8 13.9 14.0 14.1 14.2 14.25 14.3 14.4 14.5 14.6 14.7 14.75 14.8 14.9 0.28 0.28 0.28 0.28 0.28 0.29 0.29 0.29 0.29 0.29 0.29 0.30 0.30 0.30 0.30 0.30 0.30 0.31 0.31 0.31 0.31 0.31 0.32 0.32 15.0 15.1 15.2 15.25 15.3 15.4 15.5 15.6 15.7 15.75 15.8 15.9 16.0 16.1 16.2 16.25 16.3 16.4 16.5 16.6 16.7 16.75 16.8 16.9 0.32 0.32 0.32 0.32 0.33 0.33 0.33 0.33 0.33 0.34 0.34 0.34 0.34 0.34 0.34 0.35 0.35 0.35 0.35 0.35 0.36 0.36 0.36 0.36

INFORMATION ON SWEEP CHARGE PROCEDURE FOR SEALED SYSTEM REPAIR Sweep Charge Procedure for the 90s To order call: 800-851-4605 Job Aid 4321717 Video 4321718
INSTRUCTION SHEET 4388020 AUG. 97