Challenges for Low Temperature Refrigeration .....................................

2
Function of a Cascade Refrigeration System ................................................................... 3
Sanyo Refrigeration System Cutaway.............................................................................. 5
Sanyo Ultra Low Freezer Electrical System Operation..................................................... 6
Electrical and Electronic Component Access ................................................................... 8
Control Panel (MDF U4086S and MDF U5086W) ............................................................ 8
Control Panel (MDF U3086S & MDF U5186S) ................................................................ 9
Main Control Board (MDF U6086S,MDF U50V and MDF U70)V ................................... 11
Function Modes .......................................................................................................... 14
Entering Function Mode.............................................................................................. 14
Initiating a Defrost Cycle ................................................................................................ 15
Control Board Switch Functions and Operation (all other ultra low models)................... 15
Voltage Test Points on the Microboard....................................................................... 16
TEMPERATURE CALIBRATION PROCEDURES...................................................... 16
Thermocouples............................................................................................................... 17
Self Diagnostic Functions............................................................................................... 18
Error codes ................................................................................................................. 18
DEFROST TIMING......................................................................................................... 18
CAPILLARY TUBE HEATER SPECIFICATIONS........................................................... 19
HEAT EXCHANGER TEMPERATURE CONTROL POINTS ......................................... 19
MDF-U4086S ................................................................................................. 20
Sensor Specifications..................................................................................................... 20
PT100Ω Temperature Sensor. ................................................................................... 20
502AT Thermistor Sensor........................................................................................... 20
TROUBLESHOOTING GUIDE....................................................................... 21
PROCEDURE FOR TESTING FOR A REFRIGERANT LEAK ......................23
Leak Suspected in System?........................................................................... 25
TESTING FOR DIFFICULT TO LOCATE LEAKS ON THE LOW STAGE ..................... 26
PARTS REPLACEMENT WHEN A REFRIGERATION REPAIR IS PERFORMED ....... 31
Procedure When All Refrigerant Has Escaped .............................................................. 33
PROPER EVACUATION METHODS............................................................. 33
HIGH STAGE EVACUATION PROCEDURE ................................................................. 33
LOW STAGE EVACUATION PROCEDURE .................................................................. 34
Replacement of Low Stage Compressor........................................................................ 34
CHARGING METHODS................................................................................. 35
WEIGHT CHARGING of Low Pressure Refrigerants ..................................................... 35
Removing Refrigerant from Tanks.................................................................................. 37
Charging with High Pressure Refrigerants (2nd Stage) ................................................... 38
Pressure Charging of High Pressure Refrigerants ......................................................... 38
Weight Charging of High Pressure Refrigerants ............................................................ 40
Pentane Charging Procedure......................................................................................... 43
REFRIGERANT AND PENTANE QUANTITY BY MODEL ............................45
MODEL....................................................................................................................... 45
REFRIGERATION CIRCUIT EQUILLIBRIUM PRESSURES.........................46
Heat Exchanger Access and Replacement .................................................................... 47
REFRIGERATION SYSTEM REPAIR OVERVIEW ........................................................................ 48
Challenges for Low Temperature Refrigeration
The now famous Montreal Protocol for the control of Ozone Depleting substances has effected many of us in
one form or another.
The refrigeration industry has been especially affected, since many of the refrigerants available contain ozone
depleting substances such as chlorofluorocarbons (CFC) and hydrochlorofluorocarbons (HCFC). While
refrigerant manufacturers have been hard at work
producing alternatives for the mainstream
refrigeration systems, low temperature refrigeration has not
received quite the same amount of attention, possibly due to
the much smaller market.
Low temperature refrigeration refers to any
mechanical system which cools to temperatures between
–40 and –160 degrees centigrade. Although there are many
needs for temperatures this low, typical applications include
long term storage of rare tissue and organic
substances used in medical research as well as for product
stress testing.

To better understand the effects of the phase

out of the older refrigerants, one must first
understand the basics. Refrigeration is quite
simply defined as a process of removing
heat energy from an area where it isn’t
wanted and transferring it to an area where it
is not objectionable. To accomplish this most
refrigerators rely on the principal that any
liquid will have a specific point at which it will
boil or condense depending upon the
pressure being acted upon it. For example,
at atmospheric pressure water boils (or
absorbs heat energy), at roughly 100
degrees centigrade. Refrigerants are quite
simply, liquids which have a very low boiling
point, most often at temperatures well below
0 degrees C. In a standard refrigeration
system, refrigerants which perform the
cooling need to both boil and condense inside the system. This is performed in part by controlling the pressure of
the refrigerant at various points in the refrigeration cycle. Basically the refrigerant needs to be allowed to
condense into a liquid before it can remove heat from the chamber. Condensing the refrigerant is performed by
subjecting it to a high pressure and removing heat energy by passing it through a cooling medium, this will allow it
to condense into a liquid. The pressure of the liquid is then drastically reduced by passing in through a small
orifice into a larger area, this changes the boiling point, thus the liquid will boil by removing heat from the
surrounding area. In a standard system, this can be accomplished utilizing one refrigeration compressor .The
refrigeration methods used to cool at very low temperature however are usually different than what is normally
found in standard systems. The problem relates to the extremely high pressure needed to get the low temperature
refrigerants to condense into a liquid. Standard refrigeration compressors typically will not be able to perform the
task. To solve this problem, low temperature freezers most often use a method of refrigeration known as
cascading. In a cascade system two ore more compressors are used with different refrigerants in each system.
One stage is used solely to cool the next stage through a heat exchanger. This brings the pressures required
down low enough to allow the refrigerants to be condensed at more reasonable pressures. Unfortunately, this
method will often stress standard refrigeration compressors to the limits of their endurance. When the
conventional refrigerants were phased out, manufacturers of this type of equipment had no choice but to look for
alternatives. Unfortunately, many of the refrigerant options available were very stressful on compressors,
extremely flammable or would drastically reduce the performance of the cooling system.

To address these issues, Sanyo Electric Company in conjunction with ICI Chemical Corportation embarked on
an aggressive program to develop new refrigerants which do not produce harmful effects on the ozone layer,
while still providing long term reliability. To accomplish this many factors needed to be considered which
included the ability of the refrigerants to cool to extremely temperatures and the effect on the components in the
refrigeration system. Compounding this problem is the requirement for any new refrigerants to be used as a
replacement for systems still utilizing the older ozone depleting substances. This factor is especially important
in ultra-low temperature freezers due to the expense of the refrigerants and components involved. If too many
modifications are required to adapt to the new refrigerants, the cost of a change-over or repair could easily
exceed the cost of a new freezer. The result was a new ultra-low temperature refrigerant known as TP5R3,
which received recognition in North America in 1993 and is more commonly known here as R-508. As part of a
cascade refrigeration system, this refrigerant is capable of producing a refrigeration system which will maintain
temperatures below –86 degrees centigrade. R-508 is an HFC refrigerant which is non-flammable, non-toxic
and does not deplete the ozone layer and is expected to be one of the main alternative refrigerants well into the
next century. This refrigerant is currently being used with great success in many commercial products
throughout Canada and has been in use for the last 4 years.
Advancements to refrigeration technology has resulted in Sanyo being awarded the 1995 Stratospheric Ozone
Protection Award from the United States’ Environmental Protection Agency. Although HFC refrigerants are
today considered the solution to our current environmental concerns, more work needs to be done on the new
generation of refrigerants. Although HFC’s do not harm the ozone layer, they do contribute to global warming if
released into the atmosphere. Currently Sanyo is working on new technologies which utilize newly developed
hydrogen absorbing alloys which allow hydrogen to be used as a refrigerant. By continually developing new
techniques for refrigeration instead of depending on the old methods, we can help to protect our planet for
future generations.

Function of a Cascade Refrigeration System

The cascade refrigeration system is a unit consisting of two independent refrigeration circuits connected
through a heat exchanger. Following is a schematic diagram of a basic cascade system.
The system, where the heat exchanger serves as an evaporator, is called the high stage refrigeration system.
The other side, where the heat exchanger serves as a condenser is called the low stage refrigeration system.
In the operation of this system, the low stage is the refrigeration system that actually removes the heat
energy from the freezer chamber. This heat energy is transferred through the heat exchanger to the high
stage. It is then transferred to the ambient through the hi-stage condenser along with the other heat loads
created by friction and the heat of compression for both stages.
A cascade refrigeration system is required because the compression ratio required to allow the low stage
refrigerants to evaporate at very low temperatures and re condense at near ambient temperatures would
require a compressor which would not be practical.
By allowing the refrigerants in the low stage to condense at temperatures well below zero degrees through
the heat exchanger, the compression ratio created is well within the capable range of Sanyo's compressors
designed for ultra-low applications.
Capillary tubes are chosen as metering devices for their reliability at very low temperatures. The oil separator
is used on the low stage to remove as much oil as possible from the refrigerant before it is exposed to the low
temperature portion of the system. This is done to reduce the risk of blocking the metering device at the
extremely low temperatures at which these systems operate.
Sanyo Refrigeration System Cutaway
Component Layout – Chest Freezers
Sanyo Ultra Low Freezer Electrical System Operation

Most Sanyo ultra-low freezers are operated by one main control board. Currently , there are two main
board in use in existing freezers which are described later in this chapter. Although the boards are
vastly different in their designs, they both perform the same function of controlling the refrigeration
system to keep the freezer at set temperature.

The control board is designed to cycle the low stage compressor on demand for cooling. Before it can
do this however, the heat exchanger temperature (evaporator of the high stage) must be at the proper
temperature to avoid undue stress on the low stage compressor. All boards also incorporate a so
called ‘defrost’ feature to ensure that the freezer has an off cycle where the capillary tubes are heated
to remove any possible restrictions that may have built up over time.

In looking at the diagram below:

When the heat exchanger cools down below -34 degrees centigrade, the temperature control board will apply
voltage to the temperature control relay. This will in turn apply power to the low stage compressor. The low stage
compressor will not start until the heat exchanger temperature drops below -34 degrees. This will protect the low
stage compressor from damage should the high stage system fail to cool for any reason. See page 44 and 45 for
specifics on monitoring and adjusting the heat exchanger temperature if required.
Electrical and Electronic Component Access

Access to refrigeration starting and electrical components is accessed by removing the four screws on the left
side panel on the compressor compartment.

To remove the front grill to access the condenser filter, remove the 2 thumb screws on the right side of the
front panel.

The micro control board is located behind the left control panel cover. To access the screws holding this panel,
the right front grill panel must be removed first.

Control Panel (MDF U4086S and MDF U5086W)

Alarm Lamp (and Buzzer)

The alarm lamp and buzzer will operate in the following instances:
a) If freezer temperature in the chamber rises 10 degrees above setpoint, the alarm lamp will light, If the
problem has not been corrected, the buzzer will sound 10 minutes later.
b) In the event of a power failure, both the lamp and the buzzer will activate immediately.
c) When the outer door is open, the lamp will light. If the door remains open for more than 30
seconds, the buzzer will sound.

C02 Back-up Lamp

This light will come on when the optional C02 back-up system is in operation. The back-up system is used to
maintain freezer temperature in the event of a failure.
Filter Check Lamp
This lamp will light when the condenser filter is clogged. The filter should be cleaned immediately to avoid
reduced freezer performance. See maintenance section for details.

Buzzer Key
When pressed, this switch will silence the audible alarm for several minutes, if the abnormality which caused
the alarm to sound has not been corrected, the audible alarm will automatically sound again.

Alarm Test Key

If the freezer is operating within its normal set parameters, pressing this button will test the proper operation of
the audible and visual alarms.

Temperature Setting Key

Pressing this button will toggle between PV and SV
PV present temperature in cabinet is displayed
SV setpoint is displayed. At this point using the Figure Shift, Digit Shift and Enter Keys will allow setting of
the desired set point.

Digit Shift Key

Pressing this switch when in temperature set mode will cause the flashing digit to increment. Using this key
and the Digit Switch (41 in conjunction is the process used to adjust the setpoint. Once this has been done,
pressing the Set Switch (3) will lock this value into memory.
Figure Shift Key
Pressing this switch when in temperature set mode will cause the flashing digit in the digital display 20 shift to
the next number to allow the setpoint to be changed.

Entry Key
Pressing this switch momentarily after the desired set point temperature has been set will store
the point in memory. This point will be maintained even in the event of a power failure.

Control Panel (MDF U3086S & MDF U5186S)

(1) Temperature Setting Key

Pressing this button will toggle between PV and SV
PV present temperature in cabinet is displayed
SV setpoint is displayed. At this point using the Figure Shift, Digit Shift and Enter Keys will allow setting of
the desired set point.

(2) Digit Shift Key

Pressing this switch when in temperature set mode will cause the flashing digit to increment. Using this key
and the Digit Switch (4) in conjunction is the process used to adjust the setpoint. Once this has been done,
pressing the Set Switch (3) will lock this value into memory.
(3) Figure Shift Key
Pressing this switch when in temperature set mode will cause the flashing digit in the digital display to shift to
the next number to allow the setpoint to be changed.

(4) Entry Key

Pressing this switch momentarily after the desired set point temperature has been set will store the point in
memory. This point will be maintained even in the event of a power failure.

(5) Alarm Test Key

If the freezer is operating within its normal set parameters, pressing this button will test the proper operation
of the audible and visual alarms.

(6) Buzzer Key

When pressed, this switch will silence the audible alarm for several minutes, if the abnormality which caused
the alarm to sound has not been corrected, the audible alarm will automatically sound again.

(7) Alarm Lamp (and Buzzer)

The alarm lamp and buzzer will operate in the following instances:
a) If freezer temperature in the chamber rises 10 degrees above setpoint, the alarm lamp will light. If the
problem has not been corrected, the buzzer will sound 10 minutes later.
b) In the event of a power failure, both the lamp and the buzzer will activate immediately.
c) When the outer door is open, the lamp will light. If the door remains open for more than 30
seconds, the buzzer will sound.

(8) Filter Check Lamp

This lamp will light when the condenser filter is clogged. The filter should be cleaned immediately to avoid
reduced freezer performance. See maintenance section for details.
Control Panel (MDF U6086S, MDF U70V, MDF U71V, MDF U50V)

Function of Keys

Buzzer Key (BUZZER) To stop the alarm from sounding, press this key. Should a further
abnormality occur, the buzzer will sound automatically.

Alarm Test Key (ALARM TEST) Check that the alarm lamp and the buzzer functional when the
deep freezer is operating well.

AIarm Set Key (ALARM SET) A key for setting alarm temperature. Pressing this key leads the
setting mode for high and low temperature alarm. Set a desired temperature by
using the shift key, and then press the set key. (see page 12)
Set Key (SET) Temperature setting mode will be led by pressing this key. The changeable digit
will be flashed. Press this key again after setting desired temperature, and temperature
setting will be stored.

Digit Shift Key ( H ) Pressing this key in the setting mode will cause the changeable digits to
move. Key lock will be caused by pressing this key when in the temperature
display mode. As for details, see page 11 "Key lock Function'

Numerical Value Shift Key Pressing this key in the setting mode will cause the numerical value
to move. ONOFF" of key lock can be selected by pressing this key
when in the Key Lock mode

Digital Temperature Indicator (TEMPERATURE (°C)) This indicator shows the present
temperature or setting temperature.

Filter Check Lamp (FILTER) This lamp lights when the condenser filter is clogged. Clean the
condenser filter.

Alarm Lamp (ALARM) This lamp will be flashed when the internal temperature will be
exceeded the alarm setting temperature, or at the time of power failure.

Setting the High and Low Alarm Points

1) High/Low alarm temperature setting
1. Press ALARM SET key 5 seconds continuously when normal mode.
2.1t turns to the high alarm temp. mode.- lOC is ready set (high alarm temp).
3. Using → and  keys set the desired temp.- (The range:5 to 20C).
4. Press SET key (stored the high temp.) The display will then turn to the low alarm temp.mode
5. Using → and  keys , set the desired temp. .- (The range:5 to 20C).
6. Press SET kev (high/'low alarm temps. are set) to return to normal mode.
Main Control Board (MDF U6086S,MDF U50V and MDF U70V)

Battery,6VDC

VR1

VR2 VR1

VR1 Used to allow adjustment of displayed temperature vs. chamber

temperature. Calibrate using a NIST1 traceable thermometer located
adjacent to chamber probe.

VR2 Used to adjust the duration of the defrost ‘ON’ cycle. During defrost the
low stage compressor will be off and the capillary heaters will energize.
VR3 Used to adjust the temperature cut-in point where the low
stage compressor will start. Not adjusted under normal circumstances.

1
National Institute of Standards and Technology
13
Function Modes

The control boards used on the MDF-U6086S, MDF U70V, MDF U71V and the MDF U50V
can be calibrated and adjusted utilizing function modes. Function modes are adjusted via
the front panel and provide other useful purposes such as testing for proper operation and
making adjustments.

Entering Function Mode

1.Press the ‘SET’ key on the front panel to get into set mode.
2. Press and hold the ‘ALARM SET’ key for about 5 seconds
3. ‘FO’ should appear in the display
4. use the ‘UP” key to get into the function mode required.

F1- line test mode used at the factory only.

F2- used to change the status of the capillary heater during defrost
O=normal position, cap tube heaters come on during defrost
1= default position. Cap tube heaters will not come on.

F3- used to set the duration of time that the cap heaters will come on during
defrost. The range is between 0 and 10. The minimum duration is 6 minutes (0).
The maximum is 16 minutes (10). Each increment from zero represents 1 extra
minute. (i.e. A setting of 5 is a defrost of 11 minutes, 6+5=11). The adjustment is
made by adjusting pot VR2 on the control board while watching the display.

F4- zero adjustment of the display temperature. The range is between 00 and 60.
00 means that 3º will be added to the displayed temperature
60 means 3º will be subtracted from the display temperature
The preset value is 30 (neutral), set at the factory. The adjustment is made by
adjusting pot VR1 on the control board while watching the display.
i.e. The displayed temperature is –80º. The actual temperature is –82º. Make the
indicator read 50 while in F4 mode to add 2 degrees to the calibration.

F5- Transformer secondary voltage. Factory test.

F6- Displays chambers temperature in 1/10 of a degree. Used for fine calibration.

F7- Display the present temperature of the Heat Exchanger.

F8- factory only. Do not use

F9- factory only. Do Not Use.

VR3 – used to adjust the temperature span when the freezer is at set temperature
14
 Initiating a Defrost Cycle

A defrost cycle can be used to clear a possible restriction in a capillary tube. This should
be done before any refrigeration gauges are connected to the system.

1. Go into function mode.

2. Go to Function mode 2 (F2) , This mode is used to change the state of the capillary
heater. When you initially go into this mode, the display should read ‘0’, indicating a
normal defrost will take place. Change this to zero by using the ‘up arrow’ key on
the control panel. Then press ‘set’. You will have disabled the capillary tube cycle.

3. Go back into function mode ‘F2’, but this time change the ‘1’ back to a ‘0’and press
‘set’. When you do this, you will be setting the capillary heater back to default mode.
When this happens, the freezer should automatically go into a defrost cycle
immediately.

Control Board Switch Functions and Operation (all other ultra low models)

SW2- Press this switch to display the present temperature of the cascade condenser. 1. (This is
required when making adjustments using VR-3 described on the following page).

SW3- Not Used

SW4- Press this switch to display chamber temperature in 0.1 degree increments on the front
panel L.E.D. temperature display.

SW5- Toggle this switch 'on' and then 'off' again to force the freezer into a defrost cycle. LED 1
will light indicating that the capillary tube heaters have been activated, and the low stage
compressor will turn off. Each time this switch is toggled, the defrost cycle will be extended
the equivalent of one defrost cycle time period.

SW6- Used for factory inspection, drives freezer to its coldest point. This
switch MUST be off under normal circumstances.

SW7- Model and Mode Setting Switch. This switch is used to allow the control board to adjust to
different models of freezers.
The switch is also used to tell the freezer whether there is
liquid CO2 back-up system connected to the freezer.

Important Note
Switch number 3 on SW7 MUST be switched to the on position if a
back-up system is installed on freezers using this type of control
board. Failure to do this will prevent the back-up system from
operating when it is called upon.

15
Voltage Test Points on the Microboard

This microboard has 5 different test points. When diagnosing problems with the microboard, use these test
points to aid in diagnosis of discrete component failure. All voltages are in DC values.

Items at test point Measuring points. Standard.

Output voltage of bridge. T P 2 and T P 3 1 3. 5 ± 1. 0 V
Driver IC output. T P 4 and T P 3 5. 0 ± 1. 0 V
ROM positive voltage. T P 5 and T P 3 5. 0 ± 1. 0 V
IC positive voltage. T P 6 and T P 3 8. 5 ± 1. 0 V
IC negative voltage. T P 7 and T P 3 - 8. 5 ± 1. 0 V

TEMPERATURE CALIBRATION PROCEDURES

16
Refer to the circuit board layout diagram on the previous page for location of the trim pots
refereed to in the following chart.

Adjustments are only required when there is a difference between the actual measured
temperature in the chamber and the temperature displayed on the unit's control panel.

Temperature readings for calibration purposes should be taken using a N.I.S.T. traceable
thermometer, and should be taken from the center of the freezer chamber. The
temperature inside the freezer must be allowed to stabilize before adjustments can be
made accurately.

Improper adjustments could result in reduced performance.

Variable Resistor Function Procedure

VR1 Zero Adjustment Once the freezer has stabilized at

the setpoint temperature, Adjust
VR1 to make the display agree with
the internal chamber temperature.

VR2 Span Adjustment Adjust the span when the freezer is

at room temperature only. Adjust
VR2 to make the digital display
agree with the internal chamber
temperature

VR3 Cascade Sensor VR3 is used to perform calibration

on the cascade condenser sensor.
Calibration should be done in
conjunction with SW2 on the
control board (SW2 when pressed
indicates the cascade condenser
sensor temperature. This can be
calibrated against the HX sensor
on the back of the freezer.

Thermocouples

Sanyo upright and chest freezers contain thermocouples to aid in diagnosis of refrigeration
problems.

It is important to remember that all Sanyo freezer employ T-Type thermocouples.

17
Using a temperature meter that does not read t-type thermocouple probes will cause
erroneous reading which could lead to misdiagnosis of a potential problem.

L EVA OUT – indicates the outlet temperature of the low stage evaporator.

H EVA OUT – indicates the temperature of the high stage evaporator.

The following table provides test data on a typical freezer in a 30ºC ambient with no load
in the freezer.

Lowest Temperature -80 setpoint controlled

H EVA Out L EVA Out H EVA Out L EVA Out
-32.2ºC -90.3ºC -22.5ºC to –46.5ºC -48.5º C to –77.8 ºC

Self Diagnostic Functions

Error codes

Error codes are in indication of a probe failure and will cause a freezer alarm. The
temperature display will indicate the error code which has occurred.

Error code. Cause. Safety operatron.

E1 Temperature sensor abnormality. Compressor runs alarm will
In case the temperature sensor continuously. Remote alarm will
goes open or short circuit. be activated
E2 Filter sensor abnormality. Remote alarm will be
Filter sensor has gone open or shorted activated.
E3 Cascade sensor abnormality. Remote alarm will be
Cascade sensor has gone open or activated.
shorted

DEFROST TIMING
The following information specifies the timing for each model's 'defrost' cycle.

18
ON TIME- means that the freezer has entered a defrost cycle. During this cycle, the low
stage compressor will turn off and power will be supplied to the capillary tube
heaters.

OFF TIME- means that the freezer is allowed to operate under normal control.

All timing functions are electronic and located on the main temperature control board.

MODEL ON TIME OFF TIME

MDF-U3086S 8 minutes 12.0 hours
MDF-U4086S 8 minutes 17.5 hours
MDF-U5086W 8 minutes 17.5 hours
MDF-U5186S 8 minutes 17.5 hours
MDF U6086S
MDF U70V
MDF U50V

CAPILLARY TUBE HEATER SPECIFICATIONS

The capillary tube heater is used to heat the end of the low stage capillary tube during the 'defrost'
cycle. It can only be accessed by removing the heat exchanger access panel at the rear of the
freezer. If it is found necessary to test the operation of the heaters, the electrical leads to the
heaters can be accessed from the control board for testing resistance and operation. Individual
specifications are given for each heater on the table below, but in most cases, two or more heaters
are used connected in parallel. Therefore composite or total vales are also given for the purposes
of testing the circuit from the control board. Keep in mind that heater resistance with respect to
ground should always be approaching infinite for a properly operating heater.
For all freezer models, the composite resistance of each heater is 833Ω. The total
resistance where the capillary heaters plug into the control board is 416.5Ω due to the fact
that the heaters are connected in parallel.

HEAT EXCHANGER TEMPERATURE CONTROL POINTS

When the temperature controller calls for cooling, the low stage compressor is not permitted to come on unless the heat
exchanger temperature is within a set temperature range. Initially, the low stage compressor will not start until the 'ON
POINT' temperature is reached. Once the low stage compressor is running, it will continue to remain on unless the 'OFF
POINT' temperature is reached, or the temperature controller shuts down the compressor indicating that setpoint
temperature has been reached.

MODEL ON POINT OFF POINT

MDF-U3086S -34 degrees centigrade -18 degrees centigrade

19
 MDF-U4086S -34 degrees centigrade -12 degrees centigrade
MDF-U5086W -34 degrees centigrade -12 degrees centigrade
MDF-U5186S -34 degrees centigrade -12 degrees centigrade

MDF U6086S -32 degrees centigrade -12 degrees centigrade

MDF U70V -32 degrees centigrade -12 degrees centigrade

MDF U50V -32 degrees centigrade -12 degrees centigrade

Sensor Specifications

PT100Ω Temperature Sensor.

This sensor is used as the main chamber temperature sensor in most sanyou Ultra-Low
freezers

ºC Ω ºC Ω ºC Ω ºC Ω
-160 35. 79 -110 56. 19 -60 76. 33 -10 96. 09
-150 39. 82 -100 60. 25 -50 80. 31 0 100. 0
-140 43. 87 -90 64. 30 -40 84. 27 10 103. 9
-130 48. 00 -80 68. 33 -30 88. 22 20 107. 8
-120 52. 11 -70 72. 33 -20 92. 16 30 116. 7

502AT Thermistor Sensor

This sensor is used as the main heat exchanger sensor connected to the main control
board. It is also used as the high stage condenser sensor which is also connected to the
control board and is used to control the ‘ Check Filter’ light on the main display.
The check filter light is designed to illuminate at about 48ºC.

ºC KΩ ºC KΩ ºC KΩ ºC KΩ
-50 154. 5 -36 71. 80 -22 3S. 65 0 13. 29
-49 145. 9 -35 68. 15 -21 33. 99 5 10. 80
-48 137. 8 -34 64. 71 -20 32. 43 10 8. 84
-47 130. 2 -33 61. 48 -19 30. 92 15 7. 20

20
 -46 123. 1 -32 58. 43 -18 29. S0 20 6. 0 1
-45 116. 5 -31 55. 55 -17 28. 14 25 S. 00
-44 110. 2 -30 52. 84 -16 26. 87 30 4. 17
-43 104. 4 -29 50. 23 -15 25. 65 35 3. S0
-42 98. 87 -28 47. 77 -14 24. 51 40 2. 96
-41 93. 70 -27 45. 45 -13 23. 42 45 2. 51
-40 88. 85 -26 43. 26 -12 22. 39 50 2. 13
-39 84. 18 -25 41. 19 -11 21. 41 SS 1. 82
-38 79. 80 -24 39. 24 -10 20. 48 60 1. 56
-37 75. 67 -23 37. 39 -5 16. 43 65 1. 35

Troubleshooting Guide

The following information is to be used as a guide in troubleshooting the system if a problem

occurs. Actual servicing of the unit should be performed by a qualified service person only.

FREEZER APPEARS TO BE COMPLETELY INOPERATIVE. DIGITAL DISPLAY IS

BLANK FREEZER IS SILENT.

Possible Cause: -power cord is disconnected

-circuit breaker or fuse supplying power to unit has tripped. Ensure that
no other equipment is connected to the same circuit.

CHAMBER TEMPERATURE FLUCTUATES SUBSTANTIALLY FROM SETPOINT.

COMPRESSORS AND FANS ARE OPERATING.

Possible Cause: -Dirty condenser filter or other obstruction of air flow through
compressor area. Clean filter or remove obstruction.
-Too much warm product has been put in the freezer at one time.
-Chamber door has been open for an extended period of time, or door s
not sealing properly against the gasket.
-Temperature controller requires calibration. See pages 43 to 46.
-Chamber Access Stopper is missing (located on side of freezer).
-Refrigeration System is malfunctioning. (See troubleshooting problems
11 & 121.
-Oil Logging due to overload. (see troubleshooting problem 11 &12).

CHAMBER TEMPERATURE FLUCTUATES SUBSTANTIALLY FROM SETPOINT. LOW STAGE

COMPRESSOR IS CYCLING ON THERMAL OVERLOAD.

Possible Cause: -Defective thermal overload on compressor.

-Low voltage supply to freezer. Should be within 10% of freezer
voltage rating under load.
-High Stage malfunction. See problem number 11 .

CHAMBER NOT COOLING DOWN. BOTH HIGH AND LOW STAGE COMPRESSORS ARE RUNNING.

21
Possible Cause: - Low stage malfunction. See problem number 12.

CHAMBER NOT COOLING. LOW STAGE COMPRESSOR NOT RUNNING.COMPRESSOR IS COOL.

COMPRESSOR NOT RECEIVING POWER.

Possible Cause: - Thermal overload on low stage compressor is open.

- Defective temp control relay. See electrical diagram.
- Controller is defective or not sending out signal. See electrical diagram.
- Defective compressor start relay.
- Defective timer circuit. (included on main control board).
- Poor cooling in high stage refrigeration system. (see # 111

CHAMBER NOT COOLING. LOW STAGE COMPRESSOR NOT RUNNING. COMPRESS ISWARM.
COMPRESSOR RECEIVING POWER.

Possible Cause: -Low stage compressor start relay is defective.

-Low stage start capacitor is defective.
-Low stage compressor has a locked rotor. Check current draw by
compressor.
-Low voltage to freezer. Voltage should be within 10% of rated voltage
for freezer under load conditions.
-Poor cooling in high stage refrigeration system. (see #11)

CHAMBER NOT COOLING. BOTH COMPRESSORS NOT RUNNING. HIGH STAGE

COMPRESSOR IS WARM. HIGH STAGE COMPRESSOR CYCLING ON THERMAL
OVERLOAD.

Possible Cause: -High stage compressor start relay is defective.

-High stage compressor start capacitor is defective.
-High stage compressor has a locked rotor. Check current draw by
compressor.
-Low voltage to freezer. Voltage should be within 10% of rated voltage
for freezer under load conditions.

CHAMBER NOT COOLING. BOTH COMPRESSORS AND CONDENSER FAN NOT

OPERATING. BOTH COMPRESSORS ARE COOL. DIGITAL DISPLAY IS ON.

Possible Cause: -No power to freezer.

-Defective temperature controller.
-Defective start relay for compressor(s).

FREEZER IS NOISY

Possible Cause: -Condenser fan blade is loose or bent.

-Loose bolts or screws on refrigeration compartment area.
-Refrigeration tubing in contact with compressor, frame or other tubing.

ERROR CODE OF "E01" OR "E02" ON DIGITAL DISPLAY

Possible Cause: -Temperature sensor or cascade sensor are open or short circuit.

HIGH STAGE REFRIGERATION SYSTEM NOT FUNCTIONING

22
Possible Cause: -Refrigerant charge either too high or too low.
-Moisture is present in the refrigeration system.
-There is a refrigerant leak in the system. Without the low stage
operating, the cascade condenser should drop below -35 degrees
centigrade.
-Capillary tube is blocked or plugged, can be caused by low charge.
-High stage compressor or starting components are defective.
-Non-condensable gases (air, nitrogen etc..) are present in the refrigeration
system.
-The air cooled condenser is dirty.

LOW STAGE REFRIGERATION SYSTEM NOT FUNCTIONING

Possible Cause: -Refrigerant or Pentane charge is either too high or too low.
-Moisture is present in the refrigeration system.
-Capillary tube is blocked or plugged. This can be caused by low
refrigerant charge.
-Defective oil separator or capillary tube heater open circuit or not
receiving power from control board.
-Non-condensable (air, nitrogen etc..) are present in the refrigeration
system.
-High stage refrigeration system is not functioning. See problem 11 .

PROCEDURE FOR TESTING FOR A REFRIGERANT LEAK

HIGH STAGE

The high stage system is charged with either R-412A or R-407D. The usual symptoms for a loss of
refrigerant in the high stage include the inability of the heat exchanger to remove heat from the second
stage system. If symptoms indicate a loss of refrigerant, look for signs of oil around the accessible
refrigerant tubing. A large refrigerant leak will sometimes leave refrigerant oil residue at the location
where the leak occurred. Recover any remaining refrigerant from the high stage system, and
pressurize the system using an inert gas such as dry nitrogen. Do not allow the pressure to exceed
285 psi.

After pressurizing the system, remove the refrigeration gauges. Often a leak can occur at the service
valve access port, and connecting refrigeration gauges will eliminate the source of the leak. Use soap
bubbles to locate the source of the leak. It may be necessary to remove the heat exchanger cover and
insulation from the back of the freezer to access the remaining components if the leak cannot be easily
found. Use a mirror to check any points in the system which is not easily visible.

After the leak is repaired, it will be necessary to test for leaks again. You cannot assume that there will be
only one leak in the system.

LOW STAGE

The low stage system is charged with R-508. This refrigerant will not be picked up easily with an
electronic leak detector. If the symptoms indicate a leak, it will be necessary to recover the existing

23
refrigerant and pressurize the refrigeration system with dry nitrogen. Do not allow the pressure to
exceed 285 psi.

After pressurizing the system, remove the refrigeration gauges. Often a leak can occur at the service valve
access port, and connecting refrigeration gauges will eliminate the source of the leak. Use soap bubbles to
locate the source of the leak. It may be necessary to remove the heat exchanger cover and insulation from
the back of the freezer to access the remaining components if the leak cannot be easily found. Use a mirror
to check any points in the system which is not easily visible.

If the leak cannot be found, it will be necessary to divide the refrigeration piping into 4 parts, then
connecting a pressure gauge to each part, and pressurizing with dry nitrogen after pulling a vacuum on
each section. (Details follow later in this section).

After the leak is repaired, it will be necessary to test for leaks again. You cannot assume that there will be
only one leak in the system.

24
Leak Suspected in System?

Measure the resistance of the capillary

Tube heaters. Are they accurate?
(see electrical section)

Replace Replace
Capillary tube Capillary heater

25
TESTING FOR DIFFICULT TO LOCATE LEAKS ON THE LOW STAGE

1. If it has been determined that a gas leak is present and leak test procedures laid out
on the previous have been followed and leak cannot be located, recover the
remaining refrigerant.

2. Divide the refrigeration into three parts. Refer to figures 1 to 4 on the following pages
on where to make the cuts. Perform the tests one section at a time to avoid
unnecessary work.

3. Connect service access fittings to each part.

4. Pull a vacuum on each section to remove any gas that could cause errors in the
following procedures. Some gases under pressure will mix with refrigerant oil and
cause the appearance of a leak when in fact, none exists.

5. Put a pressure gauge on each section, and pressurize with dry nitrogen to a pressure
not to exceed 285 psi. If using refrigeration gauges, it is recommended that the
standard colored hoses not be used. Many of these hoses will leak through the walls
of the hose under high pressure. On a small refrigeration system, this could cause the
appearance of a leak, where none exists. Special high pressure hoses, copper or
braided stainless hoses are recommended for this procedure.

6. Disconnect supply of nitrogen and note the pressure indicated on the gauge.
Leave for 1 day, and note if there is a pressure drop on the gauges. If a drop is noted,
re-test this section of the refrigeration system for signs of leakage.

NOTES:

- do not make cuts at existing braze joints. Make cuts at portions where rebrazing after
a repair will be easiest.

- After leak has been located, repeat leakage test before reconnecting the system. After
refrigeration system has been reconnected, the entire system must be leak tested
again to insure integrity.

26
Figure 1

Refrigeration Circuit Diagram

Divide the refrigeration system into portions as per the diagram below.

27
Figure 2

Refrigeration Circuit Diagram

Divide the refrigeration system into portions as per the diagram below.

28
Figure 3

Refrigeration Circuit Diagram

Divide the refrigeration system into portions as per the diagram below.

29
Figure 4

Refrigeration Circuit Diagram

Divide the refrigeration system into portions as per the diagram below

30
PARTS REPLACEMENT WHEN A REFRIGERATION REPAIR IS
PERFORMED

The following chart will provide an indication of which parts should be repaired dependant upon the
diagnosis of the problem with the refrigeration system.

Both an acid test and an oil color test of the refrigerant oil should be performed whenever there is a
failure of the compressor for whatever reason. Acid test kits are available from your refrigeration
wholesaler. After taking a sample of the oil, compare it to the color chart on the following page to
determine its acceptance before proceeding to the acid test mixing procedure. A positive indication
on either test requires that the refrigeration system be flushed.

31
32
Procedure When All Refrigerant Has Escaped

A leak in the suction side of the refrigeration system where the gas has completely escaped can
allow ambient air and moisture to enter the refrigeration system. This will have a detrimental effect on
the refrigerant oil and the long term reliability on the refrigeration system. It is therefore
recommended that all components containing refrigerant oil as well as the filter/drier be replaced
whenever this condition occurs.

When all repairs have been completed and the refrigeration system has been recharged, the system
should be started up and operated for 24 hours to ensure that the freezer reaches setpoint
temperature. At this point the freezer should be turned off and allowed to warm up to room
temperature. The freezer should be restarted once again and tested to ensure that it reaches setpoint
temperature. Ideally this procedure should be repeated for a period of one week.

PROPER EVACUATION METHODS

The following procedure outlines the proper method of performing a vacuum evacuation on
the components for the high stage and low stage refrigeration systems. Failure to follow this
procedure may lead to equipment failure due to the fact that non-condensable and moisture
may be left in the system following repair.

HIGH STAGE EVACUATION PROCEDURE

MODEL METHOD OF EVACUATION VACUUM

MDF-U3086S 2 point. Suction and discharge sides 200 mT

MDF-U4086S 2 point. Suction and discharge sides 200 mT

MDF-U5086W 2 point. Suction and discharge sides 200 mT

MDF-U61 86S 2 point. Suction and discharge sides 200 mT

MDF U50V 2 point. Suction and discharge sides 200 mT

MDF U70V 2 point. Suction and discharge sides 200 mT

MDF U71V 2 point. Suction and discharge sides 200 mT

IMPORTANT NOTE: Vacuum must be pulled on the high stage refrigeration system for a
period of no less than three (3) hours regardless of the vacuum level. This will ensure the
effective removal of non condensables.

33
LOW STAGE EVACUATION PROCEDURE

MODEL METHOD OF EVACUATION VACUUM

MDF-U2086S 3 point. 1 on discharge, 2 on suction 200 mT

MDF-U3086S 2 point. 1 on discharge, 1 on suction.' 200 mT

MDF-U4086S 3 point. 1 on discharge, 2 on suction. 200 mT
MDF-U5086S 3 point. 1 on discharge, 2 on suction. 200 mT

MDF-U5186S 3 point. 1 on discharge, 2 on suction. 200 mT

MDF U6086S 3 point 1 on discharge, 2 on suction. 200 mT
MDF U50V 3 point 1 on discharge, 2 on suction. 200 mT
MDF U70V 3 point 1 on discharge, 2 on suction. 200 mT
MDF U71V 3 point 1 on discharge, 2 on suction. 200 mT

Vacuum must be pulled on the low stage refrigeration system for a period of no less
than three (3) hours regardless of the Vacuum level. This will ensure the effective
removal of non-condensibles.

• Model MDF U3086S employs a sealed in-line expansion tank which does not require a
separate evacuation point.

Replacement of Low Stage Compressor

When replacing the low stage compressor, it is important to note that the refrigerant from
both the high and low stages must be removed. This is due to the fact that the high stage
refrigerant loops through the oil cooling loop in the low stage compressor.

34
Failure to remove the low stage refrigerant when removing the low stage compressor can
result in future high stage system failure.

CHARGING METHODS

WEIGHT CHARGING of Low Pressure Refrigerants

R134a, R-412a, R-407D and R-509

This method of charging works best with small charging tanks. An example of the charging tank is
pictured below. Although freezers can be charged directly from the main refrigerant cylinders, the
difference between the weight of the tank and the weight of the refrigerant charge required is often
large dependant upon the size of the supply tank. Therefore, measuring the charge accurately with
standard refrigeration scales is often difficult and can cause an over or under charge in the system.

The system pictured below utilizes two shut off valves with standard refrigeration access valves on
the end.

1. Connect a vacuum pump on VS2 of the small charging tank, connect VS1 to the
refrigerant cylinder containing the refrigerant you will be charging with. Ensuring that
all connections are air tight, open VS1 and VS2 and pull a vacuum for a minimum of
5 minutes, and close VS2.

2. Weigh the empty small charging tank on the refrigeration scales. Use scales which are
capable of accurately measuring to +/- 1.0g.

3. Weigh the refrigerant into the small charging tank at the specified weight of the unit

35
 to be charged, +/- 5 g. ( example: if the small tank weighs 5OOg and the charge
required on the unit to be repaired is 490g, charge the cylinder to 990 g). Charge by
opening the valve on the main tank, when the desired amount of refrigerant has been
metered into the small tank, close the main tank valve and then close VS1.

4. Connect the small charging tank to the manifold gauge (see fig. 1)

5. Open MV1, MV2, MV3 and MV4.

Evacuate the high stage refrigeration system for more than 1 hour. Close MV3 when
the evacuation is finished before turning off the vacuum pump.

36
6. Close MV1 and open VS2 on the small charging tank and slowly charge refrigerant to
the high stage refrigeration system by opening MV4 and charging through the suction
side.
Caution: Do not open VS1.

7. When no more refrigerant will flow into the system, run the high stage compressor to
pull in the rest of the remaining refrigerant. It may be necessary to heat up the small
charging tank to force out the rest of the remaining refrigerant.

8. When all of the refrigerant has entered the system, close MV4, MV2 and VS2.

9. Weigh the small charging cylinder again, if the weight is not the same as the cylinder
weighed when it was empty, some refrigerant remains in the tank. Reconnect the tank
to the manifold, evacuate the hoses and manifold with the vacuum pump and charge
the remaining refrigerant.

10. Pinch off the process stubs and braze shut, or close the access valves, whichever
applies. Always test for leaks on the process stubs or valves after closing.

Removing Refrigerant from Tanks

R-412A

R-412A is a non-azeotropic refrigerant. This

characteristic means that the combined
refrigerants will partially boil out of at different
temperatures. Therefore it is important to ensure
that only liquid is drawn from the cylinder for
charging purposes to ensure the correct
refrigerant mix.

The cylinders used for R-412A contain siphon

tubes to ensure that liquid is drawn during the
charging process. It is important to ensure that
the cylinder is NOT inverted while charging. The
siphon tube does not reach all the way to the
bottom of the cylinder. Therefore it is important
that only 90% of the total weight of the cylinder
be used during charging.

37
Charging with High Pressure Refrigerants (2nd Stage)

There are two methods of charging the low or 2nd stage refrigeration system. The system can
be charged by weight or pressure. When charging by pressure, it is important that the ambient
room temperature in the location where the freezer is being repaired is stable. Either method
will produce satisfactory results.

Pressure Charging of High Pressure Refrigerants

R-508

This method of charging is used to charge the low stage refrigeration system using R-508. The
diagram below assumes that the refrigerant will be metered into the refrigeration system using a
pressure method. To perform this procedure properly, the unit being repaired must be at a stable
ambient temperature.

Following the diagram pictured below, connect the components needed to evacuate and charge the
low stage refrigeration system. The pentane cylinder must be charged in advance with n-pentane with
the volume specific to the system being recharged. As mentioned previously, the Sanyo low stage
refrigeration systems require 3-point evacuation.
The connection points are:
1- Process tube on low stage compressor. (suction side).
2- Service valve on the expansion tank. (suction side).
3- Process tube on outlet pipe of the oil separator. (discharge side). Install a brazed access
valve at this point. The high pressures reached when the compressor is running during
testing are too high for a process tube adapter.

38
Vacuum Procedure

1. Open all valves on the 4-way refrigeration manifold fully and evacuate the refrigeration
system to 200 millitorres. Ensure that the vacuum will hold at 200 millitorres by closing
the shut off valve to the vacuum pump. Once the proper vacuum has been obtained,
close MV3.

Charging Procedure

2. Charge the system with n-pentane first by opening valve VS2 on the pentane cylinder.
Once the pentane has been pulled into the refrigeration system, close VS2.
NOTES: It is important to charge with pentane first since pressures created by the
refrigerant would make it difficult to allow the pentane to flow into the refrigeration
system.
It is important that the hose connecting the pentane cylinder to the t-connection not
form a u-trap which could trap some of the pentane.

3. Determine the charging pressure for the R-508 by referring to the table: 'CONVERSION
TABLE FOR TEMPERATURE-PRESSURE OF R-508'
This table provides specific charging information by model number at different ambient
temperatures. Please note that it is very important that the freezer temperature be at
ambient for proper charging to occur.

4. Open MV2 and slowly charge the refrigeration system from the R-508 supply through
MV4. As the proper charge pressure is approached, close MV2 and watch the pressures
39
 on the gauges GL and GH. When the pressures on both gauges equalize, slowly meter
refrigerant into the system in small amounts by opening MV2. Allow to equalize, and
continue to perform this process until proper charge pressure has been obtained. Allow
system pressures to stabilize for a minimum of 5 minutes before proceeding.

5. Start up the freezer to pull in any refrigerants remaining in the lines. Monitor temperatures
and pressures to ensure that the freezer operates to proper pressure and temperature
specifications.

6. Once proper operation of the freezer has been assured, pinch off and cut process tube
connections. Braze the ends dosed as well. Close service valve to the expansion tank.
Ensure that the valve and the process stubs are leak free.

Weight Charging of High Pressure Refrigerants

R-508

This method of charging is used to charge the low stage refrigeration system using R-508. The
diagram below assumes that the refrigerant will be metered to a smaller tank that is refillable and is
certified to withstand pressures above 1150psi. Barring this, the main cylinder can be weighed and the
refrigerant can be charged into the system directly.

1. As in the procedure for charging the high stage, pull a vacuum on the small pressure
vessel, for at least 5 minutes.

2. Charge the R-508 into the smaller cylinder to the specified weight for the unit being
repaired +/- 5 grams. The refrigerant should be weighed in as per FIG. 2. Connect the
two tanks using a looped capillary tube fixed to a stand so that movements will not
affect the weight registered on the digital scale.

40
3. Ensuring that there is no air in the capillary tube, open the valve on the main R-508
cylinder and adjust the pressure regulator to a secondary pressure of 30 to 40 psi.

4. Open the valve on the smaller tank, and slowly charge it to the desired volume. Adjust
the pressure gauge secondary pressure to obtain the desired weight in the secondary
tank. Once the weight has been achieved, close the main valve on both tanks, starting
with the main tank.

5. Connect the small charging tank to the manifold gauge (see fig. 3).

6. Open MV1, MV2. MV3 and MV4.

Evacuate the low stage refrigeration system to below 500 millitorres. Close MV3 when
the evacuation is finished before turning off the vacuum pump.

7. Close MV 1 and charge the system first with n-pentane first by opening valve VP on the
pentane cylinder and opening MV4 to charge through the suction side. Once the
pentane has been pulled into the refrigeration system, close VP.
NOTE: It is important to charge with the pentane first since pressures created by the
refrigerant would make it difficult to allow the pentane to flow into the refrigeration
system. It is also important that the hose connecting the pentane cylinder to the t
connector not form a u-trap which could trap some of the refrigerant.
41
8. Open the valve on the small charging tank and slowly charge refrigerant to the low
stage refrigeration system through the suction side.( A pressure regulator should be
used here as well to charge the system.

9. When no more refrigerant will flow into the system, run the low stage compressor to
pull in the rest of the remaining refrigerant. It may be necessary to heat up the small
charging tank to force out the rest of the remaining refrigerant.

10. When all the refrigerant has entered the system, close MV4, MV2 and the tank valve.

11. Weigh the small charging cylinder again, if the weight is not the same as the cylinder weighed
when it was empty, some refrigerant remains in the tank. Reconnect the tank to the manifold,
evacuate the hoses and manifold with the vacuum pump and charge the remaining refrigerant.

12. Pinch off the process stubs and braze shut, or close the access valves,
whichever applies. Always test for leaks on the process stubs or valves after closing.

42
 CONVERSION TABLE FOR TEMPERATURE VS. PRESSURE FOR R-508

MDF-292
76 MDF-392
MDF-492
71 MDF-592
PRESSURE (psia)

MDF-792
66
MDF-U3086S
MDF-U4086S
61
MDF-U5086W

56 MDF-U5186S
MDF-U6086S
51 MDF-U70v

46
0 5 10 15 20 25 30 35
M D F-292 54 56.1 58.4 60.4 62.5 64.6 66.7 69
58 59.9 62 64.1 66.2 68.3 70.4 72.5 TEMP. (C)
M D F-392
M D F-492 55.3 57.9 60.5 63.1 65.5 68.2 70.7 73.1
M D F-592 57.5 60.1 62.7 65.3 67.9 70.5 73.1 75.7
M D F-792 58.5 61.1 63.7 66.3 68.9 71.5 74.1 76.4
M D F-U 3086S 54.8 56.8 58.9 60.9 63 65.1 67.2 69.3
M D F-U 4086S 50.5 53 55.5 58 60.5 63 65.5 68
M D F-U 5086W 49.7 52.6 55.5 58.4 61.3 64.4 67.3 69.8
M D F-U 5186S 47.7 49.5 51.1 53 54.7 56.5 58.3 60

Pentane Charging Procedure

This method of charging works best with a medium sized mist infuser so that it can be used several times
without purging or recharging, yet is small enough to allow for accurate charging. An example of the mist
infuser used as a charging cylinder is pictured below.

The system pictured below utilizes two shut off valves with standard refrigeration access fittings on the VS2
and VS1 valves.

1. Referring to the diagram pictured below. Connect a vacuum pump on VS2 of the small charging
cylinder through a refrigeration manifold. Connect VS1 to a fresh dryer. Ensure that all connections
are air tight.

43
When charging with pentane, keep exposure to the atmosphere as short as possible. Any moisture
that has been absorbed by the pentane must be removed with a dryer during the charging process.
PENTANE IS FLAMMABLE AND VOLATILE. DO NOT HANDLE AT TEMPERATURES ABOVE
30 DEGREES CENTIGRADE. USE IN A WELL VENTILATED AREA NOT NEAR OPEN
FLAMES.

1. Make sure that the mist infuser is held in the upright position and that the line
connected to the vacuum pump is connected to the top of the mist infuser to avoid
pulling liquid pentane into the vacuum pump.

2. Note the amount of pentane required for the unit being recharged on the chart on page
72.

3. Insert the flexible hose into the bottle of n-Pentane. Start the vacuum pump and open
MV3,MV4,VS1 and VS2 in this order. The pentane will begin being pulled into the mist
infuser through the drier. Regulate the flow of pentane using VS1 and VS2 until the
proper level has been obtained in the mist infuser. Close VS2,VS1,MV4 and MV3 and
shut off the vacuum pump.

4. Follow the Low Stage Charging procedure to meter the pentane into the refrigeration
system.

44
 REFRIGERANT AND PENTANE QUANTITY BY MODEL

HIGH LOW STAGE

STAGE PENTANE2
MODEL
R-508A g cc3 Mm4
R-412A (g)
MDF-292 200 185 26 43 50
MDF-392 300 205 29 48 55
MDF-492 630 305 47 78 90
MDF-592 505 340 50 83 95
MDF-792 520 345 50 83 95
MDF-U3086S 325 210 29 48 55
MDF-U4086S 410 245 35 55 65
MDF-U5086W 505 250 35 55 65
MDF-U5186S 550 245 35 55 65

MODEL HIGH STAGE HIGH STAGE LOW STAGE LOW STAGE

R-407D (g) PENTANE1 (g) R-508A (g) PENTANE1 (g)
MDF U6086S 446 29 255 35
MDF-U70V 508 32 290 41
MDF U71V 5455 35 290 41
MDF U50V 447 28 255 36

2
Recommend HPLC Grade of Pentane
3
1cc is equivalent to 1ml of measure
4
This column is used if the Sanyo Custom Charging Cylinder is used which is available from Sanyo Scientific.

5
Some older designs may show 508g on the serial number plate, correct charge for this model is 545g.
45
 REFRIGERATION CIRCUIT EQUILLIBRIUM PRESSURES

MODEL HI STAGE CHARGE LOW STAGE LOW STAGE LOW STAGE

REFRIGERANT AMOUNT REFRIGERANT CHARGE STATIC
(g) (g) (PSIG)

MDF-192 MU-519 MIX 463 -- -- --

MDF-293 R-407D 301 R-508 185 67.2
MDF-392 R-412A 300 R-508 205 65.8
MDF-492 R-412A 630 R-508 305 71.4
MDF-592 R-412A 505 R-508 340 72.8
MDF-792 R-412A 520 R-508 345 74.2
MDF-0400 MU440 MIX 809 -- -- --
MDF-0830 R-412A 580 R-508 320 61.2
MDF-U281 MU528 MIX 790 -- -- --
MDF-382 R-412A 325 R-508 210 67.2
MDF-U481 R-412A 410 R-508 245 65.8
MDF-U581 R-412A 485 R-508 270 70
MDF-U2086S MU528 MIX 790 -- -- --
MDF-U3086S R-412A 325 R-508 210 67.2
MDF-U4086S R-412A 410 R-508 245 65.8
MDF-U5086W R-412A 505 R-508 250 61.0
MDF-U5186S R-412A 550 R-508 245 61
MDF-U6086S R-407D 447 R-508 255 61.6
MDF-U70V R-407D 508 R-508 290 55
MDF U71V R-407D 545 R-508 290 55
MDF-2136 R-412A 675 MU621 770 81.2
MDF-1155 R-412A 540 MU711 843 111.2
MDF-U460B R-412A 400 R-509 240 71.4
MDF-U442 R-134a 277 R-404A 134 78.3
MDF-135 R-509 290 -- -- --
MDF-235 R-509 310 -- -- --
MDF-435 R-509 400 -- -- --
MDF-U332 R-134a 226 -- -- --
MDF-U536 R-412A 275 -- -- --
MDF-U536D R-412A 330 -- -- --
MDF-U0541 R-509 270 -- -- --

46
Heat Exchanger Access and Replacement

The cascade heat exchanger in the Sanyo

freezers is sealed within a foam block which was
formed under pressure. Access to the heat
exchanger is gained by removing the access panel
which is located at the rear of the freezer.

Procedure:

1. Remove all of the screws holding the panel

in place.
2. Cut the silicone seal around the panel with
a knife. Noting that not all units have this
seal on the outside. Some units have the
seal inside the panel.
3. Gently pry off the cover being careful not to
bend.
4. The individual pieces of glass wool
insulation within the compartment are
sealed in plastic. It is recommended that
each piece be numbered as it is removed to
insure that they are eventually replaced in
the proper location.
5. Pull on the foam block slightly to allow
access to the tubing and heaters.
6. Remove the capillary tube heaters and
temperature probe. Cut lines where
required. Use a heat shield to protect the
insulation if unbrazing.
7. Install the new condenser in the reverse
order paying close attention to ensure that
the connections are in the proper location.
8. Attach the capillary heaters and insert the
temperature probe in the hole provided with
heat transfer compound.
9. Insert the glass wool insulation, paying
attention to the proper location of each batt

47
 10. Remove all traces of the old silicone seal from around the panel and back of the
freezer.
11. Replace the access panel with screws and seal with RTV silicone. Ensure that the
seal is complete and air tight. Any leaks can cause a reduction of performance
and eventual failure.

REFRIGERATION SYSTEM REPAIR OVERVIEW

1. Diagnosis of defect in refrigeration system.

2. Recover refrigerant following applicable laws and procedures.

3. Replace gas in system with dry nitrogen. This will help prevent a layer of oxidation from
building up in the refrigeration piping, as well as the carbonization of refrigerant oil
caused by heating during the brazing process.

4. Replace parts, run nitrogen through refrigeration system before brazing.

5. Leak test refrigeration system.

6. Vacuum evacuation. Perform 3 point evacuation. One point on discharge and two
points on suction side of the refrigeration system. (for most models)

7. Charge with refrigerant and sweeping agent where necessary through the suction side.

B. Pinch off and braze closed process tubes. Check for leaks.
OR
Close access valves and seal. Check for leaks. Which ever is applicable.

9. Cooling performance test, and final leak test.

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 Substitute Refrigerant

for

R-508A and R-407D in Ultra-Low Freezer Models

Sanyo would like to announce that the following solutions may help in cases where the
SANYO standard refrigerants is not readily available.

1. For ICI R-508A Used in Low Stage

DuPont R-508B can be used as a substitute refrigerant for SANYO standard

ICI R-508A, in cases where R-508A is not readily available.
The refrigeration and performance properties of ICI R508A is superior since the
makeup of R508A and R508B is not same, but it will not create a problem in the
performance of our freezer.
The amount of DuPont R-508B should be 96% of ICI R-508A by weight.
Models & Charging quantity:
(Model) (R-508B) (n-Pentane)
MDF-U71V 281g 41g
MDF-U70V 281g 41g
MDF-U50V 250g 36g
MDF-U481 235g 35g
MDF-U581 259g 42g
MDF-U3086S 202g 29g
MDF-U4086S 235g 35g
MDF-U5186S 235g 35g
MDF-U5086W 240g 35g
MDF-U6086S 245g 36g
MDF-792 331g 50g
MDF-592 326g 50g
MDF-492(up to S/N.90604919) 293g 47g
MDF-492(after S/N.90604920) 264g 39g
MDF-392 197g 29g
MDF-293 178g 26g
MDF-382 202g 29g

Note : These refrigerant should be charged in the following order:

(1) n-Pentane (2) R-508A. Refer to the Sanyo Service Manuals for specific service
procedures.

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2. For ICI R-407D Refrigerant Used in High Stage.

R-134a and R-410A can be used as a substitute refrigerant for SANYO

standard ICI R-407D, in cases where R-407D is not readily available.
The ratio of R410A and R134a is 30 % by weight of R-410A and 70% by weight
of R-134a.
Models & Charging quantity:
(Model) (R-410A) (R-134a) (n-Pentane) TOTAL
MDF-U50V 134g 312g 29g 475g
MDF-U71V 152g 356g 32g 540g
MDF-U70V 152g 356g 32g 540g
MDF-U6086S 134g 312g 29g 475g
MDF-293 87g 204g 19g 310g

Note-1 : These refrigerant should be charged in the following order;

(1) n-Pentane (2)R-134a (3)R410A

Note-2 : Sanyo standard ICI R-407D is produced under license of Matsushita Electric
Industrial Co., Ltd.. Therefore, the approval of Matsushita Electric Co., Ltd. is
required before blending this refrigerant.

50