Movincool | Classic 18 | Service manual | Movincool Classic 18 Service manual

Movincool Classic 18 Service manual
SERVICE MANUAL
CLASSIC P LU S 1 4
FOREWORD
This manual has been published to service the MovinCool Classic Plus 14. Please use this service manual only
when servicing the Classic Plus 14.
DEFINITION OF TERMS
WARNING: Describes precautions that should be observed in order to prevent injury to the user during
installation or unit operation.
CAUTION: Describes precautions that should be observed in order to prevent damage to the unit or its
components, which may occur during installation or unit operation if sufficient care is not taken.
NOTE: Provides additional information that facilitates installation or unit operation.
GENERAL PRECAUTIONS
WARNINGS:
•
•
•
•
•
All electrical work if necessary, should only be performed by qualified electrical personnel. Repair to
electrical components by non-certified technicians may result in personal injury and/or damage to the
unit. All electrical components replaced must be genuine MovinCool, purchased from an authorized
reseller.
When handling refrigerant, always wear proper eye protection and do not allow the refrigerant to
come in contact with your skin.
Do not expose refrigerant to an open flame.
The proper electrical outlet for MovinCool units must be equipped with a “UL” approved ground-fault
breaker to prevent electrical shock from the unit.
When brazing any tubing, always wear eye protection and work only in a well ventilated area.
i
ii
TABLE OF CONTENTS
FOREWORD ............................................................................................... i
DEFINITION OF TERMS ............................................................................ i
GENERAL PRECAUTIONS ........................................................................ i
TABLE OF CONTENTS ............................................................................ iii
GENERAL DESCRIPTION ......................................................................... 1
CONSTRUCTION, SPECIFICATIONS, & DATA ........................................ 3
REFRIGERANT SYSTEM .......................................................................... 9
ELECTRICAL SYSTEM............................................................................ 13
TROUBLESHOOTING & REPAIR ............................................................ 19
iii
iv
GENERAL DESCRIPTION
CONDENSER
(OUTDOOR UNIT)
Generally speaking, conventional air conditioners cool
the entire enclosed environment. They act as “heat
exchangers”, requiring an interior unit (evaporator) to
blow cool air into the interior and an exterior unit
(condenser) to exhaust exchanged heat to the outdoors. Unlike conventional air conditioners, the
MovinCool Spot Cooling System is a spot cooler
which directs cool air to particular areas or objects.
MovinCool Spot Cooling Systems have the following
features:
EVAPORATOR
(INDOOR UNIT)
Conventional Air Conditioner
Air Flow of MovinCool Spot Cooling System
1
1.
Compact Design
The innovative design of MovinCool has
resulted in one compact unit, replacing the
need for two separate units.
2.
Easy Transportation and Installation
With the whole cooling system built into one
compact unit, MovinCool requires no piping
and can be easily transported and installed.
3.
Energy Conservation
MovinCool is economical because it cools
only the area or objects which need to be
cooled.
GENERAL DESCRIPTION
2
CONSTRUCTION, SPECIFICATIONS & DATA
Cool Air Duct
Exhaust Air Duct
Centrifugal Fan
Capillary Tube
Housing for
Condenser Fan
Condenser
Caster with Brake
Compressor
Drain Switch
Control Box
Caster
Construction of Classic Plus 14
3
CONSTRUCTION, SPECIFICATIONS & DATA
Evaporator Fan
Control Box
Control Panel
Cool Air Ducts
Upper Panel
Fan Motor
Side Panel
Front Panel
Condenser Fan
Air Filter(condenser)
Evaporator
Air Filter
(evaporator)
Capillary Tube
Accumulator
Compressor
Air Filter (condenser)
Drain Tank
Condenser
Power Cord
Casters
Base Panel
Construction Diagram
4
CONSTRUCTION, SPECIFICATIONS & DATA
1.
Basic Construction
The MovinCool Spot Cooling System is
compact in construction because the condenser and the evaporator are enclosed in
one unit. The interior is divided into three
sections. The upper front face is equipped
with the evaporator, while the lower front face
contains the drain tank. The rear section
contains the condenser, the compressor and
the control box.
2.
Air Flow
Air drawn from the right side face passes
through the condenser which extracts the
heat. This hot air is blown out through the
upper exhaust air duct. Air taken in from the
front face is cooled by the evaporator and
then blown through the cool air duct which
can be turned in any direction. All the air
inlets are equipped with filters, while the
exhaust air duct is protected by wire mesh.
3.
Compressor and Fans
The compressor is hermetically sealed. A
two-speed fan motor is used with two centrifugal fans to draw air across the evaporator
and condenser.
4.
Drain Tank
The capacity of the drain tank is 5.0 gallons
(19 liters). The unit is equipped with a "Tank
Full" LED and a device to automatically stop
the operation of the unit when the drain tank
reaches a level of approximately 4.0 gallons
(15 liters).
Air Flow
5
CONSTRUCTION, SPECIFICATIONS & DATA
Rating Conditions
dry bulb ...................................................................................................95 oF (35 oC)
wet bulb .................................................................................................. 83 oF (28.3 oC)
humidity .................................................................................................. (60%)
Specifications
power frequency .....................................................................................60Hz
line voltage ............................................................................................. single phase 115 V
power consumption ................................................................................ 1.41 Kw
current consumption ...............................................................................12.3 Amps
power factor ............................................................................................95%
starting current ....................................................................................... 32A
power wiring ........................................................................................... 14 (3-core) AWG
Cooling Unit
cooling capability .................................................................................... 3,300 Kcal/hr
................................................................................................................ 13,200 BTU/hr
cooling system ....................................................................................... direct expansion
Blower
type of fan ............................................................................................... centrifugal fan
air volume: Evaporator (Hi speed) ......................................................... 470 ft 3/min
Condenser (Hi speed) .......................................................... 882 ft 3/min
motor output ........................................................................................... 0.24 Kw (High)
................................................................................................................ 0.19 Kw (Low)
Compressor
type ........................................................................................................ rotary
output ..................................................................................................... 0.8 Kw
refrigerant type ....................................................................................... R-22
refrigerant capacity ................................................................................. 1.50 lbs (0.68 kg)
Safety Devices
compressor overload relay...................................................................... included
fan motor protector .................................................................................included
anti-freezing thermister ........................................................................... included
full drain tank switch ............................................................................... included
power interruption restart feature ........................................................... included
time delay feature ................................................................................... included
Dimensions & Weight
W x D x H ............................................................................................... 19.4" x 26.5" x 41.5"
............................................................................................................... 493 x 673 x 1054 (mm)
weight .................................................................................................... 165lbs (75kg)
Operating Conditions
inlet air (relative humidity) ...................................................................... 113 oF (45 oC), < 50%
................................................................................................................ 70oF (21.1 oC), > 50%
Control Device
temperature control ................................................................................ included
two speed fan ......................................................................................... included
Specifications
Specifications are subject to change without notice.
6
CONSTRUCTION, SPECIFICATIONS & DATA
26.5
41.5
3.8
37.7
21.1
16.6
12.5
19.4
2.8
Exterior Dimensions
7
20.6
25.6
2.2
CONSTRUCTION, SPECIFICATIONS & DATA
@ 115V
@ 115V
4.0 (15.9)
14 (25.2)
Temperature ˚C (˚F)
Cooling Capability
(x103 kcal/h (BTU/h))
3.6 (14.3)
3.2 (12.7)
12 (21.6)
10 (18.0)
8 (14.4)
2.8 (11.1)
6 (10.8)
2.4 (9.5)
40
50
60
70
Relative Humidity of Inlet Air (%)
Cool Air Temperature Difference Curve
40 (104)
35 (95)
@ 115V
1.7
30 (86)
15
(59)
20
(68)
25
(77)
30
(86)
1.5
Power Consumption (kW)
25 (77)
Wet Bulb Temperature ˚C (˚F)
Cooling Capability Curve
1.3
1.1
0.9
45 (113)
Dry Bulb Temperature ˚C (˚F)
Dry Bulb Temperature ˚C (˚F)
45 (113)
40 (104)
35 (95)
30 (86)
25 (77)
25
(77)
30
(86)
35
(95)
Wet Bulb Temperature ˚C (˚F)
Power Consumption Curve
8
40
(104)
REFRIGERANT SYSTEM
1. The component parts of the refrigerant system include the following:
• Accumulator
• Capillary tube
• Compressor
• Evaporator
• Condenser
These parts are all connected by copper tubing. All the connections have been brazed.
Condenser
Evaporator
Capillary Tube
Compressor
Accumulator
REFRIGERANT
FLOW
CONDENSER
ACCUMULATOR
CAPILLARY
TUBE
FAN
MOTOR
EVAPORATOR
Refrigerant System
9
COMPRESSOR
REFRIGERANT SYSTEM
2.
Compressor
The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in one casing.
A. Compressor Construction
The construction of a rotary type compressor is divided into two mechanisms the drive mechanism (compressor motor)
and the compression mechanism (compressor). When the rotor shaft of the
motor (drive mechanism) turns, the roller
of the compressor (compression mechanism) rotates to compress the refrigerant.
B. Basic Compressor Operation
The roller (compression mechanism) is set
eccentrically with a certain distance given
from the axis of the center of the cylinder.
A spring loaded blade is mounted on the
cylinder. The roller turns to compress the
refrigerant in the space between the
cylinder and eccentrically mounted roller.
The blade is in contact with the roller by
means of spring force. It partitions the
space between the suction side and the
discharge side to keep compressed
refrigerant from returning to the suction
side.
Compressor Operation
There is no suction valve. The discharge
valve is designed not to open until the
pressure of the refrigerant within the
cylinder reaches or exceeds that of the
refrigerant on the discharge side. This
design prevents the backward flow of
discharge gas.
3.
Condenser
The condenser is a heat exchanger with
copper tubes that are covered with thin
aluminum projections called spine fins. Heat
is given off and absorbed by air being pulled
across the condenser fins by the centrifugal
fan and then expelled through the exhaust air
duct.
10
REFRIGERANT SYSTEM
4.
High Temp. / High Press.
Liquid Refrigerant
Capillary Tube
The capillary tube is a long thin tube utilizing
line flow resistance to serve as an expansion
valve. The length and the inner diameter of
the capillary tube are determined by to the
capacity of refrigeration system, operating
conditions, and the amount of refrigerant.
The capillary tube causes the high pressure,
high temperature liquid refrigerant sent from
the condenser to expand rapidly as the
refrigerant is sprayed out through the fixed
orifice in the capillary tube. As a result, the
temperature and state of the refrigerant
become low and mist-like respectively,
causing it to evaporate easily.
Low Temp. / Low Press.
Gas and Liquid Mixture
Capillary Tube
To Compressor
Accumulator
11
5.
Evaporator
The evaporator, like the condenser, is a heat
exchanger covered with spine fins. Heat is
removed from the air being pulled across the
evaporator by the centrifugal fan and the
resulting cool air is expelled through the cool
air ducts.
6.
Accumulator
The accumulator is mounted on the suction
gas piping between the evaporator and the
compressor. The accumulator separates the
liquid refrigerant from the gas refrigerant letting only the gas refrigerant enter the
compressor. The construction of the accumulator is as shown. In the accumulator, suction
gas is led into a vessel having a cylindrical
body, and the gas speed is decreased inside
the vessel. This separates the refrigerant
contained in the gas by the force of gravity
causing it to accumulate at the bottom of the
vessel. This protects the compressor from
possible damage caused by the intake of
liquid refrigerant.
REFRIGERANT SYSTEM
Condenser Inlet Pipe
Evaporator
Inlet Pipe
Compressor
Discharge
Pipe
Capillary Tube
Evaporator
Outlet Pipe
Condenser
Outlet
Pipe
Connecting
Pipe (evaporator
to compressor)
Connecting
Tube (condenser
to capillary tube)
Compressor
Suction Pipe
(insulated)
Refrigerant System Piping
12
ELECTRICAL SYSTEM
AP
THS
RTH
DS
3
G
T R
R1
R2
1
SCP
1
CC
2
2
TB
MC
G
G
1
CF
1
2
L0
0LC
2
MF
HI
J4
IOLF
J8 (AUX1)
AUX2
J5
G
J6
J2
J1
J3
AP
TB
CB
RB
MF
MC
CF
CC
RB
CB
OLC Overload Relay of Compressor
DS
Full Drain Warning Switch
THS Freeze Protection Thermistor
RTH Room Thermistor
SCP Short Circuit Plate
G
Ground
J8 (AUX1) Auxiliary Connector (CPK3)
AUX2 Auxiliary Connector (Not Used)
Attachment Plug
Terminal Block
Control Board
Relay Board
Fan Motor
Compressor Motor
Capacitor for Fan
Capacitor for Compressor
Relay Board
Relay Board Fuse
DIP Switch
Terminal Block
Compressor
Capacitor
Fan Motor
Capacitor
Electrical System and Control Box for Classic Plus 14
13
ELECTRICAL SYSTEM
1.
Basic Operation of Classic Plus 14
Electrical Circuit
There are two basic components used to control the operation of the Classic Plus 14 Electrical System:
•
Control Panel Assembly
•
Control Box
The Control Panel Assembly contains the Control Panel, Control Board (with inputs for the freeze
and room temperature thermistors), drain switch, and a microprocessor.
A. Fan “Only” Mode
Low Fan Mode - When the “Low” Fan Mode button on the control panel is pressed, the microprocessor turns on the button’s LED and activates the Fan “On” Relay (Relay Board), sending line
voltage (115 VAC) to the N.C. (Normally Closed) contacts of the fan “mode” relay. This output is
connected to the J5 terminal (relay board) where the LOW SPEED wire of the fan motor is connected.
High Fan Mode – When the “High” Fan Mode button on the control panel is pressed, the microprocessor turns on the button’s LED and activates both the Fan “On” Relay and Fan “Mode” Relay.
This sends line voltage (115 VAC) from the Fan “On” Relay to the N.O. (Normally Open) contacts of
the Fan “Mode” Relay. This output is connected to the J6 terminal (Relay Board) where the HIGH
SPEED wire of the Fan Motor is connected.
B. Cool Mode - In Addition to Fan “Only” Mode (as described above)
When the Cool On/Off button on the control panel is pressed, the microprocessor turns on the
button’s LED and if the Temperature Set Point is less than the current room temperature, activates
the Compressor Relay (Relay Board). This sends line voltage (115 VAC) to the J4 terminal (Relay
Board) where the wire from pin 2 of the Compressor Overload Relay is connected. Pin 1 of the
Compressor Overload Relay is connected (by wire) to the compressor.
14
ELECTRICAL SYSTEM
2.
Control Box
A. Capacitors
The capacitors are used to temporarily
boost the power output available to the
fan motor and the compressor at start-up.
Relay Board
Relay Board Fuse
DIP Switch
The specifications of each capacitor are
listed below:
Terminal Block
CAPACITOR
APPLICATION
Compressor
Capacitor
Fan Motor
Compressor
Fan Motor
Capacitor
VOLTAGE
RATING
370
370
CAPACITANCE
(µf)
7.5
45
Control Box
B. Relay Board
J9
C
STOP
DIP Switch
Temperature Scale Display Switch
˚C
˚F
Fan Mode Control Switch
STOP
OPERATE
S1
F
OPERATE
The Relay Board receives signals and
outputs from the control board that
contains a microprocessor. The relay
board contains the compressor, fan on
and fan mode (speed) relays. It also
contains a step-down transformer that
converts the line voltage (115 VAC) to 12
volts. This is then converted from AC to
DC and used for relay coil activation. The
12(DC) power is sent to the Control Panel
Assembly where it is further reduced to 5
volts for the system logic.
The relay board also contains the DIPSwitch. The DIP-Switch is used to
change the Fan Mode operation from
Stop to Operate and change the Set Point
temperature display from ˚F to ˚C.
Relay Board
NOTE: The relay board must be serviced as a
complete assembly. It has only one serviceable
component, the fuse.
Relay Board Fuse
(a) Relay Board Fuse
NOTE: The relay board fuse is the only serviceable
component on the relay board assembly.
This fuse provides protection against
damage to the step-down transformer. It
must be replaced with the exact type of
fuse or an equivalent.
Fuse Specifications: 2/10A 250V
CAUTION: Failure to use the exact type of fuse
could result in damage to the unit and/or to components. It will also void the warranty of the unit.
DIP Switch
15
ELECTRICAL SYSTEM
3.
Fan Motor
The fan motor is a single phase, induction
type two-speed motor. The motor rotates
fans on the evaporator side and the condenser side at the same time.
Specifications: Rated Voltage: 115 volts 60 Hz
Rated Output – High – 243 watts
Low – 188 watts
UL Listed File Number – E-49807
Ground
(Green/Yellow)
NOTE: An internal overload relay is used to protect
the fan motor. This relay is built into the fan motor
and will interrupt the flow of current when there is
an overcurrent situation or if abnormally high
temperature builds up in the fan motor.
4.
Fan Motor
Compressor Motor
The compressor motor is a single phase
motor. It is contained within the same housing as the compressor.
Specifications: Rated Voltage 115 volts
Rated Output 800 Watts
5.
Compressor Overload Relay
An external compressor overload relay is used
to protect the compressor motor. This relay is
mounted within the connector housing that
attaches to the top of the compressor. The
relay will interrupt the flow of current when
there is an overload caused by a high temperature condition in the compressor.
Specifications:
Temperature
Variance
Contacts Open
284˚F / 140˚C
± 41˚F / ± 5˚C
Contacts Closed
165˚F / 74˚C
± 48˚F / ± 9˚C
Trip Time
(seconds)
2 – 12
16
CF1 (White)
CF2 (Brown/White)
J5 Low (Red)
J6 High (Black)
ELECTRICAL SYSTEM
6.
Drain Switch
The Classic Plus 14 is equipped with a drain tank switch. When the drain tank accumulates approximately 4.0 gallons (15 liters) of condensate (water) in the drain tank, the drain tank switch sends a signal
to the microprocessor. The microprocessor stops all operation of the unit and flashes the "Tank Full"
LED.
This system utilizes a .1 AMP, 250 VAC micro-switch for this function. When drain water accumulates
approximately 4.0 gallons (15 liters) in the drain tank, the drain tank base plate, which is supported at its
fulcrum, is pushed down in the direction of the arrow as shown in the figure below. When the drain tank
base plate is forced down, the top of the drain tank base plate turns off the contacts (1) – (2) of the micro
switch. This causes the ground signal at the J103 connector of the control panel assembly to go open.
When the microprocessor detects this event, it turns the unit off and flashes the "Tank Full" LED.
TOP OF
BASE
PLATE
DRAIN
SWITCH
To J103
NC
DS2
2
1
DS1
C
SPRING
;;;
yyy
;;;
yyy
;;;
yyy
EVAPORATOR
DRAIN PAN
DRAIN TUBE
DRAIN TANK
WATER
DRAIN W
BASE
FULCRUM
BASE
PLATE
Operation of Drain Switch
When the drain tank is removed (or the drain tank is emptied), the top of the drain tank base plate
returns to its original position by the tension of the coil spring. Then contacts (1) – (2) of the drain tank
switch close. This provides a ground to the microprocessor through the J103 connector. To re-start the
unit, press one of the fan mode buttons or the “Cool On/Off” button. The unit will return to the previous
Temperature Set Point.
7.
Condensate Pump Kit (optional)
The Classic Plus 14 model comes standard with a drain tank, which collects the water that forms on the
evaporator during normal cooling operation. If the unit is required to operate continuously without
periodic emptying of this tank, a condensate pump may be needed. A condensate pump kit (CPK-3) is
available for the Classic Plus 14 model.
17
ELECTRICAL SYSTEM
8.
Automatic Restart After Power Interruption
The program within the microprocessor of the Classic Plus 14 contains a feature that will automatically
restart the unit after power is lost and then regained. The unit also has memory in order to return itself
back to the operating mode (including temperature set point) it was in prior to the loss of power.
9.
Compressor Protection
There is a Time Delay program within the microprocessor. This prevents a heavy load from being applied
on the Compressor Motor when restarting the unit (Cool Mode) after a very short period of time. This
“delay” is in effect any time when the compressor is turned on by either the “Cool On/Off” button,
temperature set point (thermostatic control), power interruption restart or Condensate Pump (optional)
operation.
Time Delay Program Specifications: 120 ± 10 sec.
10.
Temperature Control
The compressor operation (Cool Mode) is controlled by the microprocessor which receives input signals
from the room temperature thermistor (evaporator inlet air) and the setting of the Temperature Set Point.
The Temperature Set Point (desired room temperature) can be adjusted by pressing the ▲ / ▼ buttons
on the Control Panel. The adjustment range of the Temperature Set point is 70˚F to 95˚F (21.1˚C to 35˚C).
11.
Fan Mode Control Switch
The fan motor operation is controlled by relays on the relay board through a microprocessor in the
control panel assembly. The fan program in the microprocessor can be changed by a DIP-Switch on the
left side of the Relay Board located in the Control Box. There are two settings:
A. Cool to Stop
When the DIP-Switch is set to the “Down” or “Stop” position, the microprocessor controls the fan
motor using the same room temperature thermistor that it uses to control the compressor. In this
case, both the fan and the compressor stop when the microprocessor receives a sufficiently low
intake air (room temperature) signal from the thermistor (equal to or less than the set point). When
the temperature increases (exceeds the set point) the microprocessor will restart the fan and compressor automatically. However, if the unit has been off for less than 130 sec., the fan will start
before the compressor (time delay feature).
B. Cool to Operate
When the DIP-Switch is set in the “Up” or Operate position, the microprocessor controls the fan
operation using control panel inputs only. The fan will operate continuously during Fan Only and
Cool Modes. (This is the factory default setting.)
12.
Temperature Scale Display Switch
When the DIP Switch is set in the “down” or ˚C position, the Set Point Temperature will be displayed in
degrees Celsius. The LED that indicates ˚C will also be illuminated.
When the DIP Switch is set in the “Up” or ˚F position, the Set Point Temperature will be displayed in
degrees Fahrenheit.. The LED that indicates ˚F will also be illuminated. (This is the “Factory Default”
setting.)
18
TROUBLESHOOTING AND REPAIR
Before troubleshooting the system, the following inspection should be performed.
1. Inspection of Power Source Voltage
Check the voltage of the power source.
Single phase 115 volts (60Hz)
Check the operation and condition of the fuse or circuit breaker in the power source.
2. Inspection of Air Filters
Remove the air filters and check the element. If the element is dirty, wash it as described in the OPERATION MANUAL supplied with the unit.
3. Inspection of Drain Tank
Be sure tank is fully drained.
The following chart is provided as a guide for categorized problem remedies. Detailed information is
contained in the OPERATION MANUAL supplied with the unit.
4. Troubleshooting Chart
Trouble
Probable Cause
Trouble
Probable Cause
Unit does not operate at all
• Check for Power at
Receptacle
• Check for Power at Terminal
Board
• Check for Power at Relay
Board
• Check all wire connections
• Defective Drain Tank Switch
• Check Relay Board Fuse
• Defective Relay Board
• Defective Control Board
Insufficient Cooling (cont’d)
• Clogged spine fins
• Set point temperature
exceeds room temperature
• Defective room temperature
thermistor
• Leak in refrigerant system
• Restriction in refrigerant
system
• Compressor not operating
Compressor not operating
• Set point temperature
exceeds room temperature
• Unit is operating in Fan Only
Mode (Cool Mode not
activated)
• Jumper on Control Board
(J104) not installed correctly
• Jumper on Relay Board (J8)
not installed correctly
• Defective Condensate Pump
(optional)
• Defective Compressor
Capacitor
• Defective overload relay
• Defective Thermistor
• Defective Compressor Motor
• Check wiring connections
• Defective Relay Board
• Defective Control Board
Fan Motor not operating
• Fan mode switch is set to
“Stop” and current Set Point
Temperature exceeds Room
Temperature
• Fan mode switch is set to
“Stop” and unit has been
equipped with optional
Condensate Pump that is
defective
• Fan mode switch is set to
“Stop” and Jumper on
Control Board (J104) or Relay
Board (J8) is not installed
correctly
• Check wire connections
• Defective fan motor capacitor
• Defective fan motor
• Defective Relay Board
• Defective Control Board
Unit starts, but stops immediately
•
•
•
•
Defective Overload Relay
Defective Fan Motor
Defective Compressor Motor
Defective Relay Board
Unit operates, but stops after a
few minutes
•
•
•
•
•
Defective Compressor Motor
Defective Overload Relay
Defective Fan Motor
Drain Tank Full
Fan Mode Switch is set to
“Stop” and compressor
cycled off
Water leakage from the unit
• Drain Tank not installed
• Drain Tank is defective
(cracked)
• Drain Pan hole is obstructed
Abnormal noise and/or shaking
• Loose Compressor mounting
nut
• Deformed or worn rubber
grommet on the compressor
mounting bolt
• Internal interference with
other components
• Damaged or out of balance
fan and scroll
Insufficient Air Flow
• Clogged spine fins or
Evaporator or Condenser
(running unit without filter(s)
• Fan mode switch on “Low”
• Defective fan motor
Insufficient Cooling
• Environmental conditions
exceed design specifications
• Clogged air filter
19
TROUBLESHOOTING AND REPAIR
In case of trouble, perform the following inspection
before disassembly.
5. Inspection of Spine Fins
To inspect the spine fins of either the evaporator
or condenser you must remove the air filters.
After removal of the air filters, inspect the spine
fins for any dirt, dust, lint, or debris that may have
caused poor cooling performance of the unit. If
cleaning of the spine fins is necessary, it is
recommended that this service be performed by
a qualified service technician.
Spine Fins
6. Examination of Operating Environment
Operating environments will vary depending on
location, climate and surrounding conditions.
Installation location also can cause operational
problems. Consult your reseller concerning
operational environment requirements.
Operating Environment
7. Inspection of Cooling Capacity
Measure the difference in temperature between the
inlet of the evaporator and the cool air duct. If the
difference is out of the range given in the graphs on
page 8 proceed with the remedy suggested in the
troubleshooting chart on page 19.
Inspection of Cooling Capacity
20
TROUBLESHOOTING AND REPAIR
8. Disassembly
2
1
4
10
4
3
16
5
11
6
12
17
7
13
8
15
9
14
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
Control panel
Upper panel
Right side panel
Air filter
Blower housing (condenser)
Condenser fan
Rear panel
Drain Switch
Caster
Disassembly
21
10.
11.
12.
13.
14.
15.
16.
17.
Front panel
Blower housing (evaporator)
Drain pan
Left side panel
Drain tank
Service panel
Room thermistor
Freeze thermistor
TROUBLESHOOTING AND REPAIR
A. Remove Drain Tank.
Removal of Drain Tank
B. Remove (8) screws from the ducts, then
remove the 2-ducts.
Removal of Duct Screws and Ducts
C. Remove (4) screws from the Service Panel.
4
Removal of Service Panel Screws
D. Remove 3 wires, then remove the power
cord.
DISCONNECT
DISCONNECT
DISCONNECT
Removal of Power Cord Screws
22
TROUBLESHOOTING AND REPAIR
E. Remove remaining (13) screws and the back
panel.
4
3
3
3
Removal of Back Panel Screws
F.
4 (backside)
4
Remove (14) screws from the Top Panel.
2
Removal of Top Panel Screws
G. Top Panel (4).
2
2
Removal of Top Panel
23
TROUBLESHOOTING AND REPAIR
9. Removal of Electrical Parts
AP
THS
RTH
DS
3
G
T R
R1
R2
1
SCP
1
CC
2
2
TB
MC
G
G
1
CF
1
L0
2
0LC
2
MF
HI
J4
IOLF
J8 (AUX1)
AUX2
J5
G
J6
J2
J1
J3
AP
TB
CB
RB
MF
MC
CF
CC
RB
CB
OLC Overload Relay of Compressor
DS
Full Drain Warning Switch
THS Freeze Protection Thermistor
RTH Room Thermistor
SCP Short Circuit Plate
G
Ground
J8 (AUX1) Auxiliary Connector (CPK3)
AUX2 Auxiliary Connector (Not Used)
Attachment Plug
Terminal Block
Control Board
Relay Board
Fan Motor
Compressor Motor
Capacitor for Fan
Capacitor for Compressor
Relay Board
Relay Board Fuse
DIP Switch
Terminal Block
Compressor
Capacitor
Fan Motor
Capacitor
Removal of Electrical Parts in the Control Box
24
TROUBLESHOOTING AND REPAIR
To Terminal Block
(R-Terminal)
Pin #2 Compressor
Overload Relay
To Fan Motor
(Low Speed)
J4
J5
J6
J2
J3
S1
C
STOP
J9
Relay Board Fuse
J8
DIP Switch
Temperature Scale Display Switch
˚C
˚F
Fan Mode Control Switch
STOP
OPERATE
Main Wiring Harness
Relay Board to Control Panel
Jumper or 2-Pin Connector of
(optional) Condensate Pump Kit - CPK-3
NOT USED
Freeze Thermistor
Room Thermistor
Main Wiring Harness
(Control Panel to Relay Board)
J201
Drain Tank Switch
J101 J102 J106 J103 J104
Connections to Relay Board
Jumper
Relay Board Ground
(not used)
F1
F
OPERATE
J1
To Terminal Block
(T-Terminal)
To Fan Motor
(High Speed)
Connections to Control Board
25
TROUBLESHOOTING AND REPAIR
10. Removal of Blower Assembly
➇
➀
1.
2.
3.
4.
➁
➂
➄
➃
Condenser fan
Blower housing (condenser)
Fan motor
Motor bracket
Disassembly of Blower
26
5.
6.
7.
8.
➅
➆
Partition plate
Evaporator fan
Blower housing (evaporator)
Air flow guide
TROUBLESHOOTING AND REPAIR
A. Loosen the set screw using an allen wrench
and then remove the centrifugal fan.
Removal of Centrifugal Fan
B. Remove the two (2) nuts on the inside of the
housing in the locations shown.
A - NUT
Removal of Blower Housing
C. Remove two nuts and two screws as depicted.
Then remove the motor bracket together with
the fan motor.
A - NUT
B - SCREW
Removal of Fan Motor Assembly
27
TROUBLESHOOTING AND REPAIR
D. Remove the centrifugal fan by loosening the
set screw on the shaft. Remove the fan
motor, by loosening “A” nuts.
Removal of Fan Motor
E. Remove (7) screws from Left Side Panel.
3
1
Removal of Left Side Panel Screws
F.
Remove (7) screws from Right Side Panel.
3
1
3
Removal of Right Side Panel Screws
28
3
TROUBLESHOOTING AND REPAIR
G. Remove (2) screws from Control Panel
Assembly Right Stay.
Removal of Right Stay Screws
H. Remove (2) screws from Control Panel
Assembly Left Stay.
Removal of Left Stay Screws
I.
Disconnect the following connectors from the
control board:
(1)
Wire Harness, Relay Board to Control
Board J201 (10-pin)
(2)
Drain Tank Switch J103 (2-pin)
(3)
Room Temperature Thermistor J101
(2-pin)
(4)
Freeze Thermistor J102 (2-pin)
NOTE: Mark each of the 2-pin connectors with a
different color marker to ensure the correct orientation when they are re-connected.
Removal of Control Panel Assembly
29
TROUBLESHOOTING AND REPAIR
J. Remove the five (5) screws from the control
board on the control panel assembly. Remove
the control board.
Removal of Control Board
11. Inspection of Capacitor (Fan Motor and
Compressor)
Ohmeter Method – Set the ohmeter to the 100K Ω
range. Place the two probes against the two
terminals of the capacitor. At first, the ohmeter
should indicate 0Ω, then the reading should
gradually increase towards infinity (∞). This
indicates that the capacitor is charging. If the
reading indicates infinity right away (shorted) or
the ohmeter fails to move from 0Ω (open), replace
the capacitor.
12. Capacitance Tester Method
Using a capacitance tester and the chart on page
15, test the capacitor for the value indicated. If
the value tested is not within 10% of indicated
capacitance, replace the capacitor.
Inspection of Capacitor
Warning: Properly discharge the capacitor(s)
before testing and after testing has been completed. Failure to do so could cause damage to
test equipment or the unit and/or result in personal injury (electrical shock) or death.
30
TROUBLESHOOTING AND REPAIR
13. Inspection of Drain Switch
Check for continuity between terminals 1 and 2.
Continuity should exist. With switch depressed,
continuity should not exist between terminals 1
and 2. If continuity is not as specified above,
replace the switch.
TOP OF
BASE
PLATE
DRAIN
SWITCH
To J103
NC
DS2
2
1
DS1
C
Inspection of Drain Switch
14. Inspection of Fan Motor
Measure resistance across the terminals of the
fan motor.
Terminals (at 77˚F (25˚C))
J6 - CF1 Approx. 3.5Ω
J5 - CF1 Approx. 4.7Ω
CF1 - CF2 Approx. 30.4Ω
Ground
(Green/Yellow)
If the measured resistance is not equal to these
standard values, replace the fan motor.
CF1 (White)
CF2 (Brown/White)
J5 Low (Red)
J6 High (Black)
Inspection of Fan Motor
15. Inspection of Compressor Motor
Measure resistance across the terminals of the
compressor motor.
Terminals (at 77˚F (25˚C))
R–C
Approx.1.1Ω
C–S
Approx.2.7Ω
S–R
Approx.3.3Ω
If the measured resistance value is not equal to
these standard values, replace the compressor.
The compressor uses an external overload relay.
For overload relay specification see chart on
page 16.
Inspection of Compressor Motor
16. Inspection of Wiring Connection
Refer to the Wiring Diagrams (pg. 40) and check for connection of each wire.
17. Inspection of Thermistor(s)
Using an Ohmeter, check the resistance value across the 2-Pin connector. At normal temperature (77˚F,
25˚C) either thermistor (Room or Freeze) should measure approx. 10,000 or 10k ohms.
31
TROUBLESHOOTING AND REPAIR
18. Inspection
In most cases, the probable cause for insufficient cooling is a clogged system, leakage or an incorrect
amount of refrigerant. In such cases, inspect the system according to the following procedure.
A. Inspection of Clogged System
Check the component parts of the refrigerant system, including piping, that could be clogged with
refrigerant. If clogged with refrigerant, only the clogged part is frosted partially. In such a case, change
the part in question.
B. Inspection of Refrigerant Leak
Carefully check all connections, and each component for leaks whenever the refrigerant system is
installed or repaired. Use an electronic gas leak tester to inspect the system.
C. Insufficient Refrigerant
In case the unit is judged to be deficient in cooling capacity, be sure to perform the inspections in
A. and B. to confirm the cause of trouble. After that, charge the system with refrigerant to the specified
amount.
19. Repair of Refrigerant System
In case there is a leak, obstruction, or trouble in the refrigerant system of the Spot Cooling System, replace
or repair the part in question. After replacing any component all connections must be brazed.
A. Proper Brazing Techniques
It is desirable to use a slightly reducing flame. Oxyacetylene is commonly used since it is easy to judge
and adjust the condition of the flame. Unlike gas welding, a secondary flame is used for brazing. It is
necessary to preheat the base metal properly depending on the shape, size or thermal conductivity of
the brazed fitting.
The most important point in flame brazing is to bring the whole brazed fitting to a proper brazing
temperature. Care should be taken to not cause overflow of brazing filler metal, oxidization of brazing
filler metal, or deterioration due to the overheating of flux.
•
BRAZED FITTING AND ITS CLEARANCE
In general, the strength of brazing filler metal
is lower than that of the base metal. So, the
shape and clearance of the brazed fitting are
quite important. As for the shape of the
brazed fitting, it is necessary to maximize its
adhesive area. The clearance of the brazed
fitting must be minimized to facilitate brazing
filler metal to flow into it by capillary action.
•
CLEANING OF BRAZING FILLER METAL
AND PIPE
Brazed Fitting and Clearance
When the refrigerant system has been
opened up, exposure to heat may have
caused brazing filler metal to stick to the
inside and outside of the pipe. Brazing filler
metal may also be compounded with oxygen
in the air to form oxide film. Fats and oils
may stick to the pipe from handling. All these
factors will reduce effectiveness of brazing. It
is necessary to eliminate excess brazing filler
32
TROUBLESHOOTING AND REPAIR
metal using sand paper and by cleaning
thoroughly with a solvent such as Trichlene.
•
USE OF DRY NITROGEN GAS
During brazing, the inside of the pipe undergoes an oxidative reaction due to the brazing
flame. Introduce dry nitrogen gas (1 liters/
min.; adjust with the flow regulator) through
the pinch-off tube of the refrigerant cycle to
prevent oxidation.
NOTE: Take care not to allow dirt, water, oil, etc. to
enter into the pipe
Vertical Down Joint
•
VERTICAL JOINT
Heat the whole brazed fitting to a proper
brazing temperature. Bring the brazing filler
metal into contact with the fitting so that the
brazing filler metal starts flowing by itself.
Stop heating the fitting as soon as the
brazing filler metal has flown into the clearance. Since the brazing filler metal flows
easily into the portion heated to a proper
temperature, it is essential to keep the whole
fitting at a proper brazing temperature.
Vertical Up Joint
33
TROUBLESHOOTING AND REPAIR
B. Removal of Refrigeration Cycle Components
CAUTION:
1.
Before any refrigeration cycle component can be replaced, it is necessary to recover the refrigerant using standard recovery procedures and equipment.
2.
To prevent oxidation, dry nitrogen should be conducted (flow rate 1 liters/min) through the pinchoff tube during any brazing operation.
3.
During any component replacement involving brazing, shield nearby parts with a steel plate,
asbestos, etc., to protect them from the flame.
(1) Evaporator
(2) Capillary tube
(3) Condenser
(4) Compressor
NOTE: Hold the compressor body, not the tube, when carrying the compressor.
A
D
C
F
E
B
Removal of Refrigeration Cycle Components (Refer to 5-2-2.)
PART REPLACED
Compressor
Condenser
Capillary tube
Evaporator
DISCONNECT AT:
A&B
A&C
D&E
E&F
Refrigeration Cycle Components
34
TROUBLESHOOTING AND REPAIR
20. Charging the System with R-22 Refrigerant
Always ensure that the refrigerant system has been properly evacuated before charging with the specified
amount of R-22.
WARNING:
When handling refrigerant (R-22), the following precautions should always be observed:
• Always wear proper eye protection while handling refrigerant.
• Maintain the temperature of the refrigerant container below 40˚C (104˚F).
• Perform repairs in a properly ventilated area. (Never in an enclosed environment.)
• Do not expose refrigerant to an open flame.
• Never smoke while performing repairs, especially when handling refrigerant.
• Be careful the liquid refrigerant does not come in contact with the skin.
If liquid refrigerant strikes eye or skin:
• Do not rub the eye or the skin.
• Splash large quantities of cool water on the eye or the skin.
• Apply clean petroleum jelly to the skin.
• Go immediately to a physician or to a hospital for professional treatment.
A. Connection of Gauge Manifold
(1) Properly remove the crushed end of the
pinch-off tube at the high pressure side
and the low pressure side of the refrigerant cycle with a pipe cutter.
(2) Fit the process tube fitting to the pinchoff tube on both sides.
Mounting of Process Tube Fitting
35
TROUBLESHOOTING AND REPAIR
(3) Connect the charging hoses (red - high
pressure side, blue - low pressure side) of
the gauge manifold to the process tube
fittings.
NOTE: Connect the hoses using care not to mistake
the high pressure side for the low pressure side and
vice versa.
(4) Connect the charging hose (green) at the
center of the gauge manifold to the
vacuum pump.
Connection of Gauge Manifold
B. Evacuation
(1) Open the high pressure valve (HI) and the
low pressure valve (LO) of the gauge
manifold.
(2) Turn on the vacuum pump to start
evacuation. (Evacuate the system for
approximately 15 minutes.)
(3) When the low pressure gauge indicates
750mmHg (30in.Hg) or larger, turn off the
vacuum pump and close the high and low
pressure valves of the gauge manifold.
Evacuation
C. Checking Vacuum
(1) Leave the high pressure valve and the
low pressure valve of the gauge manifold
closed for five minutes or more, and
confirm that the gauge pointer does not
return to zero.
(2) If the gauge pointer returns gradually to
zero there is a leak somewhere in the
system (this could also include gauge
manifold). Perform leak check according
to procedure indicated in D. Once leak
has been found and repaired evacuate
the system once more, and confirm
system holds vacuum.
Checking Vacuum
36
TROUBLESHOOTING AND REPAIR
D. Checking Gas Leak
(1) Remove the charging hose (green) from
the vacuum pump, and connect the hose
to the refrigerant cylinder (R22).
(2) Loosen the nut on the gauge manifold
side of the charging hose (green).
Evacuating Air Inside Charging Hose
(3) Open the high pressure valve of the
gauge manifold. Charge the system with
refrigerant until the low pressure gauge
indicates 57 PSIG. (4 kg/cm2G.) After
charging is complete, close the high
pressure valve.
(4) Check carefully for gas leaks inside the
refrigerant system using the gas leak
tester.
(5) Repair any leak.
WARNING: Do not attempt any repair on a
charged system.
Charging with Refrigerant for Gas Leak Check
WARNING: Before checking for gas leaks, fully
confirm that there is nothing flammable in the
area to cause an explosion or fire. Contact of
refrigerant with an open fire generates toxic gas.
E. Evacuation (Repeat)
(1) Close the valve of the refrigerant cylinder.
Then remove the charging hose (green)
from the refrigerant cylinder, and connect
it to the refrigerant recovery machine.
NOTE: Keep the high pressure valve and the low
pressure valve of the gauge manifold closed.
(2) Using procedure B., evacuate the system
until the low pressure gauge indicates
750mmHg (30in.HG) or greater. (For 15
minutes or more.)
(3) After evacuation is complete, close the
high and the low pressure valves of the
gauge manifold.
CAUTION: Be sure to evacuate the system twice
or more using the repetitive vacuum method.
Evacuate the system an additional time on rainy
or humid days.
Evacuation (repeat)
37
TROUBLESHOOTING AND REPAIR
21. Refrigerant Charging Work
A. Refrigerant Charging
(1) Remove the charging hose (green) from
the vacuum pump, and connect it to the
refrigerant cylinder (R-22).
(2) Loosen the nut on the gauge manifold
side of the charging hose (green). Open
the valve of the charging hose (green).
Open the valve of the refrigerant cylinder.
Evacuating Air Inside Charging Hose
(3) Securely place the refrigerant cylinder on
a scale with a weighing capacity of 70 lbs
(30 kg) that is graduated by 0.2 oz (5 g).
(4) Open the high pressure valve of the
gauge manifold and the valve of the
refrigerant cylinder. Charge the system
with refrigerant to the specified amount.
Standard Amount of Refrigerant:
1.50lbs (0.68kg)
If the system cannot be charged with the
specified amount of refrigerant under this
condition, follow the steps below:
Charging with Refrigerant
(a) Close the high-pressure valve of
manifold.
(b) Operate the refrigerant system.
(c) Slowly open the low-pressure valve
while observing the scale reading.
(d) When the scale reads the specified
amount, immediately close the lowpressure valve.
(e) Bring the system to a stop.
CAUTION: The amount of refrigerant charged
has a great effect on the cooling capacity of the
unit. Charge to the specified amount, always
observing the scale graduations while charging.
(5) Close the high pressure valve of the
gauge manifold and the valve of the
refrigerant cylinder.
38
TROUBLESHOOTING AND REPAIR
B. Removal of Gauge Manifold
(1) Crimp the pinch-off tube with a pinch-off
tool.
(2) Remove the gauge manifold and the
process tube fitting. Crush the end of the
pinch-off tube.
(3) Braze the end of the pinch-off tube.
(4) Ensure that a gas leak is not present at
the pinched off portion and the brazed
end.
Removal of Gauge Manifold
Reassemble the unit in the reverse order of removal.
Described below are the parts that require special
care in reassembling the unit. Perform all wiring or
rewiring as referenced in the wiring diagram.
22. Compressor Mounting
Mount the compressor on the frame, using
cushions, steel collars, spring washers, plate
washers and nuts.
Compressor Mounting
23. Blower Assembly
Install blower fans (for evaporator and condenser).
Tightening torque:
10.84 ± 2.17 lbf•ft (150 ± 30 kgf•cm)
NOTE: After reassembling, the gap between blower
fan and housing should be 0.06 inches (1.5 mm) or
more.
24. Wiring Notice
Secure the wires using clamps so that they do
not come into contact with the edges of the
structure, etc. Secure the wires using clamps in
the same position they were before removal.
Blower Assembly Mounting
25. Perform the inspection of cooling capacity
and check for abnormal noise or abnormal
vibration.
39
G
G
SCP
T R
AP
1
CF
R1
2
R2
40
G
HI
0LC
2
J3
J1
J2
J6
J5
J4
2
1
Attachment Plug
Terminal Block
Control Board
Relay Board
Fan Motor
Compressor Motor
Capacitor for Fan
Capacitor for Compressor
IOLF
MF
L0
AP
TB
CB
RB
MF
MC
CF
CC
TB
1
CC
MC
RTH
OLC Overload Relay of Compressor
DS
Full Drain Warning Switch
THS Freeze Protection Thermistor
RTH Room Thermistor
SCP Short Circuit Plate
G
Ground
J8 (AUX1) Auxiliary Connector (CPK3)
AUX2 Auxiliary Connector (Not Used)
RB
J8 (AUX1)
G
THS
3
CB
2
DS
AUX2
1
TROUBLESHOOTING AND REPAIR
26. Schematic
DSCA P/N: LA990009-0379
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