SERVICE MANUAL CLAS S IC P L U S 2 6 DENSO SALES CALIFORNIA, INC. REGISTERED TO ISO 9002 FILE NO.
© 1999 DENSO SALES CALIFORNIA, INC. All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher. DENSO SALES CALIFORNIA, INC. reserves the right to make changes without prior notice. MovinCool is a registerd trademark of DENSO Sales California, Inc.
SERVICE MANUAL CLAS S IC P L U S 2 6
FOREWORD This manual has been published to service the MovinCool Classic Plus 26. Please use this service manual only when servicing the Classic Plus 26. 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.
ii
Table of Contents FOREWORD ............................................................................................................................... i DEFINITION OF TERMS ............................................................................................................ i GENERAL PRECAUTIONS ........................................................................................................ i GENERAL DESCRIPTION .............................................................................
iv
GENERAL DESCRIPTION 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.
GENERAL DESCRIPTION 2
CONSTRUCTION, SPECIFICATIONS & DATA Construction of Classic Plus 26 3
CONSTRUCTION, SPECIFICATIONS & DATA Side Panel High Pressure Switch Blower Housing (Evaporator) Exhaust Air Outlet Evaporator Fan Condenser Side Panel Upper Panel Cool Air Duct Modulating Tank Blower Housing (Condenser) Control Panel Fan Motor Front Panel Condenser Fan Evaporator Air Filter (Condenser) Air Filter (Evaporator) Capillary Tube Control Box Drain Pan Drain Tube Service Panel Base Panel Drain Switch Rear Panel Power Cord Drain Tank Caster Construction Diagram of Classic Plus 26
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.
CONSTRUCTION, SPECIFICATIONS & DATA Rating Conditions dry bulb wet bulb humidity Specifications power frequency line voltage, single phase power consumption current consumption power factor starting current power cord Cooling Unit cooling capability 95 oF (35 oC) 83 oF (28.3 oC) (60%) 60Hz 208/230V 3.37/3.24 Kw 16.8/14.
CONSTRUCTION, SPECIFICATIONS & DATA 10.60 2.62 3.70 10.80 3.84 7.28 29.24 23.76 48.0 44.12 3.88 12.56 16.80 19.60 2.80 Exterior Dimensions 7 21.88 28.40 3.
CONSTRUCTION, SPECIFICATIONS & DATA Cool Air Temperature Difference Curve (high speed only) Cooling Capability Curve (high speed only) Power Consumption Curve (high speed only) 8
REFRIGERANT SYSTEM The component parts of the refrigerant system include the following: • Compressor • Evaporator • Condenser • High pressure switch • Capillary tube • Modulating tank These parts are all connected by copper piping. All the connections have been brazed.
REFRIGERANT SYSTEM 1. Compressor The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in one casing. A. Compressor Theory of Operation The scroll utilizes an involute spiral which, when matched with a mating scroll form, generates a series of crescent-shaped gas pockets between the two members. During compression, one scroll remains stationary (fixed scroll) while the other form (orbiting scroll) is allowed to orbit (but not rotate) around the first form.
REFRIGERANT SYSTEM 4) By the time the gas arrives at the center port, discharge pressure has been reached. 5) Actually, during operation, all six gas passages are in various stages of compression at all times, resulting in nearly continuous suction and discharge. NOTE: Upon compressor shut-off, the compressor may run backward for a moment or two until internal pressures equalize.
REFRIGERANT SYSTEM 3. Capillary Tube The capillary tube is a long thin tube and its line flow resistance serves as an expansion valve. The length and the inner diameter of the capillary tube are determined according to the capacity of refrigeration system, operating conditions and the amount of refrigerant.
REFRIGERANT SYSTEM Condenser Inlet Pipe Evaporator Inlet Pipe Evaporator Outlet Pipe Compressor Discharge Pipe Compressor Outlet Pipe Capillary Tube Connecting Tube (condenser to capillary tube) Compressor Suction Pipe (insulated) Connecting Pipe (evaperator to compressor) Refrigerant System Piping 13
ELECTRICAL SYSTEM AP RTH THS DS 3 G T R HPRS 1 CC 1 2 2 TB MC IOLC G G CF 1 2 L0 MF HI J4 IOLF J101 J102 J103 J104 J8 (AUX1) J5 G J6 J9 J201 J2 J1 J3 AP TB CB RB MF MC CF CC RB Attachment Plug Terminal Block Control Board Relay Board Fan Motor Compressor Motor Capacitor for Fan Capacitor for Compressor IOLC IOLF HPRS DS THS RTH G J8 (AUX1) CB Internal Overload Protector of Compressor Internal Overload Protector of Fan Motor High Pressure Switch Full Drain Warning Switch Freeze Pr
ELECTRICAL SYSTEM 1. Basic Operation of Classic Plus 26 Electrical Circuit There are two basic components used to control the operation of the Classic Plus 26 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.
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 Compressor Capacitor Fan Motor Capacitor CAPACITOR APPLICATION VOLTAGE RATING CAPACITANCE (µf) Fan Motor Compressor 440 370 12.5 40 Control Box B.
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: 230 volts 60 Hz Rated Output: 559 watts 355 watts CF1 (White) CF2 (Brown/White) J5 Low (Red) J6 High (Black) 4. Compressor Motor The compressor motor is a single phase motor. It is contained within the same housing as the compressor.
ELECTRICAL SYSTEM 6. Condensate Pump Kit (optional) The Classic Plus 26 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-4) is available for the Classic Plus 26 model. 7.
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 208/230 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.
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.
TROUBLESHOOTING AND REPAIR 8. Disassembly 2 1 4 10 3 4 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.
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. Disconnect and remove: ➀ Green Wire (ground) ➁ White Wire (R-Terminal) ➂ Black Wire (T-Terminal) ➀ ➁ ➂ Remove the power cord.
TROUBLESHOOTING AND REPAIR E. Remove remaining (13) screws and the back panel. 4 3 3 3 Removal of Back Panel Screws 4 (backside) 4 F. Remove (14) screws from the Top Panel. 2 Removal of Top Panel Screws G. Top Panel (4).
TROUBLESHOOTING AND REPAIR AP RTH THS DS 3 G T R HPRS 1 CC 1 2 2 TB MC IOLC G G CF 1 2 L0 MF HI J4 IOLF J101 J102 J103 J104 J8 (AUX1) J5 G J6 J9 J201 J2 J1 J3 AP TB CB RB MF MC CF CC RB Attachment Plug Terminal Block Control Board Relay Board Fan Motor Compressor Motor Capacitor for Fan Capacitor for Compressor IOLC IOLF HPRS DS THS RTH G J8 (AUX1) CB Internal Overload Protector of Compressor Internal Overload Protector of Fan Motor High Pressure Switch Full Drain Warning Switch
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-4 NOT USED Freeze Thermistor Room Thermistor Main Wiring Harness (Control Panel to Relay Board) J201 Drain Tank Switch J101 J1
TROUBLESHOOTING AND REPAIR 9. Removal of Electrical Parts ➇ ➀ 1. 2. 3. 4. ➁ ➂ Condenser fan Blower housing (condenser) Fan motor Motor bracket Disassembly of Blower 26 ➄ ➃ 5. 6. 7. 8.
TROUBLESHOOTING AND REPAIR 10. Removal of Blower Assembly 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.
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. 4 3 Removal of Left Side Panel Screws F. 3 Remove (7) screws from Right Side Panel.
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.
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.
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. 6.8Ω J5 - CF1 Approx.
TROUBLESHOOTING AND REPAIR 16. Inspection of High Pressure Switch Check for continuity across both terminals of the high pressure switch or the J104 connector. With pressure equalized when the unit is stopped, there should be continuity across both terminals and the J104 connector. If there is no continuity (open circuit), replace the high pressure switch. Specifications: Cut off pressure - 29.5kg/cm2G (420 PSIG) Reset pressure - 20.5kg/cm2G (291 PSIG) 17.
TROUBLESHOOTING AND REPAIR • 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.
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 liter/min) through the pinch-off tube during any brazing operation. 3. During any component replacement involving brazing, shield nearby parts with a steel plate, asbestos, etc.
TROUBLESHOOTING AND REPAIR 21. 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.
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.
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.
TROUBLESHOOTING AND REPAIR 22. 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.
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.
G G T R AP TB 1 2 AP TB CB RB MF MC CF CC CF 40 G HI CC Attachment Plug Terminal Block Control Board Relay Board Fan Motor Compressor Motor Capacitor for Fan Capacitor for Compressor IOLF MF L0 1 2 J3 J1 J2 J6 J5 J4 IOLC MC IOLC IOLF HPRS DS THS RTH G J8 (AUX1) RB J8 (AUX1) G J9 THS 2 DS 1 HPRS J201 CB J101 J102 J103 J104 3 Internal Overload Protector of Compressor Internal Overload Protector of Fan Motor High Pressure Switch Full Drain Warning Switch Freeze Protection Th
DENSO SALES CALIFORNIA, INC. TECHNICAL SERVICE DEPARTMENT First Issue: May 1999 DSCA P/N: LA990009-0549 Printed in U.S.A.
(800) 264-9573 www.movincool.
