SERVICE MANUAL CLASSIC PLUS 14 SERIAL NUMBER FROM JANUARY 2008 (0108) TO PRESENT DocID: 00G00019E
© 2008 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 registered trademark of DENSO Corporation.
Table of Contents Table of Contents Operation Section 1. PRECAUTIONS FOR SAFETY 1.1 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.2 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.3 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 6.5 Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 6.6 Compressor Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 6.7 Power Cord with LCDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 6.8 Drain Switch . . . . . . . . . . . . . . . . .
Table of Contents Repair Section 7. TROUBLESHOOTING 7.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 7.2 Self-Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 7.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 7.
Operation Section 1. PRECAUTIONS FOR SAFETY 1.1 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. 1.2 Definition of Terms WARNING CAUTION NOTE Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation.
Operation Section 7 2. GENERAL DESCRIPTION 2.1 Spot Cooler • In general, 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 Condenser (Outdoor Unit) Evaporator (Indoor Unit) exchanged heat to the outdoors.
Operation Section 8 3. CONSTRUCTION 3.1 Exterior Dimensions (D IA .4 .9 ) (9.3) (6.5) 3. (1.4) (1.4) (3.5) (3.5) (37.8) (3.6) (3.7) (3.7) (11.5) (41.3) 8) (18.8) (1 (26.5) (19.
Operation Section 9 3.
Operation Section 3.3 Internal Structure Fan (Evaporator) Fan Motor Evaporator Fan (Condenser) Capillary Tube Control Box Drain Pan Condenser Drain Tank Compressor Drain Switch I002336 3.4 Basic Construction • The MovinCool Classic Plus 14 is compact in construction because the condenser and the evaporator are enclosed in one unit. The interior is divided into three sections.
Operation Section 11 3.5 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 grill. Air taken in from the front face is cooled by the evaporator and then blown through the cool air ducts. All the air inlets are equipped with filters, and the exhaust air duct is protected by metal grill. Cool Air Out Exhaust Air Out Condenser Air In Evaporator Air In I002314 3.
Operation Section 12 4. SPECIFICATIONS 4.1 Technical Specifications ITEM Electronic Features Cooling Capacity*1 Refrigerant Circuit SPECIFICATIONS Control Panel Electronic Thermostat Control Electronic Capacity Compressor 13200 Btu/h (3870 W) Compression Type Hermetic Rotary Motor Rated Output 0.91 kW Evaporator Spine Fin Condenser Plate Fin Refrigerant Control Refrigerant/Enclosed quantity R-410A/1.65 lb (0.75 kg) Ventilation Equipment For Fan Type Evaporator Max.
Operation Section ITEM Operating Condition Sound Level*2 SPECIFICATIONS Inlet air: Maximum 113 °F (45 °C), 50 %RH Inlet air: Minimum 77 °F (25 °C), 50 %RH With Condenser Duct-high/low 57/55 dB (A) Without Condenser Duct-high/low 60/58 dB (A) Max. Duct Equivalent Length-Per Cold Duct Hose/Hot Duct Hose 30/60 ft (9.1/18.3 m) Condensate Tank Capacity 5 ± 0.5 gal (19 ± 2 L) • Specifications are subject to change without notice.
Operation Section 14 4.2 Characteristics Cooling Capacity (x103 Btu/h) 18 25.2(14) 23.4(13) 14 21.6(12) 12 19.8(11) Delta-T °F (°C) 16 10 Dry Bulb Temp. °F (°C) 8 113(45) 104(40) 18.0(10) 16.2(9) 14.4(8) 12.6(7) 95(35) 10.8(6) 86(30) 77(25) 68(20) 9.0(5) 30 59 (15) Current Consumption (A) 1.3 1.1 80 14 12 10 0.
Operation Section 15 5. REFRIGERANT SYSTEM 5.1 Refrigerant System Construction The component parts of the refrigerant system include the following: • Compressor, Evaporator, Condenser, Capillary tube These parts are all connected by copper tubing. All the connections have been brazed.
Operation Section 5.2 Compressor • The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in one casing. (1) 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 (compression mechanism) rotates to compress the refrigerant.
Operation Section 17 (2) 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 Discharge Hole Discharge Valve loaded blade is mounted on the cylinder. The Spring Suction Hole Blade roller turns to compress the refrigerant in the space between the cylinder and eccentrically mounted roller. The blade is in contact with the Shaft Roller roller by means of spring force.
Operation Section (3) Operation 1) Start of compression Discharge Valve 1) The cylinder is filled with low pressure gas. Blade 2) Since pressure in the discharge chamber is higher than in the cylinder, the discharge valve is kept closed. Roller I001676 2) Suction and compression Discharge Valve 1) The pressure in the cylinder increases gradually. Blade 2) Refrigerant suction begins on the suction side of the cylinder. 3) The discharge valve remains closed.
Operation Section 19 (4) Compressor lubrication •The lubrication system is comprised of a hollow shaft, an oil scraper mounted at the end face, hollow shaft, a shaft journal (shaft bearing), Rotor and the lubrication groove for the shaft journal. The lubrication groove is wider than the oil Hollow Shaft hole. When the shaft turns, oil is scraped Eccentric Shaft Cylinder upward by the oil scraper along the inside Roller diameter of the hollow shaft.
Operation Section 5.5 Evaporator • The evaporator 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 vent. 5.6 Accumulator •The accumulator is mounted on the suction gas From Evaporator piping between the evaporator and the compressor.
Operation Section 21 6. ELECTRICAL SYSTEM 6.
Operation Section 6.2 Basic Operation of The 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.
Operation Section 23 6.3 Control Box (1) Capacitors • The capacitors are used to temporarily boost the power output available to the fan motor and the compressor at start-up. • The specifications of each capacitor are listed below: Capacitor Application Voltage Rating Capacitance Fan Motor 370 VAC 7.
Operation Section (2) Relay board • The relay board receives signals and outputs from the control board that contains a Dip Switch 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 V. Temperature Scale Display Switch (°C⇔°F) Fan Mode Control Switch (STOP⇔OPERATE) • This 12 V is then converted from AC to DC and I002196 used for relay coil activation.
Operation Section 25 6.4 Fan Motor • The fan motor is a single phase, induction type two-speed motor. The motor rotates the fan on both the evaporator side and the condenser side at the same time. Specifications: - Rated Voltage: 115 V, 60 Hz - Rated Output: High-240 W, Low-190 W Ground (Green/Yellow) CF1 (White) CF2 (Brown/White) J5 Low (Red) J6 High (Black) I002198 < NOTE > An internal overload relay is used to protect the fan motor.
Operation Section 6.6 Compressor Overload Relay • An external compressor overload relay is used Bimetal to protect the compressor motor. This relay is mounted within the connector housing that attaches to the top of the compressor. The Points relay interrupts the flow of current when there is an overload condition and, high temperature Terminal builds up in the compressor.
Operation Section 27 6.8 Drain Switch • The Classic Plus 14 is equipped with a drain tank switch. When the drain tank accumulates approximately 4.0 gal (15 L) 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, flashes the "TANK FULL” LED, indicates "TANK FL” on the LCD and closes the contact of output signal. • This system utilizes a 0.1 A, 125/250 VAC micro-switch for this function.
Operation Section (1) How to re-start the unit • If the LCD indicates “PROGRAM ON”, press the COOL ON/OFF button to continue running the program. If the LCD indicates “PROGRAM ON” continuously (program activated), no further steps are necessary. If no program exists or the program was deactivated, press the FAN MODE button or the COOL ON/OFF button. The unit returns to the previous temperature set point. 6.
Operation Section 29 6.13 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.
Operation Section 30 6.15 Warning Signal Connection (Output Signal Terminal L+ and L-) • The controller is equipped with a warning signal output relay type (Form C, normal open dry contact) which can be used to monitor the failure condition.
Repair Section 31 7. TROUBLESHOOTING 7.1 Troubleshooting • 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 V (60 Hz) • 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.
Repair Section 32 7.2 Self-Diagnostic Codes • Self-diagnostic codes are displayed on the control board under the following conditions and clear method is as follows. LCD Display Description Drain tank is full Condition When the drain tank is filled with drain water. (“TANK FL” LED flashes and signal Reset/Remedy 1) Drain away. (LCD indicates “TANK”) 2) Press ON/OFF button. output (J106) turns on.) TU AM HI Condensate pump When (optional) condensate pump 1) Fix the condensate pump.
Repair Section LCD Display Description MO TU WE TH FR SA SU AM START Press HI/LO and U buttons After 5 sec., display goes back to all on mode simultaneously for 3 sec. normal mode. (To check LCD segments and LED PM LOCKED F C HI FAN LO ON COOL OFF Reset/Remedy Show LCD and LED PROGRAM ON STOP CLOCK Condition F C display.) SET TEMP ROOM TEMP TU AM Key lock mode (LCD Press ENTER and SET CLOCK Press ENTER and SET CLOCK displays “LOCKED”.) buttons simultaneously for 5 sec.
Repair Section 7.3 Troubleshooting Chart • To accurately troubleshoot the problem, it is important to carefully confirm the nature of the problem. Typical problems are: - Insufficient cooling. - Unit does not start (operate). - Overflow of drain water. - Abnormal noise or vibrations. - Others. (1) Insufficient cooling • Cooling system problem generally results from electrical or mechanical components such as fan motor, compressor, control switch.
Repair Section 35 Possible Cause Symptom Remedy Checking Area 1. Usage conditions Cause Operation near usage limits. (high temperature). 2. Dirt in condenser or Compressor operates. Air volume normal Review the installation place. Insufficient heat exchange. Clean fins. evaporator. 3. Frost in refrigeration cycle. Clogging at the frost section. Replace clogged section. 4. No temperature difference Insufficient refrigerant.
Repair Section 36 (2) Unit does not start (operate) < NOTE > • In this case, there is a possibility of safety device activating due to the clogged air filter. So make sure to first clean the air filter and then start up again to confirm if the problem lies with the air filter. • Check the installation site for operating temperature and installation space (unobstructed airflow). Possible Cause Symptom Remedy Checking Area Does not operate at all 1. Voltage. Power failure. Repair power. 2.
Repair Section 37 Possible Cause Symptom Remedy Checking Area 1. Display code “FL”. Cause Drain tank (optional) is filled Discharge the drain water. with the drain water. Improper drain switch Check connection. connection. 2. Display code “AS”. Defective drain switch. Replace drain switch. Improper routing of drain Repair drain hose, then reset hose. unit. To RESET: Press ON/OFF and HI/LO buttons on the control box simultaneously for 5 sec. Defective condensate pump.
Repair Section 38 Possible Cause Symptom Remedy Checking Area Cause 1. Fan on-off relay on the relay board. Control immediately panel after display starting normally. Replace relay board. contact. 2. Fan HI/LO change relay on Stops Open circuit or insufficient the relay board. Open circuit or insufficient Replace relay board. contact. 3. Fan motor insulation Insulation failure on fan resistance. Replace fan motor. motor. 4. Compressor relay on the relay board.
Repair Section 39 (4) Abnormal noise or vibration • To prevent abnormal noise or vibration, carefully determine the source of the problem and come up with proper countermeasures to solve the problem so that it does not occur again. Possible Cause Symptom Remedy Checking Area 1. Fan. Abnormal noise or vibration. Cause Fan interference. Repair interfering section. Fan deformation. Replace fan. 2. Compressor fixing nuts. Looseness of nuts. Tighten nuts further. 3. Piping. Pipe interference.
Repair Section (4) Inspection of cooling capacity performance • Measure the difference in temperature between the inlet of the evaporator and the cool air vent. If the difference is out of the range given in the graphs on page 14, proceed with the remedy suggested in the troubleshooting chart on page 34 to 39.
Repair Section 41 8. DISASSEMBLY 8.
Repair Section 42 8.2 Disassembly 1) Remove drain tank. I002299 2) Remove eight (8) screws from ducts. Then Screws (4) remove two (2) ducts. Screws (4) I002329 3) Remove six (6) screws from service panel. Screws (6) I002339 4) Remove thirteen (13) screws from rear panel.
Repair Section 43 5) Remove twelve (12) screws from upper panel Screws (2) and two (2) screws from blower housing (condenser). Screws (2) Screws (4) Screws (4) (Back side) Screws (2) I002332 6) Remove seven (7) screws from left panel. Screws (3) Screws (4) I002319 7) Remove thirteen (13) screws from right panel.
Repair Section 8.3 Removal of Electrical Parts (1) Control box 1) Remove six (6) screws from service panel. (See page 42.) 2) Remove electrical parts. - Terminal block: Remove two (2) screws from control box. - Terminal block (signal connection): Remove two (2) screws from control box. - Capacitor: Remove two (2) screws from control box.
Repair Section 45 (2) Relay board 1) Remove six (6) screws from service panel. (See page 42.) 2) Disconnect seven (7) connectors, and remove five (5) screws from relay board.
Repair Section 3) Disconnect the following connectors from the B C D E A control board: (A) J201 (10-pin) Wire Harness, Relay Board to Control (B) J101 (2-pin) Room Temperature Thermistor (C) J102 (2-pin with black tape) Freeze Protection Thermistor F G I002247 (D) J103 (2-pin) Drain Tank Switch (E) J104 (2-pin) Not in use.
Repair Section 47 (4) Battery replacement of control board • When the power is unplugged from the unit, and control board is automatically resetting clock and program, it is time to change the battery on the control board to avoid resetting of clock and program. 1) Disassemble control board. (See page 45 and 46.) Control Board Battery I001805 2) See diagram for battery removal.
Repair Section 8.
Repair Section 49 (1) Removal of condenser fan 1) Loosen the set screw using a hex key. Then remove condenser fan. Set Screw I002217 (2) Removal of evaporator fan and fan motor 1) Remove two (2) nuts on the inside of the condenser fan casing in the locations shown. Then remove condenser fan casing. Nut (1) Nut (1) I002218 2) Remove two (2) nuts and two (2) screws as Nut (1) Nut (1) shown. Then remove the motor stay together with the fan motor.
Repair Section 8.5 Inspection of Capacitor (for Fan Motor and Compressor) (1) Ohmmeter method • Set the ohm-meter to the 10M range. Place the two probes against the two terminals of the capacitor. At first, the ohm-meter should indicate small value, then the reading should gradually increase towards infinity. This indicates that the capacitor is charging. If the reading indicates infinity right away (open) or the ohm-meter fails to move from 0. (shorted), I001808 replace the capacitor.
Repair Section 51 8.7 Inspection of Fan Motor • Measure resistance across the terminals of the fan motor. (All terminals must be disconnected from the unit.) • Between terminals (at 77 °F (25 °C)) - J6-CF1 Approx. 7.6 ohm - J6-CF2 Approx. 27.7 ohm - CF1-CF2 Approx. 35.5 ohm Ground (Green/Yellow) • If the measured resistance is not equal to these CF1 (White) CF2 (Brown/White) J5 Low (Red) J6 High (Black) I002198 standard values, replace the fan motor. 8.
Repair Section 8.11 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. (1) 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.
Repair Section 53 9. REFRIGERANT SYSTEM REPAIR 9.1 Repair of Refrigerant System • In case there is a leak, obstruction, or trouble in the refrigerant system of the Classic Plus 14, replace or repair the part in question. After replacing any component all connections must be brazed. (1) 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.
Repair Section (4) 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 (0.27 gal/min (1 L/min); adjust with the flow regulator) through the pinch-off tube of the refrigerant. < NOTE > Take care not to allow dirt, water, oil, etc. to enter into the pipe. (5) Vertical Joint • Heat the whole brazed fitting to a proper brazing temperature.
Repair Section 55 9.2 Removal of Refrigeration Cycle Components CAUTION • Before any refrigeration cycle component can be replaced, it is necessary to recover the refrigerant using standard recovery procedures and equipment. • To prevent oxidation, dry nitrogen should be conducted (flow rate 0.27 gal/min (1 L/min)) through the pinch-off tube during any brazing operation. • During any component replacement involving brazing, shield nearby parts with a steel plate, etc., to protect them from the flame.
Repair Section 56 9.3 Charging the System with R-410A Refrigerant • Always ensure that the refrigerant system has been properly evacuated before charging with the specified amount of R-410A. • Equipments is only for R-410A. • Liquid charge (no gas charge). • Make sure not to use more than 90 % of the initial weight of R-410A in the cylinder. WARNING • When handling refrigerant (R-410A), the following precautions should always be observed: - Always wear proper eye protection while handling refrigerant.
Repair Section 57 (1) Connection of gauge manifold 1) Properly remove the crushed end of the pinch-off Charging Hose Side Refrigerant Cycle Side 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 pinch-off tube on both sides.
Repair Section 58 (3) Checking vacuum Valve Setting LO HI Closed Closed Pressure Gauge 1) Leave the high pressure valve and the low Leave valves closed for 5 min or more. Pointer of pressure gauge returning to zero indicates there is a leak. pressure valve of the gauge manifold closed for five min or more, and confirm that the gauge pointer does not return to zero.
Repair Section 59 (4) Checking gas leak 1) Remove the charging hose (green) from the Valve Setting vacuum pump, and connect the hose to the LO HI Closed Closed Air Purging refrigerant cylinder (R-410A). Charging Hose Red (Green) To Process Tube Fitting 2) Loosen the nut on the gauge manifold side of the Refrigerant Cylinder R-410A Open The Valve of Refrigerant Cylinder charging hose (green). 3) Open the valve of refrigerant cylinder perform air purging in the charging hose (green).
Repair Section (5) Evacuation (repeat) 1) Close the valve of the refrigerant cylinder. Then Valve Setting Gauge LO HI Closed Open LO HI Closed Closed 30 inHg (100 kPa) or larger Low Pressure Valve High Pressure Gauge High Pressure Valve remove the charging hose (green) from the refrigerant cylinder, and connect it to the refrigerant recovery machine. < NOTE > High Pressure Side Tube Vacuum Pump (in Operation) Keep the high pressure valve and the low pressure valve of the gauge manifold closed.
Repair Section 61 9.4 Refrigerant Charging Work (1) Refrigerant charging 1) Remove the charging hose (green) from the Valve Setting vacuum pump, and connect it to the refrigerant LO HI Closed Closed Air Purging cylinder (R-410A). Charging Hose Red (Green) To Process Tube Fitting 2) Loosen the nut on the gauge manifold side of the Refrigerant Cylinder R-410A Open The Valve of Refrigerant Cylinder charging hose (green). Open the valve of the charging hose (green).
Repair Section (2) Removal of gauge manifold 1) Crimp the pinch-off tube with a pinch-off tool. Pinch-Off Tool Pinch-Off Tube 2) Remove the gauge manifold and the process To Gauge Manifold Side tube fitting. Crush the end of the pinch-off tube. 3) Braze the end of the pinch-off tube. Charging Hose To Refrigerant Cycle Side 4) Ensure that a gas leak is not present at the pinched off portion and the brazed end.
Repair Section 63 10. REASSEMBLY 10.1 Removal of Unit • 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. 10.2 Compressor Mounting • Mount the compressor on the frame, using cushions, steel collars, spring washers, plate Nut washers and nuts. Spring Washer Plate Washer Cushion Steel Collar I001818 10.
Repair Section 10.5 Perform the Inspection • Perform the inspection of cooling performance and check for abnormal noise or abnormal vibration. 10.6 Caster Maintenance • Lubricate bearings in caster as needed with standard bearing grease using the zerk fitting. < NOTE > Casters should roll and swivel freely. Check for dirt or dust build up. Remove dust or dirt build up.
Repair Section 65 10.
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