SERVICE MANUAL CM 25 Unit Serial Number Range: 1009XXXXC25 to Present (From October 2009 to Present) DocID: 00G00045EA
SERIAL NUMBER LOCATION AND IDENTIFICATION Nameplate Label COOLING AMPS. WITH PUMP COMPR. OUTPUT REFRIGERANT/TOTAL CHARGE DESIGN PRESSURE LO/HI PART NO./WEIGHT SERIAL NO. Nameplate Label Position ▲▲ XXXX ### Month Year Model Sequential Number © 2012 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.
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 5.12 Condenser Fan Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 5.13 Internal Drain Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.14 Anti-Frost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.15 Fan Motor Reverse Rotation Protection . . . . . . .
Table of Contents Repair Section 6. TROUBLESHOOTING 6.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.2 Self-Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 6.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 6.
Operation Section 1. PRECAUTIONS FOR SAFETY 1.1 Foreword • This manual has been published to service the MovinCool CM 25. Use this manual only when servicing the CM 25. 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. SPECIFICATIONS 2.1 Exterior Dimension Diagram 0.9 2.4 0.8 10.2 0.9 19.7 53 51.3 DIA. 13.8 22.4 DIA. 0.6 6.5 14.4 DIA. 12 34.6 1.1 4 0.6 17.8 0.8 3.4 DIA. 12 4 x DIA. 0.6 29.8 9.5 16 10.7 4 31.
Operation Section 8 2.2 Technical Specifications Wall Mounted Controller (WMC) with LCD Operation display Electronic Features Electronic Characteristics Control Electronic with Inverter Circuit Voltage Requirement Single-Phase 208/230 V 60 Hz Min.- Max. Voltage Recommended Fuse Size Min. 198 V, Max.
Operation Section 9 • Dry contact type (recommended) • No-voltage contact input/Contact Fire Alarm Input Signal Connection resistance less than 100 ohm Warning Signal Output 2 A at 30 V DC/AC max. with resistive load W x D x H (without flange) 53 x 32 x 20 in (1346 x 813 x 508 mm) W x D x H (with flange) 57 x 36 x 20 in (1448 x 914 x 508 mm) Dimension Weight Net/Shipping 310/353 lb (140/160 kg) Pump Rate 5.0 gal/h (19 L/h) Internal Drain Pump Capacity Head 4 ft (1.2 m) Max.
Operation Section 2.3 Characteristics • Value range for each outdoor temperature shown in the graphs is based on the compressor speed.
Operation Section 11 (2) Cooling capacity curve 40 Condenser Inlet Air Temperature 50°F (10°C) Cooling Capacity (x103 Btu/h) 35 30 25 Condenser Inlet Air Temperature 95°F (35°C) 20 15 Condenser Inlet Air Temperature 115°F (46°C) 10 Evaporator Inlet Air Dry Bulb Temp. °F (°C) 5 95 (35) 86 (30) 77 (25) 68 (20) 59 (15) 41 (5) 50 (10) 59 (15) 68 (20) 77 (25) Evaporator Inlet Air Wet Bulb Temp. °F (°C) IILL00676-00 < NOTE > Condenser inlet air temperatures are at 50% relative humidity.
Operation Section 12 (3) Power consumption curve 4.0 3.5 Condenser Inlet Air Temperature 115°F (46°C) Power Consumption (kW) 3.0 2.5 Condenser Inlet Air Temperature 95°F (35°C) 2.0 1.5 Condenser Inlet Air Temperature 50°F (10°C) 1.0 0.5 Evaporator Inlet Air Dry Bulb Temp.°F (°C) 0 95(35) 86(30) 77(25) 68(20) 59(15) 50 (10) 59 (15) 68 (20) 77 (25) 86 (30) 95 (35) Evaporator Inlet Air Wet Bulb Temp.
Operation Section 13 (4) Current consumption curve 16 Condenser Inlet Air Temperature 115°F (46°C) 14 Current Consumption (A) 12 Condenser Inlet Air Temperature 95°F (35°C) 10 8 Condenser Inlet Air Temperature 50°F (10°C) 6 4 2 Evaporator Inlet Air Dry Bulb Temp. °F (°C) 0 95(35) 86(30) 77(25) 68(20) 59(15) 50 (10) 59 (15) 68 (20) 77 (25) 86 (30) 95 (35) Evaporator Inlet Air Wet Bulb Temp.°F (°C) ILL00678-00 < NOTE > Condenser inlet air temperatures are at 50% relative humidity.
Operation Section 14 (5) Cool air temperature difference curve Temperature Difference Between Evaporator Inlet and Outlet Air (Delta-T) °F (°C) 28.8(16) 25.2(14) Condenser Inlet Air Temperature 50°F (10°C) 21.6(12) 18.0(10) Condenser Inlet Air Temperature 95°F (35°C) 14.4 (8) 10.8 (6) Condenser Inlet Air Temperature 115°F (46°C) 7.2 (4) 3.6 (2) Evaporator Inlet Air Dry Bulb Temp.
Operation Section 15 3. CONSTRUCTION 3.1 Exterior Components Cool Air Exhaust (12.0 in.Dia.Flange) Condenser (Hot) Air Exhaust Connection For Optional Condensate Pump Evaporator (Room) Air Intake (12.0 in.Dia.
Operation Section 3.
Operation Section 17 3.3 Basic Construction • The MovinCool CM 25 is compact in construction due to the condenser and Control Box Condenser Evaporator evaporator being enclosed in one unit. The interior of the unit is divided into two sections. One section contains the evaporator which cools room interior air. The other section is comprised of the condenser, compressor and control box. Condenser Fan Motor Evaporator Fan Motor I003158 3.
Operation Section 4. REFRIGERATION SYSTEM 4.1 Refrigeration System Construction The component parts of the refrigeration system include the following: • Compressor, Evaporator, Condenser, Accumulator, Electronic expansion valve These parts are all connected by copper tubing. All the connections are brazed.
Operation Section 19 Flow of Refrigerant CTS1 (Condenser Thermistor) OLC (Compressor Overload Relay) MF1 (Condenser Fan Motor) CTS3 (Evaporator Pipe Outlet Thermistor) Accumulator Evaporator Condenser Compressor MF2 (Evaporator Fan Motor) HPRS (High-Pressure Switch) ODS (Condenser Inlet Air Thermistor) EXV (Electronic Expansion Valve) RTS2 (Evaporator Inlet Air Thermistor) CTS2 (Evaporator Pipe Inlet Thermistor) Wall Mounted Controller (WMC) RTS1 (WMC Room Thermistor) ILL00680-00
Operation Section 4.2 Compressor • The CM 25 is equipped with a variable speed compressor, which is driven by state of the art inverter technology. • A variable speed compressor automatically adjusts its speed as the heat load in the room changes. With its soft start up, a variable speed compressor reduces start up wear on the compressor and eliminates in-rush current resulting in no dip in the power supply.
Operation Section 21 (3) Operation 1) Start of compression Discharge Valve 1) The cylinder is filled with low pressure gas. 2) Since pressure in the discharge chamber is higher than in the cylinder, the discharge valve is kept closed. Piston Cylinder I003185 2) Suction and compression Discharge Valve 1) The pressure in the cylinder increases gradually. 2) Refrigerant suction begins on the suction side of the cylinder. 3) The discharge valve remains closed.
Operation Section (4) Compressor lubrication • The lubrication system is comprised of a hollow shaft, an oil scraper mounted at the bottom end of a shaft journal (shaft bearing), Rotor and the lubrication groove for the shaft journal. The lubrication groove is wider than the oil orifice. When the shaft turns, oil is scraped upward by the oil scraper along the inside Hollow Shaft Eccentric Shaft Cylinder Piston diameter of the hollow shaft.
Operation Section 23 4.4 Electronic Expansion Valve • The electronic expansion valve causes rapid refrigerant expansion by injecting "high- temperature, high-pressure liquid refrigerant" from the condenser through a small orifice.
Operation Section 4.6 Accumulator • The accumulator is mounted on the suction from Evaporator gas piping between the evaporator and the compressor. The accumulator separates the liquid refrigerant from the gas refrigerant, allowing only the gas refrigerant to enter the compressor. In the accumulator, suction gas is led into a cylindrical vessel where the speed of to Compressor the gas is decreased.
Operation Section 25 5. ELECTRICAL SYSTEM 5.
Operation Section 5.
Operation Section 27 5.3 Power Supply Requirements • The unit requires a single-phase 208/230 V, 60 Hz power supply to operate. • The power supply should be a dedicated single outlet circuit with a UL approved short-circuit and ground fault protective breaker with a fuse size of 20 A maximum. • Securely tighten each terminal.
Operation Section 28 5.4 Wall Mounted Controller (WMC) • The WMC for this unit should be mounted within the room close to the return air grill to provide convenient system control. LCD Display Control Panel 5 7 1 2 3 4 6 4.8 in (120 mm) 8 10 9 4.8 in (120 mm) 0.6 in (15 mm) I003163 1 ON/OFF button Activates (LED illuminates green) or deactivates unit operation. 2 MODE button Activates COOL or FAN ONLY operation. 3 FAN MODE button Activates fan mode RUN or AUTO.
Operation Section 29 LCD Display 11 12 13 14 15 16 17 19 18 I003164 11 COOL or FAN ONLY Illuminates to indicate COOL on or FAN ONLY on. 12 RUN or AUTO Illuminates to indicate fan mode set to RUN or AUTO. 13 HI or LO Illuminates to indicate fan speed set to High or Low. 14 Room temperature Illuminates temperature in either Fahrenheit (°F) or Celsius (°C) (See Note). 15 Set temperature Illuminates temperature in either Fahrenheit (°F) or Celsius (°C) in COOL mode (See Note).
Operation Section • WMC connection Connection Table Wall Mounted Controller Wire No. (Color) Unit Terminal Unit Terminal No. C4 G4 (Black) G4 Shield Conductor (Green) G (Ground Screw) G1 G Y2 Y1 RC C4 (White) P C4 G4 P E+ E– L+ L– P (Red) G Ground Screw Wall Mounted Controller (WMC) I003165 < NOTE > If the wiring needs to be extended, a maximum extension wire can be extended up to 316 feet. Shield wire 16-22 AWG is recommended for use as an extension wire to reduce noise interference.
Operation Section 31 For WMC supplied with the CM 25 serial number from 0113XXXXC25 to present • If the reading of the room temperature value is not accurate, adjustment can be done by setting the DIP switch located inside the WMC using the table shown below as reference. • Label of model name is located on the back cover of WMC. CAUTION To avoid static electricity, do not touch the solder joints or the non-insulated parts on the controller board.
Operation Section 5.5 Field-Supplied Millivolt Wall Thermostat (MWT) Connection • The CM 25 is equipped with terminals for connection to the MWT. The MWT can be installed for convenient access in any room. - Use with a single- and multi-stage system wall thermostat. Thermostat type: Millivolt system - Most wall thermostats provide these basic functions: Fan Mode: On/Auto (Selects the desired fan mode.) System: Cool/Heater (Selects Cool only.
Operation Section 33 5.6 Warning Signal Connection (Output Signal Terminal L+ and L-) • The unit is equipped with a warning signal output relay type (Form-C, normal open dry contact) that can be used to monitor the failure condition.
Operation Section 5.7 Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-) • The unit is equipped with a normal open input signal that can be connected directly from the fire alarm control panel. When receiving the signal from the fire alarm control panel, the unit turns off and does not turn back on until the power source is reset, or the MWT turns off and on.
Operation Section 35 5.8 Basic Operation • The following components are controlled based on settings and signals from the WMC or MWT in accordance with signals from various sensors: compressor, evaporator fan motor, condenser fan motor, electronic expansion valve, internal drain pump. 5.9 Compressor Operation (1) Startup speed control • The compressor operates at 40 rps for 120 the refrigeration cycle stabilizes, the inverter controls compressor speed.
Operation Section 5.11 Evaporator Fan Motor Operation • The evaporator fan motor is controlled by signals from the WMC or MWT. (1) When the WMC is connected • ON/OFF control and fan speed are determined by the WMC settings. Fan motor settings - AUTO: The fan motor turns ON when the compressor is ON, and OFF when the compressor is OFF. - RUN: The fan motor continuously operates, regardless of whether the compressor is ON or OFF.
Operation Section 37 5.13 Internal Drain Pump Operation • The internal drain pump evacuates evaporator condensation accumulated in the drain pan. This pump turns on only when the compressor is turned on. • After the compressor turns OFF, the internal drain pump continues to operate for 2.5 minutes before it turns OFF. I000523 5.
Operation Section 38 5.17 Relay Board • The relay board controls components such as the compressor and fan motor based on both signals received from the WMC or MWT, as well as signals from various sensors. The relay board is equipped with a compressor control device called the “STI module”. The relay board also contains fuses and a DIP switch.
Operation Section 39 (2) DIP switch configuration and setting • The controller of the unit is equipped with DIP switches that default in the OFF position. The DIP switch can be set to configure the following functions. ON OFF 1 2 DSW1 1 2 DSW2 1 2 3 4 1 DSW3 2 3 4 DSW4 I003192 Switch Switch Name Number Function ON Enables the MWT. OFF Enables the WMC. 1 DSW1 ON 2 No function. OFF ON Initializes setting of the condenser and evaporator fan motors after replacing the fan motors.
Operation Section 5.18 Compressor (1) Compressor motor • The CM 25 uses an inverter-controlled DC compressor. The compressor motor is operated by three-phase voltage outputted from the STI module on the relay board. Specifications: - Rated Voltage: DC 220 V - Rated Output: 1380 W I003143 (2) Compressor overload relay • An external compressor overload relay is used Bimetal to protect the compressor motor.
Operation Section 41 5.19 Fan Motor (1) Evaporator fan motor • The CM 25 uses an inverter-controlled DC evaporator fan motor. • The evaporator fan motor is operated by DC motor actuation voltage outputted by the relay board. Evaporator fan motor speed is controlled by a relay board built into the fan motor.
Operation Section 42 5.20 Temperature Thermistor • The temperature thermistor detects temperature as a resistance value.
Repair Section 43 6. TROUBLESHOOTING WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltages may remain in the unit immediately after the power is disconnected. 6.1 Troubleshooting • Before troubleshooting the system, the following inspection should be performed. (1) Inspection of power source voltage • Check the voltage of the power source.
Repair Section 44 6.2 Self-Diagnostic Codes • Self-diagnostic codes are displayed on the WMC and indicate by LED on the relay board under the following conditions. • LED on the relay board indicates self-diagnostic codes for the MWT under the following conditions.
Repair Section Self-Diagnostic Code Cause User Mode Service Mode E09 E09 E10 E10 OL OL E11 E11 E14 E15 Relay Board LED (Red) Alarm Pattern 1 2 3 4 Evaporator fan motor 5 6 Warning Signal Output Condenser fan motor locked Compressor overload STI module When compressor overload relay is activated. When a communication failure between the STI module and microcomputer on the relay board is detected for at least 40 seconds.
Repair Section Self-Diagnostic Code DF*1 Cause Relay Board LED (Red) Alarm Pattern 1 Freezing abnormality - 2 3 4 5 6 Warning Signal Output OFF Detection Contents When an evaporator inlet air thermistor temperature at or below 26.5°F (-3°C) is detected during compressor operation. However, detection is not possible for 5 minutes after the compressor starts. Evaporator fan motor IR*1 reverse rotation - When a fan motor reverse rotation signal (-760 rpm) is detected.
Repair Section 47 Alarm (buzzer) patterns Pattern 1 Pattern 2 Pattern 3 Pattern 4 ON OFF ON OFF ON OFF ON OFF 0.
Repair Section 48 Alarm clear method • Self-diagnostic codes are not displayed for the MWT. To identify the cause, check the LED on the relay board and refer to the charts on page 44 to 46. Self-Diagnostic Code Alarm Clear Method Cause User Mode Service Mode AL AL PU PU E07 E07 Wall Mounted Controller (WMC) Fire alarm input Condensation overflow (Internal drain pump) HP Press RESET button. Reset the power from the circuit breaker.
Repair Section Self-Diagnostic Code 49 Alarm Clear Method Cause User Mode Service Mode E18 E19 E20 E13 E21 E22 Self-Diagnostic Code DF*1 IR*1 OR*1 Wall Mounted Controller (WMC) Millivolt Wall Thermostat (MWT) Input overcurrent Power device temperature abnormality DC voltage abnormality Reset the power from the circuit Press RESET button. breaker.
Repair Section 6.3 Troubleshooting Chart • To accurately troubleshoot the problem, it is important to carefully confirm the nature of the problem. Condition Check Area Possible Cause Remedy Unit does not operate. 1. Voltage Power failure. Repair power supply. Turn the circuit breaker on. 2. Ground fault breaker trip Ground fault or defective Repair ground fault section. ground fault. Reset or repair circuit breaker. LCD display turns off. 3. Fuse Fuse is blown.
Repair Section Condition Unit does not operate. 51 Check Area Self-Diagnostic Codes (WMC) User Mode AL Buzzer Pattern Possible Cause Remedy Service Mode AL 1 Signal is input from the Check the fire alarm system and confirm fire alarm. there is no signal input to the unit, then RESET the controller*1. PU PU 3 Drain hose clogged Remove any blockage or excessive kinks (for internal drain pump). preventing water flow. Drain hose trap position Improve hose installation.
Repair Section 52 Condition Unit does not operate. Check Area Self-Diagnostic Codes (WMC) User Mode HP Buzzer Pattern Possible Cause Remedy Service Mode HP 4 Operating outside of the Check environmental condition. Do not operating temperature operate the unit outside the operating range. condition range. (See page 9.) RESET the controller*1. Insufficient air volume. Clean air filter. RESET the controller*1.
Repair Section Condition Unit does not operate. 53 Check Area Self-Diagnostic Codes (WMC) User Mode E05 Buzzer Pattern Possible Cause Remedy Service Mode E05 2 Loose CTS2 thermistor Reconnect the CTS2 thermistor and check connection. the connection. RESET the controller*1. Defective CTS2 Replace CTS2 thermistor. thermistor (short or RESET the controller*1. open). E06 E06 2 Loose CTS3 thermistor Reconnect the CTS3 thermistor and check connection. the connection.
Repair Section 54 Condition Unit does not operate. Check Area Self-Diagnostic Codes (WMC) User Mode E12 Possible Cause Buzzer Pattern Remedy Service Mode E14 4 Excessive current from RESET the controller*1 twice or three times. If the STI module to the the error still occurs, replace the compressor. compressor. E15 4 Compressor lock. RESET the controller*1 twice or three times. If the error still occurs, replace the compressor. E16 4 Compressor wires are disconnected.
Repair Section 55 Condition Check Area Possible Cause Remedy Insufficient Cooling Air is not Compressor start delay (120 Compressor starts after 120 seconds cool. seconds) is activated. automatically. Freeze protection is Compressor starts automatically when activated. evaporator outlet pipe temperature (CTS3) rises more than 43°F (6°C) while compressor stops. LCD displays normally. Evaporator fan reverse Fan rotates in reverse direction by rotation protection is abnormal air flow.
Repair Section 6.4 Self-Diagnostic Code Display Operation and Control (1) WMC • When an abnormality occurs in a unit, a selfdiagnostic code and “CHECK” will display on the WMC. Switching the self-diagnostic code display mode • The self-diagnostic code display can be switched between user mode and service Self-Diagnostic Code mode. - Press and hold the “” and “” buttons simultaneously for 3 seconds. - When in the service mode, self-diagnostic codes flash.
Repair Section 57 6.5 Self-Diagnostic Code Records Display Operation (Only When Connected With WMC) • The unit power on time, compressor operation time, and self-diagnostic codes can be displayed on the WMC when it is connected to CM 25. The unit power on time and compressor operating time can be stored up to 65535 hours (automatically cleared to 0 hour and start counting). The self-diagnostic codes can be stored up to 4 different codes.
Repair Section 58 (2) Exiting the self-diagnostic code records display • To exit the self-diagnostic code records display, press the "RESET" button, or do not operate the system for 1 minute. Display No.
Repair Section 59 6.6 Operational Status Display Control (Only When Connected With WMC) • The operational status of each functional part can be displayed while the CM 25 is running. (1) Display method • Press and hold the “”, “”, and “FAN MODE” buttons simultaneously for 3 seconds. • The display items can be switched using the “” or “” buttons. (2) Exiting operational status display • To exit the operational status display, press the “RESET” button, or do not operate the system for 1 hour.
Repair Section 60 Displayed Code Display Display Item Display Example Units 01 Compressor speed rps 90 (90 rps) 02 Electronic expansion valve position pulse 3 50 (350 pulse) 03 Evaporator fan motor speed rpm 8 80 (880 rpm) 04 Condenser fan motor speed rpm 8 65 (865 rpm) 05 Compressor operating current A 15 (15 A) 06 Evaporator inlet air thermistor (RTS2)*1 °F/°C 80 (80°F) 07 Condenser inlet air thermistor (ODS)*1 °F/°C 95 (95°F) °F/°C 120 (120°F) °F/°C 104 (104°F) 08
Repair Section 61 6.7 Initialize Fan Motor • Initialize the motor to correct the motor speed when any of the following components are replaced: evaporator fan motor, condenser fan motor, relay board. (1) Operation method 1) With the power supply OFF, turn DIP switch 2-1 ON. 2) Turn the power supply ON. 3) Turn DIP switch 3-1 ON. The evaporator fan motor and condenser fan motor will stop after operating for approximately one minute.
Repair Section Initialize Fan Motor TEST Mode ON OFF 1 2 DSW1 1 2 DSW2 1 2 3 DSW3 4 1 2 3 4 DSW4 I003178
Repair Section 63 6.8 TEST Mode • Test operation can be performed using the test mode. (1) Operation method • Set the CM 25 to standby mode, turn DIP switch 3-1 ON, then turn on the unit. The unit will automatically operate at the following conditions. - Compressor speed: 90 rps - Cool mode - Fan mode: RUN - Fan speed: HI < NOTE > The WMC (or MWT) will be rendered inoperative. (2) Quit • Turn DIP switch 3-1 OFF. CM 25 operation will stop, and the system will shift to standby status.
Repair Section 6.9 Basic Inspection • Perform the following inspection before disassembly. (1) Inspection of plate fins • To inspect the plate fins of either the evaporator or condenser, the air filter must be removed. After removal of the air filters, inspect the plate fins for any dirt, dust, lint, or debris that may have caused insufficient cooling performance of the unit.
Repair Section 65 6.10 Inspection of Compressor (1) Compressor motor W • Measure resistance across the terminals of the compressor motor. (All terminals must be disconnected from the unit.) V U • Between terminals {at 68°F (20°C)} - U-V Approx. 0.64 ohm - V-W Approx. 0.64ohm - W-U Approx. 0.64 ohm I003180 • If the measured resistance is not equal to these standard values, replace the compressor. (2) Overload relay • Check for continuity across two terminals of the overload relay.
Repair Section 6.11 Inspection of Electronic Expansion Valve Control Coil • Measure resistance across the connector pins of the electronic expansion valve control coil. • Between connector pins {at 68 °F (20 °C)} - Blue-Red Approx. 46 ohm - Amber-Red Approx. 46 ohm - Yellow-Red Approx. 46 ohm - White-Red Approx. 46 ohm • If the measured resistance is not equal to these standard values, replace the electronic expansion valve control coil.
Repair Section 67 6.14 Inspection of Refrigeration System • In most cases, the probable cause for insufficient cooling is a clog in the system, leakage or an incorrect amount of refrigerant. In such cases, inspect the system according to the following procedure. (1) Clogged refrigeration system • Check the component parts of the refrigeration system, including piping that could be clogged with refrigerant. If clogged with refrigerant, only the clogged part is partially frosted.
Repair Section 7. DISASSEMBLY WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. 7.
Repair Section 69 7.2 Disassembly 1) Loosen the bottom screw. Service Panel 2) Take out the nine (9) screws, and then remove the service panel. Screws (9) Bottom Screw (1) I003120 3) Disconnect the two (2) power supply lines from the terminal, and disconnect the ground line. Terminal CAUTION • Ground tightening torque: Ground Line - 1.0 ± 0.15 ft•lbf (1.3 ± 0.
Repair Section 70 5) Take out the thirteen (13) screws, and then remove the front right panel. Screws (9) Front Right Panel Screws (4) I003123 6) Take out the eleven (11) screws, and then remove the front left panel. Screws (4) Screws (7) Front Left Panel I003124 7) Disconnect the two (2) connectors, and disconnect the ground line. Connectors (2) Ground Line Pump I003125 8) Take off the three (3) screws and bolt, and Bolt (1) remove the internal drain pump assembly.
Repair Section 71 7.3 Removal of Evaporator Fan Assembly Frame Ring Fan Motor Set Screw Frame Fan I003127 < NOTE > Initialization is required after replacing the evaporator fan motor. (See page 61) 1) Take out the screw, and the four (4) nuts. Screw (1) Nuts (4) Evaporator Fan Assembly I003128 2) Disconnect the motor connectors (white, 5-pin Relay Board and white, 4-pin) from relay board CN3, CN4, and remove the evaporator fan assembly.
Repair Section 72 Set Screw 3) Take out the six (6) screws, and then remove the ring. Loosen the set screw with an Allen wrench Ring Set Screw and remove the fan. Screws (6) Fan I003130 4) When assembling the fan, ensure that the screws 0.12 in (3 mm) or more 0.12 in (3 mm) or more align with the motor axis positioning holes. CAUTION Set Screw • Tightening torque: - 10.0 ± 1.0 ft•lbf (14.0 ± 1.4 N•m) • Verify the clearance between the fan and case Motor Axis I003131 ring.
Repair Section 73 7.4 Removal of Condenser Fan Assembly Frame Ring Ring Set Screw Motor Fan Frame I003134 < NOTE > Initialization is required after replacing the condenser fan motor. (See page 61) 1) Take off the six (6) nuts. Nuts (2) Nuts (2) Nuts (2) Condenser Fan Assembly I003135 2) Disconnect the motor connectors (white, 4-pin Relay Board and white, 6-pin) from relay board CN1, CN2, and remove the condenser fan assembly.
Repair Section 74 Set Screw Set Screw 3) Take out the six (6) screws, and then remove the ring. Loosen the set screw with an Allen wrench and remove the fan. Ring Fan Screws (6) I003137 0.12 in (3 mm) or more 0.12 in (3 mm) or more 4) When assembling the fan, ensure that the screws align with the motor axis positioning holes. CAUTION Set Screw • Tightening torque: - 10.0 ± 1.0 ft•lbf (14.0 ± 1.4 N•m) • Verify the clearance between the fan and case Motor Axis I003138 ring.
Repair Section 75 7.
Repair Section (1) Relay board to Compressor Overlord Relay to Wall Mounted Controller to High-Pressure Switch to Electronic Expansion Valve to Millivolt Thermostat to Float Switch to Stop Switch DIP Switch to Evaporator Pipe Inlet Thermistor and Evaporator Outlet to Evaporator Thermistor Inlet Air Thermistor to Condenser Thermistor CN12 CN13 CN14 CN11 CN10 CN9 CN8 CN7 CN6 CN5 CN21 CN19 CN20 CN17 LED 7 LED1 LED2 LED3 LED4 LED5 LED6 to Output Signal CN18 to Internal Drain Pump
Repair Section 77 Replacement of Relay Board 1) Attach the relay board with the six (6) screws. Always tighten the ground line for the relay board together with the bottom right screw. Make sure that the DIP switches on the new relay board are all set to the off position. 2) Reconnect all 25 connectors to the new relay board. Refer to the figure “Relay Board” to identify the connectors that need to be connected.
Repair Section 8. REFRIGERATION SYSTEM REPAIR WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltages may remain in the unit immediately after the power is disconnected. 8.1 Repair of Refrigeration System • In case there is a leak, obstruction, or trouble in the refrigeration system, replace or repair the part in question. After replacing any component all connections must be brazed.
Repair Section 79 (3) Cleaning brazing filler metal and pipe • When the refrigeration 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 can reduce the effectiveness of brazing.
Repair Section 80 8.2 Removal of Refrigeration System Components WARNING • Before replacing any refrigeration cycle component, recover the refrigerant using standard recovery procedures and equipment. • When recovering the refrigerant, use the pinch-off tubes at the low pressure side (tube 1) and high pressure side (tube 2) as shown in the figure below. CAUTION • To prevent oxidation, dry nitrogen should be conducted {flow rate 0.
Repair Section 81 8.3 Charging the System with R-410A Refrigerant • Always ensure that the refrigeration system has been properly evacuated before charging with the specified amount of R-410A. • Equipment 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 (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 83 (3) Checking vacuum Valve Setting LO HI Closed Closed Pressure Gauge 1) Leave the high-pressure valve and the lowLeave valves closed for 5 minutes or more. Pointer of pressure gauge returning to zero indicates there is a leak. pressure valve of the gauge manifold closed for 5 minutes or more, and confirm that the gauge pointer does not return to zero.
Repair Section (4) Checking for gas leaks 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 the refrigerant cylinder and perform air purging in the charging hose (green).
Repair Section 85 (5) Evacuation (repeat) 1) Close the valve of the refrigerant cylinder. Then Valve Setting Gauge Low-Pressure Valve LO HI Closed Open LO HI Closed Closed 30 inHg (100 k Pa) or larger High-Pressure Gauge High-Pressure Valve High-Pressure Side Tube Vacuum Pump (in Operation) 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 lowpressure valve of the gauge manifold closed.
Repair Section 8.4 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 87 (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 9. REASSEMBLY 9.1 Reassembly 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. 9.2 Compressor Mounting • Mount the compressor on the frame, using cushions, steel collars, plate washers, and Nut nuts. Plate Washer Cushion Steel Collar ILL00178-00 9.3 Evaporator Fan Assembly • Install the evaporator fan.
P/N: SV0075-01 Second Issue: January 2013
