Service Manual
Contents
1. IDEALATT page 37 700870 700875 700877 SERVICE MANUAL Screws 5 Back Cover y Screws 10 lt Air Filter Air Filter F Screws 8 MA e Left Side Panel 38 page Portable Air Conditioners 8 Take out the five 5 screws and then remove the back cover 9 Remove the air filter from the right side panel 10 Take out the ten 10 screws and then remove the Right side panel A CAUTION Be careful not to damage temperature sensor 11 Remove the air filter from the left side panel 12 Take out the eight 8 screws and then remove the Left side panel IDEALAlr 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Control Panel Removal Screws 1 Take out the four 4 screws and then remove the control panel Control Panel suene IDEAL TT page 39 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Electrical parts and relay board removal2. lt 700870 gt Full Drain Switch Z Compressor 9 Condenser Motor E on m L2 6 SS Capacitor Z e SIND For Compressor N bl se 9 O CO FT FT FU FU PS PS o Pis T TH2 SG ET III Ms gt 1 M b A 0 Data Cable Connector 6 LE FUSE n j FUSE LEMC EXT CP AC j ale D mme i ee 0 4 PY RE p MC Magnetic contactor Ling d lol RET POWER SUPPLY amp M N 1 E3 f 4 jl Compressor ID R C IE Q E L 1 N 1 Fan Motor PIE for Condenser 6 e L 2 w MCCB Mold Case Current Braker co OCR Over Current Relay 40 page IDEAIA F 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners lt 700870 gt bow Cable Tie Relay Board Capacitor for Compressor OCR Over Current Relay Control Box V y N MCCB Mold Case Current Braker IDEALT page 41 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Fan Motor Removal lt 700870 gt 5 Condenser Motor Bracket 1 Eva Top Cover b 6 Evaporator Motor 6 Evaporator Motor Bracket 2 Evaporator Fan Partition 3 Eva Scroll 1 Take off the three 3 bolts of evaporator top cover 2 Loosen the set screw with a hex key and then
3. Control panel Before operating the unit it is important to be familiar with the basic operation of the control panel ET EE POWER BLOWER SPOT COOL ROOM COOL 1 POWER BUTTON Activates unit when POWER BUTTON is pressed Fan starts on low speed f POWER BUTTON is pressed during operation unit stops 2 BLOWER BUTTON Changes fan speed from LOW to HIGH when pressed 3 SPOT COOL BUTTON Activates compressor and begins producing cool air 5 seconds after button is pressed Regulates temperature based on outlet cool air temperature 4 ROOM COOL BUTTON Activates compressor and produces cool air 5 seconds after button is pressed Regulates temperature based on inlet ambient air temperature AAA AAA AAA IDEALT page 19 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners 5 SET TEMP BUTTON e Change target temperature data value by 1 e Change data value by 10 by pressing continually e Press the SET TEMP BUTTONS to set temperature e Upper button is to heighten temperature and Lower button is to lower temperature ALARM e Alarm indicator light blinks and indicates abnormal system operation If Alarm occurs compressor stops System operation stops when ALARM light is activated blinking longer than 3 minutes CURRENT TEMP Room cool mode displays current room te
4. 26 page IDEALA 700870 700875 700877 SERVICE MANUAL Self Diagnostic Codes Self diagnostic codes are displayed on the Display Panel under the following conditions Portable Air Conditioners Alarm Display Problem Corrective Action Frost prevention sensor and Abnormal temperature sensor value Indoor heat exchanger temperature too low TH3 temperature sensor has a loose or broken connection e Do not use the air conditioner if ambient temperature is lower than 18 C 64 F Contact a qualified service agent Refrigerant high pressure switch Blocked air filter Blocked kinked exhaust duct Ambient temperature is too high e Clean air filter Ensure exhaust duct is not blocked kinked Do not use the air conditioner if ambient temperature is higher than 45 C 113 F Abnormal temperature sensor value TH1 Outlet temperature sensor has a loose or broken connection Contact a qualified service agent Abnormal temperature sensor value TH2 Inlet temperature sensor has a loose or broken connection Contact a qualified service agent Ambient temperature is Do not use the air conditioner if ambient temperature is higher than Compressor too high n overloaded Unstable voltage supply 45 C 113 F Defective compressor Contact a qualified service agent Replace compressor eEmpty the water tank Condensate e
5. 6 Evaporator 2 Evaporator Fan Partition Motor Brocket 1 Take off the three 3 bolts of evaporator top cover 2 Loosen the set screw with a hex key and then remove the evaporator fan 3 Take off the five 5 bolts of the Eva scroll and then remove the Eva scroll 4 Loosen the set screw with a hex key and then remove the condenser axial fan 5 Take off the four 4 hex bolts from the condenser motor bracket and then remove the condenser fan motor 6 Take off the four 4 hex bolts from the evaporator motor bracket and then remove the evaporator fan motor EM IDEALT page 49 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners REFRIGERANT SYSTEM REPAIR Brazing e n the event of a leak obstruction or trouble in the refrigerant system of the unit replace or repair the defective component After replacing defective com ponent braze all connections 1 Proper brazing technigues e When brazing use a slightly reduced flame Oxyacetylene is commonly used since the flame condition can be easily judged and adjusted Unlike gas weld ing a secondary flame is used for brazing Properly preheat the base metal according to the shape size and thermal conductivity of the brazed fitting e The most important point in flame brazing is to bring the entire brazed fitting to a proper brazing temperature Care should be taken not to cause overflow of the brazing filler metal oxidation of the brazing filler m
6. DO NOT tilt the unit DO NOT cover or obstruct the unit s inlet and outlet grilles DO NOT use the unit in areas where it will be exposed to rain or water NEVER unplug the unit while it is operating y W ARN DO use the unit in wet environments such as a laundry room to avoid the risk of electrical shock N COON 10 DO NOT place any foreign objects the unit 11 DO NOT operate the unit with wet or damp hands 12 DO NOT allow chemical substances to come into contact with the unit 13 DO NOT operate the unit in the presence of flammable substances or va pors such as alcohols pesticides gasoline etc 1 WARNING DO NOT operate the unit in explosive or flammable environments 14 DO NOT use the plug to start and to stop the unit Always use the control panel to start and to stop the unit 15 Always turn off the unit when it is not in use and unplug the power plug from the electrical outlet 16 Always turn the unit off and unplug the main power plug from the electrical outlet before cleaning moving or performing maintenance IDEALT page 33 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners 17 AVOID the use of adapter plugs or extension cords If it is necessary to use an extension cord or an adapter plug to operate the unit ensure that they are correctly rated for the application Consult a local qualified electrician and all local
7. Roller 2 Suction and compression Discharge 1 The pressure in the cylinder increases gradually 2 Refrigerant suction begins on the suc tion side of the cylinder 3 The discharge valve remains closed 3 Discharge 1 The pressure in the cylinder exceeds that in the discharge chamber and the discharge valve opens 2 On the suction side refrigerant suc tion continues Roller 4 Completion of compression 1 When compression is completed all of the refrigerant has been drawn from the suction chamber 2 Operation then returns to step 1 Start of compression and the above pro cess of suction and compression con tinues repeatedly in succession Discharge Valve 14 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners 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 and the lubrication groove for the shaft journal The lubrication groove is wider than the oil hole When the shaft turns oil is scraped Hollow Shaft upward by the oil scraper along the inside Cylinder diameter of the hollow shaft The oil is fed through the oil hole by centrifugal force then supplied to the lubrication groove for each shaft journal lubricating the bearing Oil Feed Groove In this lubrication system oil enters into Oil Hole Oil Scrapper each bearing separat
8. IDEALAit IDEAL AIR Portable Air Conditioners Models 700870 700875 700877 SERVICE MANUAL IDEALair 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Table of Contents GENERAL ALLAU AUU 4 General air conditioning system Portable air conditioning system 5 54 5 Exterior Dimension Diagram Technical Specifications Characteristics CONSTRUCTION EE 9 Internal Structure REFRIGERANT SYSTEM CONSTRUCTION 12 Compressor Compressor lubrication Condenser Capillary Tube Evaporator Accumulator 17 Circuit Diagram Control panel Program Setting Controller Board Control Specifications Self Diagnostic Codes Compressor Evaporator Fan Motor Condenser Fan Motor Capacitor Molded Case Circuit Breaker Magnetic Contact Thermal Relay Temperature Thermistor Drain Tank Switch 2 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners 32 Component parts General Safety Information Troubleshooting chart DISASSEMBLY For 700870 EL ERE 36 Disassembly Control panel removal Electrical parts and relay board removal Fan motor removal DISASSEMBLY For 70087 5 708 7 7 43 Disassembly Control panel removal Electrical parts and relay board removal Fan motor re
9. Compressor Locking Swivel Caster IDEALA page 11 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners REFRIGERANT SYSTEM CONSTRUCTION lt 700870 700875 700877 gt lt Flow of Condenser Air Outlet Refrigerant Condenser Motor Condenser Evaporator Capillary tube Drier 12 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Compressor 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 To Condenser From Evaporator Terminal Stator Strainer Cylinder Roller Lubricator Accumulator page 3 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Compressor operation 1 Start of compression Discharge 1 The cylinder is filled with low pressure Valve gas 2 Since pressure in the discharge cham ber is higher than in the cylinder the discharge valve is kept closed
10. Air Filter M NS BERK RKK RRR KR RXR ps LRR Portable Air Conditioners 6 Take out the fourteen 14 screws and then remove the upper panel 7 Unfasten the connector from the control panel and then remove the front panel 8 Remove the air filter from the back panel 9 Take out the two 2 screws and then remove the back plate panel IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Low Cover Screws 2 Screws 8 Right Side Panel 10 Take out the eight 8 screws and then remove the back cover panel 11 Take out the four 4 screws Unfasten two 2 screws to a half point and then remove the low cover panel 12 Take out the eight 8 screws and then remove the right side panel IDEALalf page 45 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Left Si y Screws 8 de Panel Control Panel Screws 4 46 page 13 Take out the eight 8 screws and then remove the left side panel 1 Take out the four 4 screws and then remove the control panel IDEAL 700870 700875 700877 SERVICE MANUAL Portable Air Conditi Electrical parts and relay board removal oners lt 700875 700877 gt Full Drain Swit
11. and therefore evaporates easily Evaporator The evaporator is a heat exchanger covered with slit fins Heat is removed from the air being pulled across the evaporator by the centrifugal fan The resulting cool air is expelled through the cooling air ducts Accumulator The accumulator is mounted on the suction gas pip ing between the evaporator and the compressor The accumulator separates the liquid refrigerant from the gas refrigerant allowing only the gas refrig erant to enter the compressor In the accumulator suction gas isled into a cylindrical vessel where the speed of the gas is decreased This process separates the refrigerant contained in From Evaporator To Compressor lt a the gas by the force of gravity causing the refrigerant to accumulate at the bot tom of the vessel As a result the compressor is protected from possible damage caused by liquid refrigerant intake 16 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners ELECTRICAL SYSTEM Circuit Diagram lt 700870 gt F MB SL STF tor POWER SH 62 IN AGIN amp lt amp COND Motor Q MC OCRI
12. remove the evaporator fan 3 Take off the five 5 bolts of the Eva scroll and then remove the Eva scroll 4 Loosen the set screw with a hex key and then remove the condenser axial fan 5 Take off the four 4 hex bolts from the condenser motor bracket and then remove the condenser fan motor 6 Take off the four 4 hex bolts from the evaporator motor bracket and then remove the evaporator fan motor 42 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners DISASSEMBLY For 7 Disassembly x Cooling Air Duct 22 Screws 12 Drain Tank 41 A Service Panel 75 7 77 1 Remove the drain tank 2 Remove two 2 support lines and remove front panel 3 Take out the twelve 12 screws and then remove the cooling air duct 700875 eight 8 screws 4 Take out the three 3 screws and then remove the service panel 5 Off the circuit breaker For safety IDEALT page 43 700870 700875 700877 SERVICE MANUAL e 7 14 Upper Panel AO W PO IO Ree 15 5609 6959604 HN so Screws 2 Back Plate Panel
13. After installation of the water level Condensate tank is full water tank press the SPOT alarm COOL or ROOM COOL button to resume operation Drain pump defective eCheck the hose connection Drain pump improper hose connection and hose including kink or blockage eReplace drain pump IDEALT page 27 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Compressor 1 Compressor motor e The compressor motor is a single phase motor and is contained within the same housing as the compressor Specifications Rated Voltage Rated Output 700870 115V 1175W 5 700875 208 230 V 2000W 1980W 700877 208 230 V 2700W 2715W 2596 2 Compressor overload relay e The compressor overload relay is used to protect the compressor motor The relay interrupts the flow of current when there is an overload condition and high temperature builds up in the compressor Inner protector Run capacitor 28 page IDEAL 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Evaporator Fan Motor e The fan motor is a single phase induction type The motor rotates the fan e The following table shows the specifications of the fan motor used for each model NOTE An internal overload relay is used to protect the fan motor This relay is built into the fan motor and interrupts the flow of current when there is an over curr
14. E CONTROL ee BOARD o 4 o na Comp Over Load Comp 6 CO co Over Load EAVP 9 H Motor L TH1 OUT TEMP 3 OUT TEMP SENSOR 8 SENSOR IN_TEMP IN TEMP TH2 SENSOR 3 SENSOR ICE TEMP QH SENSOR 3 SENSOR DRAIN FU FLOAT PUMP SWITCH PRESSURE yl PS SWITCH PRESSURE IT SWITCH FLOAT FT SWITCH FLOAT TS SWITCH page 17 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners lt 700875 700877 gt POWER BLOWER SPOTICOOL ROOMICOOL 1 MB JE 10 Power 15 a 1 AC208 230V est s CONTROL ep o BOARD Ira Comp Over Load Comp 0 6 CO co Over Load amp EAVP Motor OUT TEMP e i OUT TEMP SENSOR SENSOR IN TEMP e IN TEMP TH2 SENSOR e 3 SENSOR ICE TEMP ICE_TEMP SENSOR 3 SENSOR DRAIN Fu FLOAT PUMP SWITCH PRESSURE PS SWITCH Sl PRESSURE T SWITCH FLOAT FT SWITCH 8 FLOAT SWITCH 18 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners
15. Electrical access RUBBER STOPPERS 1 Take out the rubber stoppers from the accessory box 2 Place the rubber stoppers on the back side of air conditioner 3 Use screws enclosed inside of accessory box with rubber stoppers to install the rubber stoppers on the air conditioner as shown in Figure 4 WARM AIR TOP EXHAUST DUCT Optional A warm air top exhaust duct can be purchased separately Exhaust duct fits over the top exhaust fan duct improving cooling efficiency allowing hot air to be exhausted to another location 1 Remove duct from carton 2 Place duct on the top of air conditioner 3 Use screws enclosed inside of box with duct to install duct on air conditioner as shown in Figure 6 32 page IDEAL 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners General Safety Information Please read this manual carefully for instructions on correct installation and usage Please read all safeguards Transport and store the unit in an upright position only Leave unit in an upright position for at least 3 hours before first use Always place the unit on an even level surface 3 Ensure the unit is connected to a grounded power supply of the correct rating capacity 4 The unit will cool when the room temperature is between 18 C 64 4 F 45 C 113 F depending on the thermostat setting 5 DO NOT use this unit for functions other than those described in this instruc tion manual
16. LED shows PS output signal ON FT Tank Full Switch On Between 10 to 20 On Activates Defect control mA at DC12 V Contact Normally closed FT Off signal LED shows FT Output signal ON IDEALT page 23 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Control Specifications 1 EVAPORATOR FAN MOTOR When the BLOWER button is pressed the RL1 3 fan motor HI LOW relay on the relay board turns on operating the fan Specifications RL1 3 Fan motor HI LOW relay output 10 A at AC 250 V 2 Compressor start control When the ON OFF button is pressed the RL4 relay on the relay board turns on operating the compressor Specifications RL4 Compressor On Off relay output 5 A at AC 250 V 3 Anti freeze control Anti freeze controls turns the compressor on and off by turning the RL4 relay on in accordance with the freeze protection thermistor TH3 temperature As a result decreases in cooling performance due to frost buildup on the evaporator are prevented Compressor off conditions Freeze protection thermistor TH3 temperature lt 28 4 F 2 C Compressor on recovery conditions TH3 ICE temperature gt 33 8 F 1 C ON C3 OFF 28 4 33 8 F TH3 temperature 2 C 1 C Evaporator out temperature 24 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners 4 Compressor time delay control co
17. able Air Conditioners CONSTRUCTION Internal Structure lt 700870 gt lt Condenser Air Outlet R Control Box Relay Board Capacitor Control Panel Drain Tank Compressor Cooling Air Duct Locking Swivel Caster IDEALT page 9 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners lt 700875 gt Condenser Evaporator Motor Control Box Relay Board Capacitor Drain Tank Compressor Locking Swivel Caster 10 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners lt 700877 gt Control Panel ey P A ll So Y lt Condenser gt L T ea Evaporator Motor 5 gt a S AAA y b y ING A 4 Pa EANET 4 NIS f a IS DN A Im 22 Control lt j Relay Board Drain Tank lt gt Aa Drain Tank Switch N xN C ES l gt ES P
18. ator Drain Pan N Portion Nm Wu 222 NC 2 SN Relay Portion A Board IDEALATT page 31 700870 700875 700877 SERVICE MANUAL ASSEMBLY Component parts Cool air outlet hose lt Top fan wire grille Display Control board l Evaporator filter Guide bar for condensate water tank gt Condensate water tank Water level is sensed and the unit operation is stopped when tank is full An alarm will be Front and Right Side View displayed Empty the tank and replace to resume operation POWER CORD HOLDER 1 Take out the cord holder from the accessory box 2 Place the cord holder on the back side of air conditioner 3 Use screws enclosed inside of accessory box with cord holder to install the cord holder on the air conditioner as shown in Figure 3 DISCHARGE DUCTS SUPPLY AIR DUCT 1 Remove cool air outlet hose s from carton 2 Place the cool air outlet hose s on the front top AD of air conditioner 3 Use screws enclosed a inside of box with cool air outlet hose s to install the cool air outlet hose s on the air conditioner as shown in Figure 5 Portable Air Conditioners Rubber stopper Side handle lt Condenser filter panel 5 Power cord holder wi Caster Back and Left Side View
19. ch p MC Magnetic Contactor Compressor R for Evaporator Motor citor a ompressor 0 ca old case s sly Current Braker HLEMC EXT CP AC n la HE OCR Over Current Relay B E o 1 2 N 2 Fan Motor for Condenser FIT PH PT PI PT Compressor for Condenser Motor Data cable connector Capacitor IDEALT page 47 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners lt 700875 700877 gt Capacitor for Compressor Cable Tie Capacitor for Eva motor Es A 8 Capacitor for Cond motor eH OCR Over Current Relay Relay Board 48 page IDEAIA F 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Fan Motor Removal lt 700875 700877 gt 4 Axial Fan gt 27 1 Eva Top Cover 5 Condenser Motor Bracket
20. electrical codes to ensure proper setup Any extension cord used with this device must be rated for a minimum of 15A 18 DO NOT unplug the unit by pulling on the electrical cord Keep electrical cord away from heat sources and always completely unroll the cord to avoid overheating If the power cord becomes damaged a qualified service agent qualified electrician or similarly qualified person must replace it in order to avoid a hazard or shock WARNING Do wor operate a unit with a damaged power cord 19 The filters must be used with the product at all times When the filters are removed for cleaning always ensure that the unit has been turned off and unplugged from the electrical outlet 20 Regularly clean the filters to maintain efficiency If the filters are not cleaned regularly the units output performance and efficiency will decline and energy consumption will increase 21 DO NOT operate the unit with a damaged power cord or plug after it mal functions has been dropped or damaged 22 Only use in the upright position on an even flat surface Unit must be posi tioned at least 24 inches 60 cm from the nearest object in any direction 23 Stop operation immediately if abnormal noise or odor is noticed Contact a local service center 24 Appliance is not to used by children or persons with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision
21. ely and returns to the oil reservoir This system effectively prevents bearing temperature increases and offers high reliability In addition the specially treated shaft journal keeps the bearing from being damaged during high temperature operation Rotor Eccentric Shaft Condenser 1 The condenser is a heat exchanger with Louver fins 2 Heat is given off and absorbed by air being pulled across the condenser fins by the axial fan The air is then expelled through the condenser air outlet IDEALA I page 15 700870 700875 700877 SERVICE MANUAL Capillary Tube Portable Air Conditioners The capillary tube is a long thin tube that utilizes line flow resistance as an expansion valve The length and the inner diameter of the capillary tube are determined according to the capacity of the refrigeration system operating conditions and Low Temp Low Pressure the amount of refrigerant The high Gas and Liquid Mixture lt High Temp High Pressure Liquid Refrigerant pressure high temperature liquid re frigerant sent from the condenser expands 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 becomes low and mist like
22. ent situation or if abnormally high temperature builds up in the fan motor Condenser Fan Motor e The fan motor is a single phase induction type The motor rotates the fan e The following table shows the specifications of the fan motor used for each model NOTE An internal overload relay is used to protect the fan motor This relay is built into the fan motor and interrupts the flow of current when there is an over current situation or if abnormally high temperature builds up in the fan motor EE i IDEAL TT page 29 700870 700875 700877 SERVICE MANUAL Capacitor Capacitor e The capacitor is used to improve the rotational power of the fan motor and compressor at start up The specification for each capacitor is shown below Portable Air Conditioners Check capacitance Capacitor Rated Voltage Capacitance Compressor 250 v 45uF 700870 Evaporator Fan Motor 450 v 10uF Condenser Fan Motor 450 v 3 5uF Compressor 370v 50uF 700875 Evaporator Fan Motor 450 v 8uF Condenser Fan Motor 450 v 8uF Compressor 370v 50uF 700877 Evaporator Fan Motor 450 v 5uF Condenser Fan Motor 450 v 7uF Temperature Sensor e Outlet temp sensor TH1 is installed on top of the evaporator and detects evaporator outlet temperature as a resistance value Inlet temp sensor TH2 is installed in front of evaporator and detects evapo
23. etal or filler metal deterioration due to overheating the flux 2 Brazed fittings and fitting clearance In general the strength of the brazing filler Clearance metal is lower than that of the base metal 0 001 0 003 in As such the shape and clearance of brazed 02570075 mm fittings are very important Concerning the shape of brazed fittings adhesive area 1 7 must be maximized In addition the clear ance of the brazed fitting must be mini Clearance From The Pipe Fitting and Tubing mized so that the brazing filler metal will flow into the fitting via capillary action 50 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners 3 Cleaning brazing filler metal and piping e When the refrigerant system has been opened exposure to heat may cause the brazing filler metal to stick to the inside and outside of the piping Brazing filler metal may also combine with oxygen in the air to form an oxide film In addition grease and oils may stick to the pipe during handling All these factors will reduce the effectiveness of brazing Therefore excess brazing filler metal must be removed with sand paper and by thorough cleaning with a solvent such as Trichlene 4 Dry Nitrogen gas use e During brazing the inside of the pipe undergoes an oxidative reaction due to the brazing flame Introduce dry nitrogen gas 0 3 gal min 1 L min adjust with the flow re
24. etween 30 c to 34 2 c if dF setting is 1 5 2 c under 32 temp setting Temperature Correction 10c 10 Temperature Correction 10c 10 IC temperature setting 56 Frost prevention sensor IDEALair page 21 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Relay Board The relay board contains the compressor and fan on relays in addition to a step down transformer that converts the line voltage 700870 115 VAC 700875 208 230 700877 208 230 VAC to 12V This voltage is then converted from AC to DC and used for relay coil activation The 12 V DC power is sent to the control panel assembly 1 Power supply requirements The 700870 requires a single phase 115 V 60 Hz power supply while the 700875 700877 requires a single phase 208 230 V 60 Hz power supply 2 Relay board fuse 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 The fuse must be replaced with the exact same part or a suitable equivalent Specifications 3 15 A 250 VAC i 1 CAUTION Failure to use the exact same fuse may result in damage to the unit and or components and will also void the unit warranty 22 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners 3 Input Signal The relay board receives inputs from the control panel sensors and externa
25. gulator through the pinch off tube of the refrigerant cycle to prevent oxidation NOTE Do not get foreign matter such as dirt water or oil into the piping 5 Vertical joints e For vertical joints heat the entire brazed fitting to the proper brazing temperature Bring the brazing filler metal into contact with the fitting so that the brazing filler metal begins to flow qM Stop heating the fitting as soon as the k brazing filler metal has flown into the gap Tube clearance Since the brazing filler metal flows easily into portions heated to the proper temperature the entire fitting 1 Vertical Up Joint must be kept at the proper brazing tem perature Vertical Down Joint Brazing Filler Metal Burner Burner 45 Brazing Filler Metal IDEALA I page 51 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners 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 e Equipments is only for R 410A Liquid charge no gas charge e Make sure not to use more than 90 96 of the initial weight of R 410A in the cylinder WARNING eWhen handling refrigerant R 410A the following precautions should always be observed Always wear proper eye protection while handling refrigerant Maintain t
26. h Pressure Valve Closed Low Pressure Side Tube Vacuum Pump when stopped Low Pressure Gauge 30 inHg 100 kPa or larger Low Pressure Side Tube Vacuum Pump when stopped lowpressure valve of the gauge manifold closed for five min or more and con firm that the gauge pointer does not return to zero page 53 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Refrigerant Charging Work Refrigerant charging 1 Remove the charging hose from the vacu Low Pressure Valve um pump and connect it to the refriger cylinder ant cylinder R 410A 2 Loosen the nut on the gauge manifold side of the charging hose Open the valve of the charging hose Open the valve of the refrigerant cylinder After air purging tighten this nut and close the valve of the refrigerant cylinder 3 Securely place the refrigerant cylinder on a scale with a weighing capacity of 70 Ib 30 kg that is graduated by 0 2 oz 5 4 Open the high pressure valve of the gauge manifold and the valve of the re frigerant cylinder Charge the system with refrigerant to the specified amount Standard Amount of Refrigerant 700870 Toshiba 15 9 oz 451 g LG 15 5 oz 400 g 700875 42 3 oz 1200 g 700877 51 8 oz 1470 g 19 efrigerant linder R 410A Low Pressure Side Tube TE The amount of refrigerant charged has a great ef ect on the cooling capacity of the un
27. he temperature of the refrigerant container below 104 F 40 C Perform repairs in a properly ventilated area Never in an enclosed envi ronment 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 52 page IDEALA 700870 700875 700877 SERVICE MANUAL Connection of gauge manifold 1 Connect the charging hoses low pressure side for the gauge manifold to the tube fitting NOTE Connect the hoses using care not to mistake the high pressure side for the low pressure side and vice versa 2 Connect the charging hose at the center of the gauge manifold to the vacuum pump Evacuation 1 Open the high pressure valve LOW of the gauge manifold 2 Turn on the vacuum pump to start evacu ation Evacuate the system for approxi mately 30 min 3 When the low pressure gauge indicates 30 inHg 100 kPa turn off the vacuum pump and close the Low pressure valves of the gauge manifold 4 Leave the high pressure valve and the Portable Air Conditioners Tube Fitting Low Pressure Valve Closed Hig
28. it Charge to the A CAUTION decia er EN 9 specified amount always observing the scale gradua tions while charging 5 Close the high pressure valve of the gauge manifold and the valve of the refrigerant cylinder 4A WARNING eDo not attempt any repair on a charged system A WARNING eBefore 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 54 page IDEALA
29. l devices to perform device control Control Panel Input Symbol Indication Function Connector ON OFF Button If POWER BUTTON is pressed during operation unit stops FAN Button Changes fan speed from LOW to HIGH when pressed CON8 SET TEMP A Button Regulates temperature based on outlet cool air temperature SET TEMP V Button Regulates temperature based on inlet ambient air temperature Sensor Input Specification Symbol Type Connector Characteristic Short Detection Open Detection TH1 OUT TEMP SENSOR 10 k ohm at 77 F 181 F 83 C or 29 F 34 C or TH1 25 C more less TH2 IN TEMP SENSOR 10 at 77 F 181 83 29 F 34 C or TH2 25 C more less TH3 ICE TEMP SENSOR 10 at 77 F 181 83 29 F 34 C or TH3 25 C more less External Input Signal Specification Symbol Signal Specification Function Connector On Between 10 to 20 On Activates Defect control CO Comp Overload mA at 12 V Contact Normally open Off No signal LED shows CO Output signal ON FU External Pump Failure On Between 10 to 20 Off Activates Defect control mA at DC12 V Contact Normally open FU Off signal LED shows FU Output signal ON PS Pressure Switch On Between 10 to 20 On Activates Defect control mA at DC12 V Contact Normally closed PS Off signal
30. moval REFRGERANT SYSTEM REPAIR U ener nnn nnne nnne 50 Brazing Removal of Refrigerant System Components Charging the System with R 410A Refrigerant Refrigerant Charging Work IDEAL TT page 3 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners GENERAL DESCRIPTION General air conditioning system 1 conventional air conditioners cool the entire enclosed environment 2 They act as heat exchangers equiring an interior unit evaporator to blow cool air into the interior and an exterior unit condenser to exhaust exchanged heat to the outdoors Indoor Unit Outdoor Unit o M 24 I 25 KC Ki FR Evaporator Condenser Portable air conditioning system 1 The 700870 700875 700877 is a spot cooler which directs cool air to particular areas or objects Exhaust Hot Air 2 The 700870 700875 700877 has the following features AWN 3 The innovative design of the 700870 lt lt 2 700875 700877 has resulted in one cooling air compact unit replacing the need for two separate units 4 With the whole cooling system built into to Condenser one compact unit the 700870 700875 intakeiair 700877 requires no piping and can be easily transported and installed 5 The 700870 700875 700877 is eco nomical because it cools only the area or objects which need
31. mperature in display in Fahrenheit e SPOT COOL Mode displays outlet cool air temperature during normal operations In order to change F to C press SPOT COOL and ROOM COOL buttons together for 2 seconds C will blink 2 times and the figure will change to C ALARM codes blink and are displayed when abnormal operation occurs TARGET TEMP e Displays the unit set temperature for ROOM COOL mode only NOTE The room temperature display range is from 14 F to 122 F When displayed in the range is from 10 C to 50 C 20 page IDEAL 700870 700875 700877 SERVICE MANUAL Program Setting Portable Air Conditioners Temperature Setting Program Setting Auto restored when no setting is made in each mode 1 seconds depressing more than 30 30 E depressing more than E 3 seconds El Delay time Change Ch ange Target 1 Temperature E B Power Switch eviation 1 temperature setting 1 ON OFF when keep E a I dependence LE y Change 00 1 Change Auto restored when no setting is made in each mode Temperature IC temperature F7 Indication Description the range of setting dt Delay time setting of COMP operation EX If setting is 3mins it takes 3mins to be ON after COMP is OFF 1 5minutes control is available per 1 minute Deviation temp setting dF Ex It operates b
32. mpressor protection Compressor protection consists of a time delay program within the micropro cessor This program prevents a heavy load from being applied to the compres sor motor when restarting the unit room cool mode or spot cool mode after a very short period of time This delay is in effect any time the compressor is turned on by either the POWER ON OFF button or ROOM COOL or SPOT COOL ON OFF button Specifications Time Delay 120 sec 5 Automatic restart and recovery function The microprocessor contains a feature that automatically restart the unit after power is lost and regained and also has memory to store and recover operation status in the even of a power loss Status of memory during power interruption e When the input power is off the status items below are saved in the memory Running status on or off Operating mode Cool mode or fan only mode Set temperature Temperature mode F or C IDEAL TT page 25 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners 6 Temperature control e During cool mode temperature control changes the RL4 compressor on off relay status according to TH3 temperature in the available range 4 F to 140 F 20 C to 60 C RL4 Compressor Relay Set Temp lt Inlet Air Temperature Set Temp 3 F Set Temp 1 7 C When compressor operation continues within this range for more than 5 minutes the RL4 relay stops
33. or instruction 25 Children being supervised not to play with appliance 26 That the appliance shall be installed in accordance with national wiring regulations 27 If the supply cord is damaged it must be replaced by the manufacturer its service agent or similarly gualified persons in order to avoid a hazard SAVE THESE INSTRUCTIONS eee 34 page IDEALA 700870 700875 700877 SERVICE MANUAL Troubleshooting chart Symptom Water leakage Possible Cause s High water level in condensate tank Portable Air Conditioners Corrective Action 1 Remove blockage from drain hose 2 Remove any object stuck undeerneath of the black panel nuder the water tank The unit doesn t work 1 Check the power supply to verify that power is available to the unit 2 Verify that the power cord is connected 1 Reset the circuit breaker and restart the unit 2 Connect power cord No cold air flows from the cold air outlet 1 Ambient air cannot be properly cooled if the filter is dirty and not regularly cleaned 2 Compressor will not work if the unit isturned off and on quickly 3 The ambient air temperature may be too high 1 Clean the filter 2 Wait 2 minutes after unit is turned off before turning the unit back on 3 The temperature of the compressor can be higher when the ambient temperature is too high The compressor will not work unless the ambient air temperature is within the acceptable ope
34. rating range of the unit Water flow can be heard after compressor shuts off No cause Common to hear coolant flowing after unit shuts off Alarm displays FT with less than half of condensate water in the tank Spring is possibly broken IDEALT Spring is possibly broken Replace a new spring page 35 700870 700875 700877 SERVICE MANUAL DISASSEMBLY For 7 Disassembly Cooling Air Duct a Screws qa 4 Drain Tank Y a Screws 3 wae cover ami GER H Circuit Breake Portable Air Conditioners 7 1 Remove the drain tank 2 Take out the four 4 screws and then remove the cooling air duct 3 Take out the three 3 screws and then remove the electric cover 4 Off the circuit breaker For safety IDEAL 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners 5 Take out the seven 7 screws Unfasten two 2 screws to a half point Pull the front panel forward Screws 7 m Screws 2 y NO S Front Panel 6 Disconnect the connector from the control panel and then remove the front panel Connector 7 Take out the five 5 screws and then remove the upper panel
35. rator inlet tem perature as a resistance value Ice temp sensor TH3 is installed in the evaporator outlet piping and detects low temperature on the evaporator as a resistance value Specification Symbol Type Connector Characteristic Short Detection Open Detection TH1 OUT TEMP SENSOR 10 k ohm at 77 F 181 F 83 29 F 34 C or 25 C 1655 TH2 IN TEMP SENSOR 10 k ohm at 77 F 181 F 83 29 F 34 C or TH2 25 C more less TH3 ICE TEMP SENSOR 10 k ohm at 77 F 181 F 83 29 F 34 C or TH3 25 C more less 30 page IDEAL 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners Drain Tank Switch e The drain switch activates and stop the operation of compressor motor and fan motor when approximately 3 17 gal 12 L of drain water accumulates in the drain tank At the same time control panel display FL and compressor and fan operations stop This system uses a 250 V 0 1 A rating micro switch for this function When approximately 3 17 gal 12 of drain water accumulates in the drain tank the drain tank base plate which is supported at fulcrum a is pushed down in the direction of the arrow e When the drain tank base plate is forced down portion A located at the top of the drain tank base plate turns off micro switch contacts 1 2 r Evapor
36. s E 11 0 10 0 15 0 14 0 EER Btu Wh 8 6 8 9 9 3 Circuit Breaker Size Amps 15 15 20 Nema Plug Type 5 15P 6 15P 6 20P Power Cord Gauge Awg 14 14 12 Power Cord Length ft 10 6 6 Dimensions WxHxD TEE EE GE GEN Weight Net Gross Lbs kg eo 1485 1 Condensate tank Gallons Liters 3 17 12 3 17 12 3 17 12 No of Cool Air Outlets Pcs 1 2 3 Ambient temperature range F C 64 113 18 45 64 113 18 45 64 113 18 45 Setting temperature Room cool mode F C 64 86 18 30 64 86 18 30 64 86 18 30 Setting temperature Spot cool mode F C 32 86 0 30 32 86 0 30 32 86 0 30 Application Area Room cool mode 377 35 527 50 743 70 Type R 410A R 410A R 410A oz g 15 5040 42 3 1200 39 9 1130 Design Pressure Hi Low Psig rn 450 250 450 280 Indoor Air Flow High Low CFM CMH 83 42 4 10 90 330 pcs 4 4 4 Tien diameter 76mm 102mm 102mm Hot Air Duct Diameter In mm 12 300 16 400 16 400 Maximum Duct Length ft m 16 5 30 9 30 9 Compressor overload protector Anti freezing thermister Full drain tank switch Safety Devices Autometic restart Power interruption Compressor time delay program High pressure switch Features Temperature control Self diagnostic function Two sppeds fan Optional drain pump kit Washable filters F C display Specifications are subject to change without notice 8 page IDEALA 700870 700875 700877 SERVICE MANUAL Port
37. to be cooled Filter 4 page IDEALA Portable Air Conditioners iagram D imension PECIFICATION lt 700870 gt 700870 700875 700877 SERVICE MANUAL Exterior D C9E page 5 555555555555 xx 922222222222 19 8 L 12 13 1 17 5 IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners lt 700875 gt 16 3 17 3 d 22 1 6 page IDEALA 700870 700875 700877 SERVICE MANUAL Portable Air Conditioners lt 700877 gt 16 3 17 3 22 1 IDEALT page 7 700870 700875 700877 SERVICE MANUAL Technical Specifications Portable Air Conditioners Specifications Unit 700870 700875 700877 Cooling Capacity Btu h 13 200 19 500 21 000 28 000 29 000 Phase Single Single Single Power Supply Volts 115 208 230 208 230 Hertz 60 60 60 Power Consumption Watts 1 300 2 300 3 100 Rated Current Amp
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