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Classic 18 Service Manual for Units Produced Jan. 08

1. lt Classic18 gt ES Cory s e Output Signal 2 utput Signal ule 13 PX ha aux2 F O 1 On Board E am Controller arm 4 put 19r 8 ovs pesos 99999 999 ona Q ones op 4 pow 1 CNet 3 an Ground G om 07 ras 1gi 9 91 6 52002 52001 51 52CT TZM 9 OR 7 6 uu 8551 pg 219 6 Dip Switch Looro e 81 I I 1A e ERR UBI trace CN17 CN01 60Hz 510 1 lA i 8 1 CN12 CN11 16 15 52CM A Q I e 110 Control Box e CN Jumper Line CTS RTS Drain Tank SW AUX1 TB1 Terminal Block1 CN Connector for Option TB2 Terminal Block2 Drain Pump RB Relay Board CTS Freeze Protection Thermistor MF Fan Motor RTS Room Thermistor MC Compressor Motor G Ground CF Capacitor for Fan Motor CB Control Board Capacitor for Compressor RX Auxiliary Relay OLC Overload Protector Control Board GE un n DIG CN8 SW1 COOL ON OFF Switch wo Sto SW2 FAN Switch o 6 swz SW3 SET TEM
2. lt Classic10 gt ES CD E KA 1 G OLC i LE i TB CF cc Llo Output Signal tH E EH L 1 4 aux pa 19 Ene Alarm put 11 8 9 O CN24 1 112 Ground 6 6 oo RB 618 211 526 1O 1 3 0 O4 8 ow OOR 6 Dip Switch 115V TB1 68 i 118 112 T 1PHASE AR ewm F CNO01 60Hz 1 8 CN13 CN12 CN11 CN16 CN15 52CM s 6 eee ooo OO 22 1 54 1 5 1 3 1 2 4 3 1 2 4 8 i Control Box 549 zs CN lo 0 JEET O o Jumper O Line CTS RTS Drain Tank SW AUX1 TB1 Terminal Block1 CN Connector for Option TB2 Terminal Block2 Drain Pump RB Relay Board CTS Freeze Protection Thermistor MF Fan Motor RTS Room Thermistor MC Compressor Motor G Ground CF Capacitor for Fan Motor CB Control Board Capacitor for Compressor OLC Overload Protector Control Board En un Bh CN9 DIG 5 4 3 1 O 2 R108 pau CN8 SW1 COOL ON OFF Switch 5 9 SW2 FAN Switch eoo 2 5 SW3 SET TEMP Y Switch o SW4 575 15 Sw4 SET TEMP A Switch 1001683 Operation Section 21
3. llli rss 44 7 9 Thermistor Inspection neeo tr e eR RPM be vas na 45 7 9 Wiring Connection Inspection ec ceren liiis re EOE DE e eea 45 7 10 Refrigerant System Inspection 45 8 DISASSEMBLY For Classic10 6 4 Parts Constructions uv A A AA die tbe 46 9 27 DISASS OMV a EE 47 8 3 Control Panel Removal o o o o oo ooo 50 8 4 Electrical Components Removal 0 00000 cee rss 50 8 5 Fan Motof RemoVval vieiras da eee ain sale Ke RT RIO RA ERR Rp du 53 8 6 Full Drain Switch Removal 0 56 9 4 Assembly eie ed eoo ed dee ctn dave d o edt e Ee din 56 9 DISASSEMBLY For Classic18 9 1 i Parts Construction sob ad A Eta wade ERN S IRR REO ae EG os 57 9 2 Disassembly a died See eed eeu Ld uL de EUN qus 58 9 3 Control Panel Removal o o cococcoo lll rs 61 9 4 Electrical Components Removal 61 9 5 Fan Motor Removal as passe aes xu t apad ESO E eG aude Dixi det cp y gelo De aa 64 9 6 Full Drain Switch Removal 0 67 9 7 Assembly xc oed eh en epe Edd aee d ERE es 67 10 REFRIGERANT SYSTEM REPAIR 19 1 Braz urere a A ted venis 68 10 2 Removal of Refrigerant System Components 4
4. Operation Section 2901 3 i z z ON PO II RO RRR RR RD PO RN PO RR AA RO AAA RRR RRR EY KERRY RI PO NNNM RRR RRR RRR RRR RRR RRR KERRY RI WYNO PO RRR RRR RRR RI PI II PO A RRR RRR RRR RRR PI II PI II OONO PO AA PR RRR RRR RRR RR A PS II PO A PR KERR PI II RRR RRR RRR II IIA LAIA RI II PI RRR KR RRR RRR RR RRR RRR RK RY RI RI II OOA PO RR RRR RR PANN DR PI II POR KR RK PR RRR REY PI RK RRR RRR RRR RRR RRR RRR RRR RRR ERR RY POR POR PI RRR RK PO ARIA ARR ANA RR AQ RRR REK EX LR ROI RRR RRR RRR PONN O RRR 09 09 a 00 SO PO A 2 Y RRR 4 A IO OOOO OOOO 1900 04 LR delete 525 650 o o 330 420 490 oo OO
5. 70 10 3 System Refrigerant 8 91 9 men 71 Operation Section 5 1 GENERAL DESCRIPTION 1 1 Foreword In general conventional air conditioners cool an entire enclosed environment Air Oo conditioners act as heat exchangers 1 a requiring an interior unit evaporator to blow po Condenser Evaporator cool air into the interior and an exterior unit Outdoor Unit Indoor Unit condenser to exhaust exchanged heat to the outdoors Unlike conventional air conditioners the MovinCool Spot Cooling System is a spot cooler that directs cool air to particular areas or objects MovinCool Spot Cooling Systems have the following features 1 2 Features 1 Compact design The innovative design of MovinCool has resulted in one compact device replacing the Exhaust Hot Air need for two separate units Cooling Air 2 Easy transportation and installation With the entire cooling system built into one Filter compact unit MovinCool requires no pipe work and can be transported and installed easily Filter Y poss Se io XXE 7 Intake air to Condenser 3 Energy conservation MovinCool is economical because only the Intake air to Ev
6. Roller 1001676 Discharge Valve Roller 1001677 Discharge Roller 1001678 Discharge Valve 1001679 Operation Section 1 Start of compression 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 2 Suction and compression 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 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 suction continues 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 process of suction and compression continues repeatedly in succession Operation Section 4 Compressor lubrication 4 3 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 upward by the oil scraper along the inside diameter of the hollow shaft The oil is fed through the oil hole by centrifugal force then sup
7. 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 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 Fan mode Fan operation mode fan on or fan stop mode fan auto Operation Section 6 Temperature control 29 During cool mode temperature control changes the 52CM compressor on off relay status according to RTS temperature in the available range 4 to 140 F 20 to 60 C 52CM Compressor Relay OFF t Set Temp 3 F Set Temp Set Temp 1 7 C gt Inlet Air Temperature When compressor operation continues within this range for more than 5 minutes the 52CM relay stops 1001689 7 Fire alarm signal control When receiving the signal from the fire alarm control panel the buzzer sounds and the 52CT signal output relay on the relay board turns on 30 5 6 Self Diagnostic Codes Operation Section Self diagnostic codes are displayed on the control board under the following conditions ets Output Buzzer Indication Co
8. NY S LARES Compressor and ASS Drain Tank Accumulator KE T ho LOS o 7 Locking Swivel Caster Front Control Box Relay Board Wa Full Drain Switch Capacitor UY Caster Rear 1001671 Operation Section lt Classic18 gt i 1 1 1 1 Y IAS ea III VIA A Room Thermistor RTS Condenser Air Outlet Housing for Condenser Fan A Y Y Condenser Fan Gj and Motor d A Condenser Compressor and Accumulator Si ASS co V LE Control Box Relay Board Capacitor Auxiliary Relay 997 RS Y K Y SA E 77447 222 ILI TT eT LLL TIL L7 7 WZ77 47 gt Cag 17 7 Tay COLL LOE Le A ALIAS LPT UT T LAR LL LEP LEE RRA Full Drain Switch Caster Rear Housing for Evaporator Fan Evaporator Freeze Protection Thermistor CTS Capillary Tube Drain Tank Locking Swivel Caster Front 1001672 Operation Section 13 4 REFRIGERANT SYSTEM 4 1 Refrigerant System Construction The component parts of the refrigerant system include the following Compressor Evaporator Condenser Accumulator Capillary tube The parts above are all connected by copper piping with brazed connections The circled portion in the figure below shows
9. 24 m 33 43 41 A1 34 44 42 A2 1001694 Relay Board CN16 Full Drain Switch 1001745 Repair Section 45 7 8 Thermistor Inspection Use an ohmmeter to check the resistance across the 2 pin connector at normal temperature 77 F 25 C Specification Type Characteristic 58 Q at 77 F 25 C Room Thermistor RTS B 3 970 K Freeze Protection Thermistor 5k Q at 77 F 25 C 1001695 CTS B 3 970 K 7 9 Wiring Connection Inspection While referring to the wiring diagrams check the connection of each wire N CAUTION Secure the wires using clamps to prevent contact with the edges of the structure etc Secure the wires in the same position as prior to removal 7 10 Refrigerant System Inspection In most cases the most probable causes of insufficient cooling are a clogged system leakage or an incorrect amount of refrigerant In such cases inspect the system according to the following procedure 1 System clog inspection Check refrigerant system components including piping that could be clogged with refrigerant When a component is clogged with refrigerant only the clogged part will be partially frosted In such cases replace the part in question 2 Refrigerant leak inspection Each time the refrigerant system is installed or repaired use an electronic gas leak tester to carefully check all connections and each
10. SW1 ON OFF Button On off control for unit operation Turns the unit on and off Changes the fan control mode between continuous and automatic SW2 FAN Button on off control are SET TEMP A Increases the set temperature CN17 Button sw SET TEMP V Decreases the set temperature Button Operation Section 26 Sensor Input Specification Symbol Type Connector Characteristic Short Detection Open Detection 5k Q at 77 F 25 C 181 F 83 C or 29 F 34 C or RTS Room Thermistor CN11 B 3 970 K more less Freeze Protection 5k Q at 77 F 25 C 181 F 83 C or 29 F 34 C or CTS CN12 Thermistor B 3 970 K more less External Input Signal Specification Symbol Signal Specification Function Connector On Activates Defect control Fire On Between 10 to 20 Contact Normally open AUX2 Alarm mA at DC12 V f CN15 LED shows AL Output signal ON Input Off No signal P onal On board buzzer sound On Between 10 to 20 Off Activates Defect control mA at DC12 V Contact Normally closed CN16 Off No signal LED shows FL Output signal ON TANK Tank Full FULL S W Switch Off External On Between 10 to 20 1 lt 180 sec Compressor stops AUX1 Pump mA at DC12 V CN13 i 2 180 sec lt Compressor stops Failure Off No signal LED shows AS output si
11. case of short check the compressor relay on the relay board Compressor E Does Not 2 Compressor on off relay Open circuit or poor contact Replace relay board Operate 52CM on the relay board 3 Capacitor for compressor Capacitor malfunction Replace capacitor 4 Compressor overload relay Overload relay fault Replace overload relay 5 Voltage Low voltage Repair power 1 Coil resistance of fan motor Short or open circuit Replace fan motor 0 O or o 2 2 Fan motor on off relay 521D Open circuit or poor contact Replace relay board No Air on the relay board 3 Auxiliary relay in the control Open circuit or poor contact Replace auxiliary relay Insufficient box Classic18 only No excite coil on the relay Check and replace relay Air Volume no voltage board 1 Air filter Clogged air filter Clean air filter 2 Evaporator Clogged evaporator or Repair and clean fins or ente Ent crushed fins replace Air Volume 3 Duct connection state Improper connection Repair duct connection 4 Fan motor Poor rotation Replace motor 2 Unit does not start operate lt NOTE gt In this case there is a possibility of safety device activating due to the clogged air filter So be 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 In the case above the
12. connection Defective freeze protection Replace freeze protection thermistor thermistor 1 Fan motor on off relay 521D Open circuit or poor contact Replace relay board Stops Lep on the relay board Displays Immediately Normally 2 Fan motor insulation Insulation failure on fan Replace fan motor resistance motor 1 Coil resistance of fan motor Defective fan motor Replace fan motor 2 Compressor temperature Compressor overload relay Replace compressor abnormally high operates due to compressor Service dirty areas Stops after LED malfu cti n Runninga Displays While Normally Insufficient refrigerant or gas Repair and charge leakage refrigerant 3 Dirt on air filter or condenser Insufficient condenser Clean condenser cooling Repair Section 39 3 Drain water overflow Possible Cause Symptom Remedy Check Area Cause 1 Drain pan Cracks in drain pan Check and repair 2 Water level in drain pan Clogged drain hose Check and replace 3 Drain hole Reversed air flow from drain Insert a trap on the hole discharge drain hose Overflow from Unit 4 Clogged air filter Reversed air flow from drain Clean air filter hole due to the excessive negative pressure inside of the unit 4 Abnormal noise or vibration To prevent from abnormal noise or vibration first carefully determine the source Next devise proper countermeasures to elimin
13. high pressure valve HI of the gauge manifold Turn on the vacuum pump to start evacuation Evacuate the system for approximately 15 minutes When the high pressure gauge indicates at least 750 mmHg 30 in Hg close the gauge manifold high pressure valve and turn the vacuum pump off Leave the gauge manifold high pressure valve and the low pressure valve closed for five minutes or more Confirm that the gauge pointer does not return to zero If the gauge pointer returns gradually to zero there is a leak somewhere in the system this could also include the gauge manifold Perform a leak check according to the procedure indicated in the next step Once the leak has been found and repaired evacuate the system again and confirm that the system holds vacuum 74 Repair Section 4 Gas leak check Valve Setting LO Closed Air Purging y Open The Valve of Refrigerant Cylinder pA Green To Process Tube Fitting Charging Hose Refrigerant Cylinder R 22 1000571 Valve Setting Closed Open Gauge Reading 4 kg cm G Low Pressure 57982 Valve Closed Cylinder R 22 Refrigerant Cylinder Valve Open Refrigerant LO HI Closed Closed Open High Pressure Valve Process Tube Fitting p High Pressure Side Tube 1001900 1 Remove the charging hose green from the vacuum pump and connect the hose t
14. the part connections lt Classic10 gt EN Condenser Evaporator L 2 IR i Pondeneek K a SS zm Evaporator Inlet Pipe Inlet Pipe 4 a SS i Capillary Tube EE Evaporator Outlet Pipe Compressor y 7 Discharge Pipe GZ i y Connecting Pipe Evaporator to Compressor SN 8 in E C Condenser Outlet Pipe Re NN Cl Connecting Pipe Condenser to Capillary Tube x AL S 1 i C y Compressor Suction Pipe aes Covered Insulation Accumulator Condenser lt Flow of Refrigerant Compressor Evaporator 1001673 Operation Section lt Classic18 gt Condenser Condenser Inlet Pipe Compressor Discharge Pipe Condenser Outlet Pipe Compressor Capillary NN IN SAA Condenser Evaporator um Evaporator Evaporator Inlet Pipe Evaporator Outlet Pipe Capillary Tube Connecting Pipe Evaporator to Compressor Connecting Pipe Condenser to Capillary Tube Compressor Suction Pipe Covered Insulation lt Flow of Refrigerant Accumulator Compressor 1001674 Operation Section 4 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
15. with a weighing capacity of 70 lbs 30 kg that is graduated to 0 2 oz 5 g 4 Open the gauge manifold high pressure valve and the refrigerant cylinder valve Charge the system with the specified amount of refrigerant Standard Refrigerant Amount e Classic10 1 06 Ibs 4800 e Classic18 1 59 lbs 720g N CAUTION The amount of refrigerant charged has a great influence on the cooling capacity of the unit Charge to the specified amount always observing the scale graduations while charging 5 Close the manifold high pressure valve and the refrigerant cylinder valve 1 Crimp the pinch off tube with a pinch off tool 2 Remove the gauge manifold and the process tube fitting Crush the end of the pinch off tube 3 Braze the end of the pinch off tube 4 Ensure that no gas leaks from the pinched off portion and the brazed end Repair Section 17 DENSO DENSO SALES CALIFORNIA INC Long Beach CA 90810 www movincool com First Issue April 2008
16. 001747 Upper Panel Screws Screws aS Z 7 f Screws Screws Upper Panel Screws Housing for Condenser 1001748 Clamp NI e E Room Thermistor Harness Connector IN 1001730 Repair Section 59 6 Take out the thirteen screws and then remove the rear panel 7 Take out the fourteen screws and then remove the upper panel N CAUTION The two screws used on the front side of the upper panel differ from the rest Ensure that the correct screws are used when attaching the upper panel 8 Unfasten the connector on the room thermistor wiring harness 9 Remove the wiring harness from the clamp Repair Section 60 Control Panel Connectors p ae Board Clamp Upper Panel PA Left Side Panel ns 1001750 Air Filter 1001751 Screws NS IAS Right Side Panel 1001752 10 Unfasten the two connectors 11 pin 5 pin from the control panel 11 Remove the wiring harnesses from the clamp and board clamp 12 Take out the seven screws and then remove the left side panel N CAUTION The screw on the front side of the left side panel differs from the rest Ensure that the correct screw is used when attaching the left side panel 13 Remove the two air filters from the right side panel 14 Take out the sev
17. 14 24 34 44142 Specifications Rated Voltage AC230 V Rated Current 10 amps 1001694 5 11 Temperature Thermistor e The room thermistor RTS is installed upstream of the evaporator and detects evaporator inlet temperature as a resistance value The freeze protection thermistor CTS is installed in the evaporator outlet piping and detects low temperature on the evaporator as a resistance value 1001695 Specification Type Characteristic Short Detection Open Detection n 5k Q at 77 F 25 C Room Thermistor RTS 181 F 83 C or more 29 F 34 C or less B 3 970 K Freeze Protection 5k Q at 77 F 25 C A 181 F 83 C or more 29 F 34 C or less Thermistor CTS B 3 970 K Operation Section 34 5 12 Drain Tank Switch The drain switch activates and stop the operation of compressor motor and fan motor when approximately 4 4 gal 16 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 4 4 gal 16 L 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 When the drain tank base plate is forced down portion A located at the top o
18. DOS coooaooooogaogogouo H coooaoaoaoeoaoaoaoooo 175 95 lt Classic18 gt 1001667 mm Uni 8 Operation Section 2 2 Technical Specifications Technical Specifications Classic10 Classic18 Electronic Control Panel Electronic Thermostat Control Electronic Cooling Rating Condition 95 F 2 92 kW 2520 kcal h 5 27 kW 4540 kcal h Capacity 60 RH 10 000 BTU h 18 000 BTU h Voltage Requirement 1 Phase 115 V 60 Hz 1 Phase 208 230 V 60 Hz Total Power Consumption 1 1 kW 2 1 kW Electrical Current Consumption 10 0A 10 8 10 0 A Characteristics Recommended Fuse Size 15 15A NEMA Plug Configuration 5 15 6 15 Min Max Voltage 105 125 V 198 250 V Fan Type Sirocco Fan Fans Air Volume 450 m h 265 CFM 880 900 m h 518 530 CFM Motor Output 0 14 kW 0 35 kW eor Type Hermetic Rotary Output 0 6 kW 1 10 kW dba R 22 0 48 kg 1 06 lbs 0 72 kg 1 59 Ibs Dimension W x D x H without air duct 492 x 673 x 1054 mm 19 4 x 26 5 x 41 5 inches Net Weight Shipping Weight 66 83 kg 145 183 lbs 76 94 kg 167 208 55 teme Gauge 14 AWG 3 core Length 3 0 m 10 ft 1 8 m 6 ft Co
19. GO eee ROS s 20 5 2 Control Box and Relay Board 0 2 0 0c eee eee 22 5 37 Basic Operations os cua eeu aa dex 23 5 4 Relay Boatd cuc a ache ay ee aes 25 5 5 Control Specifications 0 27 5 6 Self Diagnostic COJES ya ius dol br Wl ETE RE a 30 5 f COmpIessOE sus noct deb De CR DR E ded Fas Paula yaad pa cp me viet Baka 31 5 9 Ran Motor eeu dete edet hes atten cepe se edic dod od ene eed a 32 5 95 Capacitor moni et Roe Ho taa daft omuibus the UM a ab Han 2 aerae oae a sete 32 5 10 Auxiliary Relay For Classic18 Only sssseeseeeeee n 33 5 11 Temperature Thermistor o ooooooooo eel rs 33 5 12 Drain Tank Switch ed REEL EXER Ee Eee 34 Table of Contents Repair Section 6 PRECAUTIONS FOR SAFETY 6 1 Definition OF Terms it a A ue eid ea aks 35 6 2 General Preca tilons ent en eid eae eee es BA Gt a Ce eee e 35 7 TROUBLESHOOTING Z 1 TIro bl shootlng 2 teen este teat reta qun xao alae ee cw ah 36 1 2 Basic Inspections usos cote eom ttr RT el FO a ae RUP ah 40 7 3 Compressor Inspection llli 42 7 4 Fan Motor Inspection lude uw s ELI dr AEN ree MN RR AERA PA AES 42 7 5 Capacitor Inspection For Fan Motor and 0 8880 1101 1 0 0 666 43 7 6 Auxiliary Relay Inspection For Classic18 Only snua uaaa aaau 44 7 7 Full Drain Switch Inspection
20. P Y Switch o oO SW4 5s 15 SW4 SET TEMP A Switch 1001684 Operation Section 5 2 Control Box and Relay Board TB2 Terminal Block2 o o TB2 lO ES Lae RE Relay Board d f e DG 2 G Ground s IAR TB1 Terminal Block1 CC Capacitor for Sen il cm CF Capacitor for Fan Motor co 1001685 CN15 CN16 CN14 CNO2 CN03 CNO4 CN11 CN12 CN13 a FE E 3E ES A OD 4 Position Dip Switch O 6 6 O OU 1 CN17 d E s gt CN25 CNO1 NO ANO Relay Board Fuse 5A 6 LJ o Ed CN24 CN21 CN22 CN23 OFF Position O 1001686 5 3 Basic Operation 1 Control panel Operation Section 23 Before operating the unit it is important to be familiar with the basic operation of the control panel SET TEMP A Y AS MOVINCOOL 3 COOL ON OFF Button Activates deactivates the cool mode turns the unit off 2 FAN Button Activates deactivates the fan only mode turns the unit off SET TEMP Buttons A V Increases decreases the temperature set point during cool mode Room Temperature Shows a blinking set point temperature for five seconds th
21. SERVICE MANUAL Classic10 and Classic18 SERIAL NUMBER FROM JANUARY 2008 0108 TO DECEMBER 2008 1208 Dsum MOVINCOOL THE 1 SPOT COOLING SOLUTION DoclD 00G00009E 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 GENERAL DESCRIPTION 1 1 Foreword a aed sd eared at RUN 5 41 2 at Se 5 2 SPECIFICATIONS 2 1 Exterior Dimension Diagram qeq eee eee 6 2 2 Technical Specifications sisaria ine vob zeit eb bep UP Ne ee peg d baterias 8 2 9 Characteristics 24s ou ae nce dde RR ERR RON n resta Hap hu ERR EA RET ate 9 3 CONSTRUCTION 3 1 Internal Str cture A I Mem ir P LA M 11 4 REFRIGERANT SYSTEM 4 1 Refrigerant System Construction lisse rn 13 42 EE AAA ees e e us bas Rob ated ote ida ca Aude 15 43 3Condenser coss e ELO EEUU EE Aaa suae gau riae te 18 44 Capillary TUDE iir suse ke aet e acea RR rd er 4 85 8 9 4 5 DR Re HR od 19 4 5 EVApOrator xiv rb RR erRUEP PRADA M be aed ed ee p Rd ei tbe 19 46 Accumulator ox coo os duce dde nre a RR RR a ag Sls Gert E AA a 19 5 ELECTRICAL SYSTEM 5 1 Circuit Diagram a d de e ed
22. Temperature Model OFF open contacts ON closed contacts Classic10 275 F 135 C 156 F 69 C Classic18 293 F 145 C 156 F 69 C If there is no continuity across the terminals replace the overload relay 7 4 Fan Motor Inspection Measure resistance across the terminals of the fan motor Resistance at 68 F 20 C Model CF1 TBT CF2 TBT Classic10 Approx 7 Q Approx 9 Q Classic18 Approx 14 4 Q Approx 12 Q the measured resistance is not equal to the standard values listed above replace the fan motor 1001701 TBT THS CF2 CF1 1001702 Repair Section 43 7 5 Capacitor Inspection For Fan Motor and Compressor 1 2 Ohmmeter method Set the ohmmeter to the 10 MQ range Place the two probes against the two terminals of the capacitor At first the ohmmeter indicates small value then the reading should gradually increase towards infinity oc indicating that the capacitor is charging If the reading indicates infinity immediately open or the ohmmeter fails to move from 0 shorted replace the capacitor Capacitance tester method Use a capacitance tester to check the capacitor for the values indicated below If the value tested is not within 10 of the indicated capacitance replace the capacitor Rated Capacitance Model Capacitor Volta
23. aning with a solvent such as Trichlene 4 Dry Nitrogen gas use During brazing the inside of the pipe undergoes an oxidative reaction due to the brazing flame Introduce dry nitrogen gas 1 l min adjust with the flow regulator through the pinch off tube of the refrigerant cycle to prevent oxidation lt NOTE gt Do not get foreign matter such as dirt water or oil into the piping 5 Vertical joints 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 Stop heating the fitting as soon as the brazing filler metal has flown into the gap clearance Since the brazing filler metal flows easily into portions heated to the proper temperature the entire fitting must be kept at the proper brazing temperature Tube Vertical Down Joint 45 Brazing Filler Metal Burner 1000564 Vertical Up Joint Burner Brazing Filler Metal 1001725 Repair Section 70 10 2 Removal of Refrigerant System Components N CAUTION Before any refrigerant cycle component can be replaced recover the refrigerant using the standard recovery procedures and equipment To prevent oxidation pump dry nitrogen flow rate 1 l min through the pinch off tube while brazing During any component r
24. aporator required area or object is cooled rather than an entire enclosed environment 1001665 Operation Section crol 45 z POR POOOO OOOO AAAA A AAA AA AAA DOQQ OOO POO AAAA AAA AAA AA AAAA LAXAXQUQUOUOUOUOUOUOUOUOUOUOUOUX PI ASA DOQQ OOOO QUOD QUOGQUQUQUUQUE RI OOOO PI LAXAXQUQUOUOUOUQUOUOQUOUOUOUQUOUC PI XXX LXX AQUOUOUOUQUOUOUOUOUOUOUOUX RI II OOOO OYA RI II d Te LAXQUOUOQUOQUOQUQUOQUOUOUOUGQUOQUQUO RR OQ XXX XN DOQQ OY OYA AAA AAA AAA AAA RAK RRR RRR RRR RR 9 0 9 0 0 0 0 6 0 6 0 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 041 POO OOO EXAXXXQUOUQUQUQUOQUQUQUOQUQUQUOU RE RRR RRR RRR RRR QO YOO X I XXX 0 00 0 PO OCQUQOUQUUQGUQGQUQGQUQOUQOUOUGQUGQUGQUGG AN PO AN 999209 09 99 99 99 9 9999 1 A POO AX RN A 4 AV OO A ete cc e o SSeS RSLS eoo 525 650 iagram D imension 330 420 490 ccc ior 140 2 SPECIFICATIONS Di 2 1 Exter lt Classic10 gt 1001666 Unit mm
25. ate the noise or vibration and prevent reoccurrence Possible Cause Symptom Remedy Check Area Cause 1 Fan Fan interference Repair interfering section Fan deformation Replace fan Abnormal Noise or 2 2 Compressor fixing nuts Looseness of nuts Tighten nuts further Vibration 3 Piping Pipe interference Repair interfering section 4 Panel fixing screws Looseness of screws Tighten screws further 40 Repair Section 7 2 Basic Inspection Perform the following inspections before disassembly 1 Power source voltage inspection Check the power supply voltage Classic10 Single phase 115 V 60 Hz Classic18 Single phase 208 230 V 60 Hz Check the operation and condition of the fuse or circuit breaker for the power source 2 Air filter inspection Remove the air filters and check the element If dirty wash the element 3 Fin inspection Remove the air filters and inspect the spine fins for any dirt dust lint or debris that may cause poor cooling performance If spine fin cleaning is necessary it is recommended that this service be performed by a qualified service technician Air Filter for Evaporator 4 Air Filter for Condenser 1001697 SIN SN NN KAU ww Y E n D WM SR NAN N SR Nn SN 1000526 4 Operating environment inspection Check the environment arou
26. component for leaks Repair Section 8 DISASSEMBLY For Classic10 8 1 Parts Construction lt Classic10 gt Room Thermistor Control Panel Right Side Panel Air Filter Housing for Condenser Fan Condenser Fan and Motor Rear Panel Service Panel Full Drain Switch Caster Upper Panel Cooling Air Duct Front Panel Air Filter Drain Tank Locking Swivel Caster Housing for Evaporator Fan Left Side Panel Drain Pan 1001704 8 2 Disassembly Cooling Air Duct Screws Drain Tank 1001723 1001726 H Fara Terminal ro Power Supply Line Ground Line 1001727 Repair Section 47 1 Remove the drain tank 2 Unfasten the two clips and the lower side hook and then remove the front panel 3 Take out the four screws and then remove the cooling air duct 4 Take out the seven screws and then remove the service panel 5 Remove the two power supply lines from the terminal and remove the ground wire Repair Section 1 c 12 N a 1001728 Screws e Upper Panel md m Screws Screws Upper Panel Screws 1 el Housing for Condenser Fan 1001729 Room Thermistor Harness Connector IN 5 1001730 6 Take out the thirteen screws and
27. 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 n From Evaporator Terminal Accumulator Stator 1001675 Operation Section 2 Basic compressor operation The roller compression mechanism is set Discharge Hole Discharge the axis of the center of the cylinder A spring Valve eccentrically with a certain distance given from Spring Suction loaded blade is mounted on the cylinder The roller turns to compress the refrigerant in the space between the cylinder and eccentrically mounted roller The blade is in contact with the l cylinder roller by means of spring force The blade 1000510 partitions the space between the suction side and the discharge side to keep compressed refrigerant from returning to the suction side There is no suction valve The discharge valve is designed not to open until the pressure of the refrigerant within the cylinder reaches or exceeds discharge side pressure As a result the discharge valve prevents the backward flow of refrigerant gas 3 Operation Discharge Valve
28. e capillary tube As a result the temperature and state of the refrigerant become low and mist like and therefore evaporates easily Evaporator The evaporator like the condenser is a heat exchanger covered with spine fins Heat 5 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 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 the gas is decreased This process separates the refrigerant contained in the gas by the force 1001682 From Evaporator To Compressor 1000514 of gravity causing the refrigerant to accumulate at the bottom of the vessel As a result the compressor is protected from possible damage caused by liquid refrigerant intake Operation Section 20 5 ELECTRICAL SYSTEM 5 1 Circuit Diagram
29. eas Splash large quantities of cool water on the affected areas Apply clean petroleum jelly to the affected skin Seek a physician or go to a hospital for professional treatment Repair Section 1 Gauge manifold connection Charging Hose Side Refrigerant Cycle Side Pinch Off Tube 1000567 Low Pressure Valve Closed High Pressure Valve Closed Green Hose Red Hose Process Tube Fitting High Pressure Side Tube when stopped 1000568 1 Use a pipe cutter to completely remove the crushed end of the pinch off tube on the high pressure side of the refrigerant cycle 2 Fit the process tube fitting to the pinch off tube 3 Connect the charging hoses red high pressure side for the gauge manifold to the process tube fitting 4 Connect the charging hose green at the center of the gauge manifold to the vacuum pump 2 Evacuation Valve Setting LO HI LO HI Closed Open Closed Closed 750 mmHg or greater Gauge Low Pressure Gale High Pressure Gauge High Pressure Valve High Pressure Side Tube Vacuum Pump in Operation 1001824 3 Vacuum check Valve netting Leave valves closed for 5 minutes or more Pointer of pressure gauge returning to zero indicates there 15 a leak Pressure Gauge TS Pipe Brazing 1001585 1 2 3 1 2 Repair Section 73 Open the
30. en continuously 4 Set Point Display indicates room temperature 5 Temperature Scale LED Illuminates to indicate the current temperature being displayed is either in C or F 6 ONLED llluminates during fan only mode and cool mode using fan operate mode 7 AUTOLED llluminates during cool mode using fan stop mode LED Display Indication In normal operation LED displays the following indication Display Indication Conditions Right decimal segment is on Power stand by or during fan only mode m e SS Indicates room temperature when display is solid During cool mode LI Left fig Room temp at 78 F l1 Indicates set point temperature During set point temperature adjustment when display is flashing or cool mode on I l Left fig Set Point temp at 75 F 5 seconds 1001710 lt NOTE gt The room temperature display range is from O to 109 F When displayed in C the range is from 9 C to 60 C Fahrenheit only when the display value is greater than 99 F 100 F 101 F and 109 F are displayed as 00 01 and 09 respectively 24 Operation Section 2 Fan only mode When the FAN button on the control panel is pressed the FAN ON LED illuminates and the fan operates At this time the compressor is off and only the fan is in operation When the FAN button is pressed again the
31. en screws and then remove the right side panel N CAUTION The screw on the front side of the right side panel differs from the rest Ensure that the correct screw is used when attaching the right side panel 9 3 Control Panel Removal D D SSS D Screws ES SL um gt gt Screws Control Panel 1001753 Repair Section 61 1 Take out the eight screws and then remove the control panel 9 4 Electrical Components Removal 1 Control box 1001736 1 Take off the three nuts and then remove the control box 62 Repair Section 2 Electrical parts and relay board removal Unfasten each connector and then remove the electrical parts from the control box lt Classic18 gt E Red Red TB2 Terminal Block 2 L Brown L Brown 2 P Brown 3 P Red 2 P Red RB Relay Board 5 P G Green CN25 RXA1 Black RX13 Black Mors RX Auxiliary Relay E Sey B1 RX14 Black RXA2 Black G Green G Green CC1 White CC1 White CC Capacitor for Com
32. eplacement involving brazing shield nearby components from the flame using materials such as a steel plate or asbestos Evaporator Capillary tube Condenser Compressor NOTE Hold the compressor body not the tube when carrying the compressor Classic10 Part to Replace Compressor Condenser Capillary Tube Evaporator Disconnect at A amp B A amp C D amp E E amp F 1001706 Repair Section 71 lt Classic18 gt Part to Replace Disconnect at Compressor A amp B Condenser A amp C Capillary Tube D amp E Evaporator E amp F 1001904 10 3 System Refrigerant Charging Always ensure that the refrigerant system has been properly evacuated before charging with the specified amount of R 22 Z WARNING When handling refrigerant R 22 always observe the following precautions Always wear proper eye protection while handling refrigerant Maintain the temperature of the refrigerant container below 104 F 40 C Perform repairs in a properly ventilated area Never perform repairs in an enclosed environment Do not expose the refrigerant to an open flame Never smoke while performing repairs especially when handling refrigerant Ensure that the liquid refrigerant does not come in contact with skin Z WARNING If liquid refrigerant contacts eye or skin Do not rub the affected ar
33. f the drain tank base plate turns off micro switch contacts 1 2 Evaporator Portion A Drain Pan Full Drain Switch Relay Board CN16 Drain Tank Drain Water 1001696 Repair Section 6 PRECAUTIONS FOR SAFETY 6 1 Definition of Terms WARNING Describes pr cautyns hal nono be 5 in order to prevent injury to the user during installation or unit operation A CAUTION Describes precautions that should be observed in order to prevent damage to the unit or its components which may occur during installation or unit operation if sufficient care is not taken NOTE Provides additional information that facilitates installation or unit operation 6 2 General Precautions N WARNING When necessary electrical work should only be performed by qualified electrical personnel Repair to electrical components by non certified technicians may result in personal injury and or damage to the unit All electrical components replaced must be genuine MovinCool parts purchased from an authorized reseller When handling refrigerant always wear proper eye protection and do not allow the refrigerant to come in contact with your skin Do not expose refrigerant to an open flame The proper electrical outlet for MovinCool units must be equipped with a UL approved ground fault breaker to prevent electrical shock from the unit When brazing an
34. fan stops 3 Cool mode When the COOL ON OFF button is pressed the FAN ON LED illuminates and room temperature is shown on the display At this time the compressor and fan begin to operate to provide cooling When the COOL ON OFF button is pressed again the compressor and fan stop When the COOL ON OFF button is pressed in fan only mode room temperature is shown on the display and the compressor operates to provide cooling room temperature reaches the set temperature during cooling operations the compressor stops and only the fan continues to operate Fan operate mode Initial setting lt NOTE gt The fan only mode will not operate after the cool mode has been activated Once the cool mode is activated the unit cannot be turned off by pressing the fan button Rather the COOL ON OFF button must be pressed Fan stop mode In fan stop mode if room temperature reaches the set temperature during cooling operations both the compressor and fan stop The fan stop mode setting can be changed using the dip switch on the relay board For details refer to page 26 During cooling operations when in the fan stop mode the FAN AUTO LED illuminates 4 Change temperature mode C and F The temperature display can be switched between C and F by holding the SET TEMP arrow buttons A V and the FAN button down simultaneously for at least three seconds 5 Diagnostic code Most of
35. ge V UF For Fan Motor 400 10 Classic10 For Compressor 370 25 For Fan Motor 200 16 Classic18 For Compressor 370 25 N WARNING Control Box CC Capacitor for CF Capacitor for Compressor Fan Motor 1001703 Check capacitance 1001693 Properly discharge the capacitor s before and after testing Failure to discharge the capacitor may cause damage to the test equipment and or unit and result in personal injury electrical shock or death 44 Repair Section 7 6 Auxiliary Relay Inspection For Classic18 Only Measure the resistance across terminals A1 and A2 Standard resistance 1 6 2 4k O If the resistance is out of the range specified above replace the auxiliary relay Check the continuity across the terminals 13 and 14 when the test button is depressed as well as when released Terminals State of Reset Switch Continuity Depressed Continuity 13 14 Released No continuity Reference Depressed Continuity 23 24 Released No continuity Depressed Continuity 33 34 Released No continuity 43 41 Depressed Continuity 44 42 Released No continuity 7 7 Full Drain Switch Inspection Depress the full drain switch to check for continuity If there is no continuity replace the switch Normally Continuity across 1 and 2 Switch Depressed Continuity across 1 and 3 13 23 14
36. gnal ON 4 Dip switch setting The controller is equipped with a four position dip switch that defaults in the OFF position The dip switch can be set to configure the following functions Symbol Item Function On Disable onboard buzzer DSW4 Buzzer Off Valid DSW3 N A DSW2 N A Change Fan Mode DSW1 Fan Mode On Fan stop mode Fan AUTO Off Fan operate mode Fan ON 1001711 Operation Section 27 5 5 Control Specifications 1 Fan control When the FAN button is pressed the 52ID fan motor on off relay on the relay board turns on operating the fan e For the Classic18 the 52ID relay turns the auxiliary relay on to operate the fan 521D Fan motor On Off relay output specification 5 A at AC250 V 2 Compressor start control When the ON OFF button is pressed the 52CM relay on the relay board turns on operating the compressor 52CM Compressor On Off relay output specification 20 A at AC250 V 3 Anti freeze control Anti freeze controls turns the compressor on and off by turning the 52CM relay on in accordance with the freeze protection thermistor CTS temperature As a result decreases in cooling performance due to frost buildup on the evaporator are prevented Compressor off conditions Freeze protection thermistor CTS temperature lt 29 F 1 5 C C
37. ic18 gt At 115 V At 208 230 V 2 4 Y Y A 5 5 2 2 is 2 0 5 2 S p 50 52 1 8 1 6 kw 0 8 kw 1 4 104 40 104 40 2 95 35 2 95 35 za A a E A a 3 2 86 30 I 4 D 86 30 ar RM ag P 4 77 25 77 25 68 77 86 85 F 68 77 86 95 F F C 20 25 30 35 eF 20 25 30 35 C Wet Bulb Temp Wet Bulb Temp 1001669 Operation Section 10 3 Cool air temperature difference curve lt Classic10 gt lt Classic18 gt At 115 V At 208 230 V F C F C 27 0 15 27 0 15 25 2 14 25 2 14 1 a S 8 23 4 13 8 23 4 13 M c c oO oO NJ Sp 21602 g 216 12 x lt a a o o 195 11 o 19 8 11 ES X 5 5 N Ya c 18 0 10 t c 18 0 10 I M o9 5 8 a a N EZ 12 E 162 9 S x ea ga YN NI 14 4 8 14 4 8 NK 12 6 7 12 6 7 40 50 60 70 40 50 60 70 Relative Humidity Relative Humidity 1001670 Operation Section 11 3 CONSTRUCTION 3 1 Internal Structure Classic10 Control Panel Condenser Air Outlet A Cooling Air Duct Housing for Condenser Fan Housing for Evaporator Fan Condenser Fan and Motor Evaporator Freeze Protection Thermistor CTS Condenser Capillary Tube
38. nd the unit Inlet air Temperature 104 F Humidity 50 or lower 40 C or lower Do not operate the unit above the temperature and humidity specified above 5 Cooling capacity inspection Measure the temperature difference between the evaporator inlet and the cooling air duct outlet the difference is out of the range shown in the graphs on page 10 proceed with the remedy suggested in the troubleshooting chart on page 37 Repair Section 41 40 C Humidity Over 50 96 1001698 Thermometer Inlet of Evaporator 1001699 42 Repair Section 7 3 Compressor Inspection 1 Compressor motor inspection Measure resistance across the terminals of the compressor motor Resistance at 77 F 25 C Model R C C S Classic10 Approx 0 7 O Approx 9 2 Q Classic18 Approx 1 5 Q Approx 4 0 Q the measured resistance is not equal to the 1001700 standard values listed above replace the compressor The compressor has an external overload relay The overload relay should be operational if the above resistance is obtained under normal temperature For overload relay specifications refer to the chart below 2 Overlord relay inspection Check for continuity across two terminals of the overload relay At normal temperature there should be continuity across the terminals Operating
39. ndensate Tank Capacity 19 L 5 gal Cd Min Max 50 RH 70 105 F 21 40 C 1 Max Duct Cold Duct Hose 12 m 40 ft 15 m 50 ft Length 2 Hot Duct Hose 18 m 60 ft 18 m 60 ft Max Static Cold Duct Hose 0 33 IWG 0 52 IWG Hot Duct Hose 0 13 IWG 0 25 IWG Level Without Condenser Duct High Low 58 dB A 67 dB A 1 When ambient temperature is lower than 77 F operation may cease due to anti freeze protection activation 2 Confirm pressure drop of duct filter with manufacturer s specifications 1001709 Operation Section 9 2 3 Charact eristics 1 Cooling capacity curve lt Classic10 gt lt Classic18 gt At 115 V At 208 230 V 13 9 3 5 20 6 5 2 11 9 3 0 2 gt 19 0 4 8 25 38 9 9 2 5 o Gc o 17 5 4 4 00 7 9 2 0 15 9 4 0 x103 x103 8 8 6 0 1 5 kcal h 65 kcal h 12 7 3 6 104 40 d N 104 40 2 95 35 2 E 3 E 3 95 35 gt gt ae ee N 830 77 25 77 25 59 68 77 86 F 59 68 77 66 F F C 15 20 25 20 F C 15 20 25 20 Wet Bulb Temp Wet Bulb Temp 1001668 2 Power consumption curve lt Classic10 gt lt Class
40. ndition Se On Board When the drain tank switch is activated the LED displays FL and the unit turns off CooL automatically Once emptying the drain tank procedure is Na EB Ke completed and ON OFF has been pushed unit Tes No ser CA CV returns to normal operation MOVINCOOL Classic 10 When the fire alarm control panel input signal is CLOSED the unit turns off the LED displays AL and the buzzer turns on bic This condition returns to normal when the input No 2 oO FAN O signal is once again OPEN and unit has been Yes Yes ON AUTO RESET dia CAD To RESET hold down the SET TEMP buttons 5 A V simultaneously for 3 seconds and the controller returns to normal status Improper hose connection including kink or blockage or a defect in the condensate pump o 9 coor for more than 180 seconds will display AS on the LED resulting the compressor to stop o o immediately however fan will continue to operate No 3 AD Normal condition is resumed when condensate Yes No MOVINCOOL Classic 10 pump or hose connection is fixed and the unit has been RESET To RESET hold down the SET TEMP buttons A V simultaneously for 3 seconds and the controller returns to normal status When room thermistor becomes open or shorted display shows E1 and cool mode coe operation is off Display and cool mode Need LU WIS operation are returned to normal operation afte
41. o the refrigerant cylinder R22 2 Open the refrigerant cylinder valve loosen the nut on the gauge manifold side of the charging hose green for air purging and tighten the nut as before 3 Open the gauge manifold high pressure valve Charge the system with refrigerant until the high pressure gauge indicates 57 psiG 4 kg cm G After charging is complete close the high pressure valve Occasionally verify the high pressure gauge pressure reading after closing the high pressure valve 4 Check carefully for gas leaks inside the refrigerant system using the gas leak tester 5 Repair any leaks N WARNING Do not attempt any repairs on a charged system N WARNING Before checking for gas leaks fully confirm that there is nothing flammable in the area to cause an explosion or fire Contacting refrigerant with an open flame generates toxic gas 5 Evacuation repeat Valve Setting Gauge Low Pressure Valve Side Tube Vacuum Pump in Operation LO HI LO HI Closed Open Closed Closed 750 mmHg or greater High Pressure Gauge High Pressure Valve High Pressure 1001824 6 Refrigerant charging work Valve Setting LO Closed Air Purging Y Open The Valve of Refrigerant A Cylinder To Process Tube Fitting Charging Hose Green Refrigerant Cylinder R 22 1000571 Repair Section 75 1 Close the refrige
42. ompressor on recovery conditions CTS temperature gt 59 F 15 C ON 52CM OFF 29 F 59 F gt 5 temperature 1 5 C 15 C Evaporator out temperature 1001687 Operation Section 4 Compressor time delay control compressor protection Compressor protection consists of a time delay program within the microprocessor This program prevents a heavy load from being applied to the compressor motor when restarting the unit cool mode after a very short period of time This delay is in effect any time the compressor is turned on by either the COOL ON OFF button or power interruption restart automatic recovery Time Delay Program Specifications 120 sec 1st Time After initial set up reset circuit breaker etc Compressor turns off and on immediately within 120 sec Turn ON Example Compressor turns off and on more than 120 sec cub Controller Status OFF Compressor ON Status 52CM less than 5 sec Delay Ti t elay Time No Delay Time for Extended Period 120 sec Less than 5 sec Delay Time 120 sec after last turn off Reference Initial turn on Within 120 sec after the power cord is connected to the power supply the compressor will start with delay timer After 120 sec since the power cord was connected to the power supply the compressor will start without delay timer 1001688 5 Automatic restart and recovery function
43. orator fan Set Screw Evaporator Fan 1001740 Repair Section 5 Take off the four nuts and then remove the fan motor Fan Motor 1001757 6 Verify the clearance between the fan and housing N CAUTION 006 0 06 inch After installing the fan and fan motor ensure 1 5 mm 1 5 mm that the clearance between the fan and or more or more housing is at least 0 06 inches 1 5 mm 1001724 9 6 Full Drain Switch Removal Full Drain Switch Cover Screws 1001742 Full Drain Switch Screws 1001743 9 7 Assembly Repair Section 67 1 Take out the two screws and then remove the full drain switch cover 2 Unfasten the wiring harness connector 3 Take out the two screws and then remove the full drain switch Assemble the parts and components in the reverse order of disassembly Repair Section 10 REFRIGERANT SYSTEM REPAIR 10 1 Brazing In the event of a leak obstruction or trouble in the refrigerant system of the unit replace or repair the defective component After replacing defective component braze all connections 1 Proper brazing techniques When brazing use a slightly reduced flame Oxyacetylene is commonly used since the flame condition can be easily judged and adjusted Unlike gas welding a secondary flame is used for brazing Properl
44. peration Section 5 8 Fan Motor The fan motor is a single phase induction type The motor rotates the fan on both the evaporator side and the condenser side at the same time The following table shows the specifications of the fan motor used for each model Specifications Classic10 Classic18 1001692 Rated Voltage 115 V 60 Hz 208 230 V 60 Hz Rated Output 140 W 350 W lt NOTE gt 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 5 9 Capacitor The capacitor is used to improve the rotational power of the fan motor and compressor at startup The specification for each capacitor is shown below Rated Capacitance Model Capacitor Voltage V UF For Fan Motor 200 16 Check it Classic10 eck capacitance For Compressor 370 25 1001693 For Fan Motor 400 10 Classic18 For Compressor 370 25 Operation Section 33 5 10 Auxiliary Relay For Classic18 Only The auxiliary relay is normally closed when the unit is in operation fan or cool and supplies t t t t power to the fan motor 13 23 33 43 41 A1 e When current flows across A1 and A2 terminals 13 and 14 23 and 24 33 and 34 43 41 and 44 42 conduct
45. plied to the lubrication groove for each shaft journal lubricating the bearing In this lubrication system oil enters into each bearing separately and returns to the oil reservoir This system effectively prevents bearing temperature increases and offers high reliability In addition the specially treated Hollow Shaft Cylinder Oil Hole Rotor Eccentric Shaft Oil Scrapper 1001680 shaft journal keeps the bearing from being damaged during high temperature operation Condenser The condenser is a spine fin type heat exchange device consisting of copper tubes passing through an aluminum fin Heat is given off and absorbed by air being pulled across the condenser fins by the centrifugal fan The air is then expelled through the exhaust air duct 1001681 4 4 Capillary Tube 4 5 4 6 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 the amount of refrigerant The high pressure high temperature liquid refrigerant sent from the condenser expands rapidly as the refrigerant is sprayed out through Operation Section High Temp High Press Liquid Refrigerant c Cs Low Temp Low Press Gas and Liquid Mixture 1001822 the fixed orifice in th
46. pressor CC2 White CF1 Black 2 P Black 3 P Black 3 P 52CM4 White 52CM3 White 11 P 3 P Black TBR White TBT Black a p TBT Black TBR White TB1 Terminal Block 1 CF1 Black CF2 Black lie Capacitor for Fan Motor 1001722 Repair Section 63 lt Classic18 gt RX Auxiliary Relay Control Box CF Capacitor for Fan Motor 1001720 Repair Section 9 5 Fan Motor Removal Blower assembly removal lt Classic18 gt Condenser Fan Evaporator Fan S Partition Plate Motor Bracket Fan Motor Housing for Condenser Fan Housing for Evaporator Fan 1001708 Repair Section 65 I 1 Loosen the set screw with a hex key and then Condenser Fan remove the condenser fan N CAUTION Set Screw Torque Value for Installation 14 7 Nem 11 8 17 7 Nem 10 8 Ibeft 8 7 13 Ibeft 1 j Set Screw AVN 1001754 2 Take off the two nuts and then remove the A Housing Tor condenser fan housing Condenser H Fan Li M A Nuts Q 1001755 3 Take off the four nuts and then remove the fan motor together with the motor bracket Motor Bracket AP n 756 4 Loosen the set screw with a hex key and then remove the evap
47. r Bracket Fan Motor Housing for Condenser Fan P rtition Plate Housing for Evaporator Fan Evaporator Fan 1001707 Repair Section 54 Condenser Fan j Set Screw 4 4 AN 1001737 Housing for Condenser Fan 1001738 a Motor Bracket 1001739 Set Screw Evaporator Fan 1001740 1 Loosen the set screw with a hex key and then remove the condenser fan N CAUTION Set Screw Torque Value for Installation 14 7 Nem 11 8 17 7 Nem 10 8 Ibeft 8 7 13 Ibeft 2 Take off the two nuts and then remove the condenser fan housing 3 Take off the four nuts and then remove the fan motor together with the motor bracket 4 Loosen the set screw with a hex key and then remove the evaporator fan Screws Fan Motor 1001741 0 06 inch 1 5 mm or more 0 06 inch 1 5 mm or more 1001724 Repair Section 99 5 Take out the four screws and then remove the fan motor 6 Verify the clearance between the fan and housing N CAUTION After installing the fan and fan motor ensure that the clearance between the fan and housing is at least 0 06 inches 1 5 mm Repair Section 56 8 6 Full Drain Switch Removal 1 Take out the two screws and then remove the full drain switch cover Full Drain S
48. r v s No oN AUTO condition is corrected SET TEMP CAY MOVINCOOL Classic 10 When freeze protection thermistor becomes open or shorted display shows E2 and cool CooL mode operation is off Display and cool mode operation are returned to normal operation after No 5 REN Ro condition is corrected Yes No SET TEMP ACY MOVINCOOL Classic 10 1001712 5 7 Compressor 1 Compressor motor The compressor motor is a single phase motor and is contained within the same housing as the compressor Specifications Classic10 Rated Voltage 115 V Rated Output 600 W Specifications Classic18 Rated Voltage 208 230 V Rated Output 1100 W 2 Compressor overload relay An external compressor overload relay is used to protect the compressor motor This relay is mounted within the connector housing that attaches to the top of the compressor The relay interrupts the flow of current when there is an overload condition and high temperature builds up in the compressor Operation Section 31 1001690 Points L Bimetal Terminal 1001691 Operating Temperature Non Operating Limit at 176 F Model Marking OFF Open Contacts ON Closed Contacts 80 C A Classic10 275 F 135 C 156 69 C 10 0 MSTOOAGU 9014 Classic18 293 F 145 C 156 F 69 C 13 0 MRA98869 O
49. rant cylinder valve Next remove the charging hose green from the refrigerant cylinder and then connect the charging hose to the refrigerant recovery machine lt NOTE gt Keep the gauge manifold high pressure valve and the low pressure valve closed 2 Using procedure in the Evacuation evacuate the system until the high pressure gauge indicates 750 mmHg 30 in HG or greater for 15 minutes or more 3 After evacuation is complete close the gauge manifold high pressure valve N CAUTION Always evacuate the system at least twice using the repetitive vacuum method Evacuate the system an additional time on rainy or humid days 1 Remove the charging hose green from the vacuum pump and then connect the charging hose to the refrigerant cylinder R 22 2 Open the refrigerant cylinder valve loosen the nut on the gauge manifold side of the charging hose green for air purging and tighten the nut as before Repair Section 76 Valve Setting LO HI Specified Amount Lo HI of Refrigerant a High Pressure Valve Valve of is Refrigerant Process Tube Fitting Cylinder _5 High Pressure Side Tube 1000575 7 Gauge manifold removal Pinch Off Tool WET To Gauge Side Pinch Off Tube To Refrigerant Cycle Side ycle Si NU Process Tube Fitting e W AN Charging Hose 1000576 3 Securely place the refrigerant cylinder on a scale
50. re is the possibility of a safety device activating due to a clogged air filter First clean the air filter and then verify that the unit starts 38 Repair Section Possible Cause Symptom Remedy Check Area Cause 1 Voltage Power failure Repair power supply 2 Ground fault breaker trip Ground fault or defective Repair ground fault ground fault section Does Not A a LED Display Reset or repair breaker Operate at Turns Off 3 LCDI power cord trip LCDI power cord trip Reset power cord Replace power cord 4 Fuse Fuse blown Repair shorting section Replace fuse 1 Display code FL Drain tank is filled with drain Discharge the drain water water 2 Display code AS Improper routing of drain Repair drain hose then hose reset unit Defective condensate pump Repair or replace condensate pump then reset unit Missing jumper connector Connect jumper connector ED 3 Display code AL with beep Input signal from fire alarm Check external input Display Shows Error sound continuously signal then reset unit Turns On Codes 4 Display code AL without Input signal from fire alarm Reset unit beep sound on from before 5 Display code E1 Improper room thermistor Check connection connection Defective room thermistor Replace room thermistor 6 Display code E2 Improper freeze protection Check connection thermistor
51. the diagnostic codes can be RESET by holding the SET TEMP arrow buttons A V down simultaneously for at least three seconds For details refer to Self Diagnosis Codes Operation Section 25 5 4 Relay Board The relay board contains the compressor and fan on relays in addition to a step down transformer that converts the line voltage Classic10 115 VAC Classic18 208 230 VAC to 12 V 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 further being reduced to 5 V for the system logic Lastly the relay board also contains the dip switch 1 Power supply requirements The Classic10 requires a single phase 115 V 60 Hz power supply while the Classic18 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 Fuse Specifications 5A 250 VAC N 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 3 Input signal The relay board receives inputs from the control panel sensors and external devices to perform device control Control Panel Input Symbol Indication Function Connector
52. then remove the rear panel 7 Take out the fourteen screws and then remove the upper panel N CAUTION The two screws used on the front side of the upper panel differ from the rest Ensure that the correct screws are used when attaching the upper panel 8 Unfasten the connector on the room thermistor wiring harness 9 Remove the wiring harness from the clamp Upper Panel Control Panel Connectors Board Clamp 1001731 Left Side Panel Screws 1001732 Air Filter 1001733 Screws Screws Right Side Panel 1001734 Repair Section 49 10 Unfasten the two connectors 11 pin 5 pin from the control panel 11 Remove the wiring harness from the clamp and board clamp 12 Take out the seven screws and then remove the left side panel N CAUTION The screw on the front side of the left side panel differs from the rest Ensure that the correct screw is used when attaching the left side panel 13 Remove the air filter from the right side panel 14 Take out the eight screws and then remove the right side panel N CAUTION The screw on the front side of the right side panel differs from the rest Ensure that the correct screw is used when attaching the right side panel Repair Section 50 8 3 Control Panel Removal 1 Take out the eight screws and then remove the control panel Con
53. trol Panel 1001735 8 4 Electrical Components Removal 1 Control box 1 Take off the three nuts and then remove the control box 1001736 2 Electrical parts and relay board removal Repair Section 51 Unfasten each connector and then remove the electrical parts from the control box lt Classic10 gt E Red E Red L Brown TB2 Terminal Block 2 3 P Red 2 P Red RB Relay Board 2 P Brown G Green 3 P Black CC1 White CC1 White CC Capacitor for Compressor CC2 White CF1 Black L Brown 2 P Black 3 P Black 3 P Blue 52CM4 White 5 P 52CM3 White 11 P TBR White TBT Black TBT Black TBR White TB1 Terminal Block 1 CF1 Black CF2 Black CF Capacitor for Fan Motor 1001721 52 Repair Section lt Classic10 gt RB Relay Board TB2 Terminal Block 2 CF Capacitor for Fan Motor Control Box 1001719 8 5 Fan Motor Removal Blower assembly removal Repair Section 53 lt Classic10 gt Condenser Fan Moto
54. witch Cover 1001742 2 Unfasten the wiring harness connector 3 Take out the two screws and then remove the full drain switch Full Drain Switch Screws 1001743 8 7 Assembly Assemble the parts and components in the reverse order of disassembly Repair Section 57 9 DISASSEMBLY For Classic18 9 1 Parts Construction lt Classic18 gt Room Thermistor Upper Panel Cooling Air Duct Control Panel Front Panel Housing for Air Filter Condenser Fan Housing for Evaporator Fan Condenser Fan and Motor Left Side Panel Rear Panel Drain Pan Drain Tank Service Panel Locking Swivel Caster Full Drain Switch Caster 1001705 Repair Section 58 9 2 Disassembly Cooling Air Duct a A Front Panel Drain Tank ae Screws 1001744 s 4 4 a Screws EN 1001726 Power Supply Line Ground Line 1001746 1 Remove the drain tank 2 Unfasten the two clips and the lower side hook and then remove the front panel 3 Take out the eight screws and then remove the two cooling air ducts 4 Take out the seven screws and then remove the service panel 5 Remove the two power supply lines from the terminal and remove the ground wire Screws Rear Panel 1
55. y preheat the base metal according to the shape size and thermal conductivity of the brazed fitting 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 metal or filler metal deterioration due to overheating the flux 2 Brazed fittings and fitting clearance In general the strength of the brazing filler metal is lower than that of the base metal As Sistas such the shape and clearance of brazed a 0 025 0 075 mm fittings are very important Concerning the shape of brazed fittings adhesive area must be maximized In addition the clearance of the brazed fitting must be minimized so that the Clearance From The Pipe Fitting and Tubing brazing filler metal will flow into the fitting via 1001823 capillary action 3 Cleaning brazing filler metal and piping Repair Section 69 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 cle
56. y tubing always wear eye protection and work only in a well ventilated area Repair Section 7 TROUBLESHOOTING 7 1 Troubleshooting 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 Drain water overflow Abnormal noise or vibration Other 1 Insufficient cooling Cooling system problem generally results from electrical or mechanical components such as fan motor compressor or control switch lt NOTE gt There is a possibility that insufficient cooling is caused by air filter clogging First verify that the air filter is not clogged Check the power supply due to the possibility of a power source failure Repair Section 37 Possible Cause Symptom Remedy Check Area Cause 1 Usage conditions Operation near usage limits Review the installation high temperature place 2 Dirt in condenser or Poor heat exchange Clean fins Compressor evaporator Operates 3 Frost in refrigeration cycle Clogging at the frost section Replace clogged section 4 No temperature difference Insufficient refrigerant Check the leaking part between evaporator and then repair and charge condenser refrigerant Air Volume E T N 1 Coil resistance 0 O oro Short or open circuit Replace compressor orma In

Classic 18 Service Manual for Units Produced Jan. 08

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