SERVICE MANUAL - Gordon R Williams Corporation
Contents
1. Control Panel Housing for Evaporator Fan Evaporator Freeze Protection Thermistor CTS Capillary Tube Drain Tank High Pressure Switch Locking Swivel Caster Front Full Drain Switch Caster Rear ILL00549 00 Operation Section 11 4 REFRIGERATION SYSTEM 4 1 Refrigeration System Construction The component parts of the refrigeration system include the following e Compressor Evaporator Condenser Accumulator Capillary tube High Pressure Switch The parts above are all connected by copper piping with brazed connections Y l Evaporator 7 7 Y de 7 Condenser Condenser Al Inlet Pipe Compressor f ha Evaporator Outlet Pipe Capillary Tube Y Al Evaporator inlet Pipe WAAAY f SE A 4 A 5 Connecting Pipe Evaporator to Compressor N V YA ps Y E Connecting Pipe Condenser to Capillary Tube fr j E h Discharge Pipe ib KA meo Compressor Suction Pipe Condenser Outlet Pipe High Pressure Switch Compressor Accumulator Condenser lt Flow of Refrigerant y Capillary Tube ILL00550 00 12 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 e The construction of a rotary type compressor i2. action 62 Repair Section 3 Cleaning brazing filler metal and pipe e When the refrigeration system has been opened and exposed to the heat which could cause the brazing filler metal to stick to the inside and outside of the pipe Brazing filler metal may also be compounded with oxygen in the air to form the oxide film In addition grease and oils may stick to the pipe during handling All these factors can reduce the effectiveness of brazing It is necessary to eliminate the excessive brazing filler metal using sand paper and by thorough cleaning with solvent such as Trichlene Z CAUTION e Do not use chlorine cleaner 4 Use of Dry Nitrogen gas e During brazing the inside of the pipe undergoes an oxidative reaction due to the brazing flame Introduce dry nitrogen gas 0 27 gal min 1 L min adjust with the flow regulator through the pinch off tube of the refrigerant cycle to prevent oxidation lt NOTE gt e Make sure not to allow dirt water oil etc to enter into the pipes 5 Vertical joint e Heat the entire brazed fitting to a proper brazing temperature Bring the brazing filler metal into contact with the fitting so that the brazing filler metal starts to flow by itself e 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 the portions heated to a proper temperature it is essential to keep the whole fitting
3. 42 Repair Section 8 4 Basic Inspection e Perform the following inspections before disassembly 1 Inspection of plate fins To inspect the plate fins of either the evaporator or condenser the air filter must be lt removed After removal of the air filters inspect gt the plate fins for any dirt dust lint or debris A that may have caused insufficient cooling Q performance of the unit If cleaning of the fins o is necessary it is recommended that this Q service be performed by a qualified service oe technician 1001780 2 Examination of operating environment e Operating environments can vary depending on location climate and surrounding conditions Installation location can also cause operational problems Consult with your reseller concerning operational environment requirements 3 Cooling capacity inspection Measure the temperature difference between the evaporator inlet and the cooling air duct outlet If the difference is out of the range shown in the graphs on page 9 proceed with the remedy suggested in the troubleshooting chart on page 35 to 41 Cooling Air Duct Thermometer Inlet of Evaporator ILL00597 00 Repair Section 43 8 5 Compressor Inspection 1 Compressor motor inspection e Measure resistance across the terminals of the compressor motor Resistance at 77 F 25 C R C C S Approx 0 83 ohm App
4. 4 5 4 6 4 7 Operation Section Evaporator The evaporator is a heat exchanger covered with plate 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 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 SS ILL00552 00 From Evaporator To Compressor lt T 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 High Pressure Switch The high pressure switch prevents the condenser and compressor from being damaged by excessive high pressure in the high pressure line of the refrigeration cycle The switch is normally closed The snap disk responds to the variations in pressure and if pressure is abnormally high the snap disk moves down to push the pin down causing the internal contacts to open This interrupts the Pressure of Refrigerant Movable Point Stationary
5. CF1 Black TBR White A F TBT Black CF2 Black TA Ral al AN Martel TBT Black TBR White CF Capacitor for Fan Motor G Green CHE ws ae G Green QS eam sep CC1 White CC Capacitor for Compressor TB1 Terminal Block 1 CC2 White ILL00594 00 Repair Section 59 3 Removal of control box 1 Take out the three 3 nuts and then remove the control box 1002606 4 Removal of electrical parts Terminal block 1 power connection Remove the two 2 screws from the control box Terminal block 2 signal connection Remove the two 2 screws from the control box Capacitor for compressor Remove the one 1 screw from the control box Capacitor for fan motor Remove the one 1 screw from the control box Relay Board Remove the six 6 supports from the relay board gt TB2 Terminal Block 2 Control Box RB Relay Board TB1 Terminal Block 1 CF Capacitor for Fan Motor CC Capacitor for Compressor ILL00571 00 60 Repair Section 9 5 Full Drain Switch Removal 1 Take out the two 2 screws and then remove the full drain switch cover Full Drain Switch Cover Screws 2 iy of 1002609 2 Unfasten the wiring harness connector 3 Take out the two 2 screws and then remove the full drain switch Full Drain Switch Screws 2 1002610 Repair Section 61 10 REFRIGERATI
6. LO HI Al LO HI Gauge Closed Open Closed Closed 30 inHg 100 kPa or larger High Pressure Gauge High Pressure Valve High Pressure Side Tube Vacuum Pump in Operation 1002227 1 Properly remove the crushed end of the pinch off tube at the high pressure side and the low pressure side of the refrigerant cycle with a pipe cutter 2 Fit the process tube fitting to the pinch off tube on both sides 3 Connect the charging hoses red high pressure side for the gauge manifold to the process tube fitting lt NOTE gt Connect the hoses using care not to mistake the high pressure side for the low pressure side and vice versa 4 Connect the charging hose green at the center of the gauge manifold to the vacuum pump 1 Open the high pressure valve HI of the gauge manifold 2 Turn on the vacuum pump to start evacuation Evacuate the system for approximately 15 minutes 3 When the high pressure gauge indicates 30 inHg 100 kPa or higher turn off the vacuum pump and close the high pressure valves of the gauge manifold Repair Section 67 3 Checking vacuum Vane Seii 1 Leave the high pressure valve and the low eee Leave valves closed for 5 LO us on more Polen st pressure valve of the gauge manifold closed for Closed Closed pressure gauge returning to five minutes or more and confirm that the gauge p G zero indicates there is a leak eee AUIE pointer
7. Perform repairs in a properly ventilated area Never in an enclosed environment Do not expose refrigerant to an open flame Never smoke while performing repairs especially when handling refrigerant Take caution so that 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 Step 1 Connect manifold gauge 1 Evacuate the system 15 minutes or more Step 2 30 inHg 100 kPa or more of vacuum When leak is found 2 Stop evacuating the system repair the connection e Leave for 5 minutes or components 3 Check the vacuum Step 3 Connect to refrigerant source Step 4 Test the system for leaks Step 5 Charge the system with R 410A e i e See Technical Specifications for the specified amount Step 6 Remove manifold gauge ILL00084 00 66 Repair Section 1 Connection of gauge manifold Charging Hose Side Refrigerant Cycle Side Pinch Off Tube 1002183 Low Pressure Valve Closed High Pressure Valve Closed Red Hose Process Tube Fitting High Pressure Side Tube Vacuum Pump when stopped 1000568 2 Evacuation Valve Setting
8. Roller 1001677 Discharge Valve ue Blade Roller 1001678 Discharge Valve 1001679 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 continues suction and compression repeatedly in succession Operation Section 15 4 Compressor lubrication e The lubrication system is comprised of a hollow shaft an oil scraper mounted at the end Rot otor face hollow shaft a shaft journal shaft bearing and the lubrication groove for the shaft journal The lubrication groove is wider Hollow Shaft than the oil hole When the shaft turns oil is Cylinder scraped upward by the oil scraper along the Eccentric Shaft Roller inside diameter of the hollow shaft The oil is fed through the
9. No air 2 Fan motor on off relay 521D Open circuit or bad contact Replace relay board y on the relay board Insufficient air volume 1 Air filter Clogged air filter Clean air filter 2 Evaporator Clogged evaporator or Repair and clean fins or Insufficient crushed fins replace evaporator air volume 3 Duct connection state Improper connection Repair duct connection 4 Fan motor Insufficient rotation Replace motor 1 For unit serial number from November 2011 1111 to Present Repair Section 39 2 Unit does not start operate This problem occurs mainly from the safety devices electrical components environmental condition or installation location Refer to the troubleshooting chart below and the next page for possible causes of unit does not start and remedies Condition Possible Cause Remedy Unit does not operate Check Area Cause 1 Voltage Power failure Repair power supply 2 Ground fault breaker trip Ground fault or defective Repair ground fault ground fault breaker section Unit does Control panel Reset or repair breaker not operate LED display turns off 3 LCDI power cord trip Leakage current detected Reset power cord Replace power cord 4 Fuse Fuse blown on relay board Check and fix shorted circuit and replace fuse 1 Display code FL Drain tank is filled with the Discharge the drain
10. Repair and charge leakage refrigerant 4 Dirt on air filter or condenser Insufficient cooling of Clean air filter and condenser condenser 1 To RESET the controller press SET TEMP A V buttons simultaneously for 3 seconds 2 For unit serial number from November 2011 1111 to Present Repair Section 41 3 Drain water overflow Possible Cause Condition Remedy Check Area Cause 1 Drain pan Cracks in drain pan Check and replace 2 Water level in drain pan Clogged drain hose Check and repair 3 Drain hole Reversed air flow from drain Insert a trap on the hole discharge drain hose Overflow from the 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 abnormal noise or vibration carefully determine the source of the problem and come up with proper countermeasures to solve the problem so that it does not occur again Possible Cause Condition Remedy Check Area Cause 1 Fan Fan interference Repair interfering section Fan deformation Replace fan Abnormal noise or P 2 Compressor fixing nuts Loose nuts Tighten nuts further vibration 3 Piping Pipe interference Repair interfering section 4 Panel fixing screws Loose screws Tighten screws further
11. V and the FAN button down simultaneously for 3 seconds 5 Diagnostic code e Most of the diagnostic codes can be RESET by holding the SET TEMP arrow buttons A V down simultaneously for 3 seconds For details refer to page 35 to 36 Repair Section 35 8 TROUBLESHOOTING 8 1 Troubleshooting Before troubleshooting the system the following inspection should be performed AN WARNING Disconnect power supply from the unit before performing any service Beware that some residual voltage may remain in the unit immediately after the power is disconnected 1 Inspection Voltage of the Power Source e Check the voltage of the power source Single Phase 115V 60 Hz e Check the operation and condition of the fuse or circuit breaker in the power source 2 Inspection of Air Filters e Remove the air filters and check the element if the element is dirty wash the element as described in the OPERATION MANUAL supplied with the unit 8 2 Self Diagnostic Codes e Self diagnostic codes are displayed on the control board under the following conditions Indication Condition eed ree d When the fire alarm control panel input signal is COOL CLOSED the unit turns off the LED displays ames AL and the buzzer turns on i a This condition returns to normal when the input No 1 re ANY signal is once again OPEN and unit has been Yes Yes MOVINCOOL Classic 10 RESET To RES
12. residual voltage may remain in the unit immediately after the power is disconnected 1 Removal of control panel D o 9 SFr Ji N Screws 8 X Control Panel 1002605 1 Take out the eight 8 screws and then remove the control panel Repair Section 57 2 Removal of wire harness in control box 1 Disconnect all the wires from the electrical parts in control box For Unit Serial Number from February 2011 0211 to October 2011 1011 E Red E Red TB2 Terminal Block2 2 P Brown L Brown 2 P Black L Brown 3 P Black 3 P Red 3 P Blue 2 P Red 52CM4 White RB Relay Board 5P 5 P 52CM3 White CF1 Black AW II 1 E 3 P Black eri ABACK TBR White A 4 ae TBT Black man CF2 Black Pa lo a5 P NO TBT Black TBR White CF Capacitor for Fan Motor TB1 Terminal Block 1 G Green G Green G Green CC1 White CC1 White CC Capacitor for Compressor CC2 White ILL00569 00 58 Repair Section 2 Disconnect all the wires from the electrical parts in control box For Unit Serial Number from November 2011 1111 to Present E Red E Red TB2 Terminal Block 2 L Brown 2 P Black 2 P Black L Brown 3 P Black 3 P Red 3 P Blue 2 P Red 52CM4 White RB Relay Board 5P 2 P Brown 5 P 52CM3 White N E CF1 Black A SF 3 P Black
13. 6 ACCUEIL bas Saeed Latha wea AE as Au 16 4 7 High Pressure Switch QQ tet teens 16 5 ELECTRICAL SYSTEM 5 1 Circuit Diagram asia aana a ge asain ne SN Aa ea ease 17 9 2 Control BOK ad OMAR ae Be A Nee DAY A Ae sa 19 5 3 Control Specifications saaan aeaaaee 24 5A AA See Be Ge heater 0061 eee 27 5o Fat MotofinSeu ir b o cee Obed ieee ed AAA 28 5 6 Temperature Thermislor te eee tees 29 Dif Drain EanKSWIIGH z ss gen Baye rc heeded niie hehe aes a Oe A 30 6 CONNECTION AND SETTING 6 1 Warning Signal Connection sessa sasaaa aaaea aaee 31 6 2 Fire Alarm Control Panel Connection QQ QQ QQ Q ko 32 7 OPERATION 7 1 Operation of Control Panel QQQ On HQ nu xa 33 4 Table of Contents Repair Section 8 TROUBLESHOOTING 81 Troubleshooting secs coke A td a 35 8 2 Self Diagnostic Codes se iii datada edi dad aida re setae gi n b i ii 35 8 3 Troubleshooting Chart ses pat a ale ag eke ee a 37 8 4 Basic NSpectON miii pace Satin v03 00 eae eee A psi h i OY i ote ae oda 42 8 5 Compressor Inspection trate nia er A eae Hd Se ee 43 8 6 Fan Motor lInspection eee eee 43 8 7 Capacitor Inspection For Fan Motor and Compressor 44 8 8 Full Drain Switch lnspection ene 45 8 9 Thermistor Inspection 0
14. Point Case Molding by Resin vy Snap Disk Lead Wires PP s 1001768 ground signal at the relay board which turns the compressor off Operation Section 17 5 ELECTRICAL SYSTEM 5 1 Circuit Diagram For Unit Serial Number from February 2011 0211 to October 2011 1011 Dip Switch ON J R T OFF Default 1234 1 ON Fan Stop Mode Fan Auto OFF Fan Operate Mode Fan On 2 N A 3 N A 4 ON The Buzzer Sound Disabled On Board E Controller Fine Alarm Input O zZ Ke 11 00000 5 4 ones 5 1 09 o 2 8 S ae Ny Tol Am N o Z X m 1 E o Su ail 9 Dip Switch ON E AC115V AS 1PHASE cni7 ee CNOT Bate y 1234 CN13 CN12 CN11 CNI6 CN15 52CM 000 000 000 1 3m ER y gi gl gi El oy 8 2 Qi O00000 8 D 000 OOO EJE 5 QOOOOD OOOOOOOOOOO CB e Z 10 id olj Control Box CN LB
15. at a proper brazing temperature 2 Vertical Down Joint 450 Brazing Filler Metal Burner Af Tube gt gt 1000564 Vertical Up Joint Burner Brazing Filler Metal 1001725 Repair Section 63 10 2 Removal of Refrigeration System Components Z WARNING e Before replacing any refrigeration component recover the refrigerant using standard recovery procedures and equipment e When recovering the refrigerant use the pinch off tubes at the low pressure side tube 1 and high pressure side tube 2 as shown in figure below Ax CAUTION e To prevent oxidation dry nitrogen should be conducted flow rate 0 27 gal min 1 L min through the pinch off tube during any brazing operation e During any component replacement involving brazing shield nearby parts with a steel plate to protect them from the flame Tube 1 i SA Z2 D H Z k lt lt WAS HARO HAN E Part to Replace Disconnect at A y 2 p 4 Tube 2 e Compressor See the next page IA WU l Condenser A amp C Pipe 1 LA ag SS Pipe 2 e Capillary Tube E amp F Ni gi Evaporator D amp F di e High Pressure Switch G ILL00579 00 64 Repair Section 1 Removal of compressor assembly TBT wire 1 Disconnect CC1 and CC2 wire
16. does not operate Check Area Cause 6 Display code HP Operating outside of the Check environmental operating temperature s condition Do not use the range unit outside the operating range See page 7 RESET the controller Loose high pressure switch Reconnect the high Control panel Control panel connection pressure switch and check LED display display shows the connection turns on A ETA error codes Defective high pressure Replace high pressure switch short open switch Refrigerant is over charged Charge the correct amount of refrigerant See page 70 RESET the controller 1 Fan Motor on off relay 521D Open circuit or insufficient Replace relay board on the relay board contact Unit stops Control panel 2 Fan Motor insulation Insulation failure on fan Replace fan motor immediately LED displays resistance motor after starting normal 3 Compressor insulation Insulation failure on Replace compressor resistance compressor 1 Coil resistance of fan motor Defective fan motor Replace fan motor 2 Temperature of fan motor Operation of safety device Replace fan motor abnormally high IOLF due to fan motor malfunction Unit stops Control E 3 Temperature of compressor Operation of safety device Replace compressor after running LED displays abnormally high IOLC due to compressor for a while normal malfunction Insufficient refrigerant or gas
17. does not return to zero 2 If the gauge pointer returns gradually to zero gt there is a leak somewhere in the system this Pipe brazing could also include gauge manifold Perform a 1003203 leak check according to the procedure indicated in the next step Once the leak has been found and repaired evacuate the system once more to confirm that the system holds vacuum 68 Repair Section 4 Checking gas leak Valve Setting LO Closed Air Purging 2 Open The Valve of Refrigerant KL Cylinder To Process Tube Fitting 8 Charging Hose Green Refrigerant Cylinder R 410A 1001901 Valve Setting LO HI LLO Hi Closed Open Gauge Reading Closed Closed 57 psi 390 kPa Low Pressure Valve Closed Open High Pressure Valve Process Tube Fitting Refrigerant A l Cylinder z AN e Valve PE ide Tube Open E 1002228 1 Remove the charging hose green from the vacuum pump and connect the hose to the refrigerant cylinder R 410A 2 Loosen the nut on the gauge manifold side of the charging hose green 3 Open the valve of the refrigerant cylinder and perform air purging in the charging hose green Then tighten the nut 4 Open the high pressure valve of the gauge manifold Charge the system with refrigerant until the high pressure gauge indicates 57 psi 390 kPa After chargin
18. interrupts the flow of current when there is an overload condition such as high current draw and or high temperature build up in the Lager Terminal compressor 1001691 Operating Temperature Non Operating Limit at 212 F Marking OFF Open Contacts ON Closed Contacts 100 C 302 F 150 C 142 F 61 C 12 8A MRA1261 12026 28 Operation Section 5 5 Fan Motor 1 For unit serial number from February 2011 0211 to March 2011 0311 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 Specifications Rated Voltage 115V Rated Output 140 W 1001692 2 For unit serial number from April 2011 0411 to Present 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 Specifications Rated Voltage 115V Rated Output 150 W ILL00560 00 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 there is an abnormally high temperature build up in the fan motor 5 6 Temperature Thermistor e The room upstream of the evaporator thermistor RTS is installed and detec
19. oil hole by centrifugal force then supplied to the lubrication groove for each shaft journal lubricating the bearing In this Oil Feed Groove lubrication system oil enters into each bearing Oil Hole Oil Scrapper separately and returns to the oil reservoir 1001680 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 4 3 Condenser The condenser is a heat exchanger with copper tubes that are covered with thin aluminum projections called plate fins e e Heat is given off and absorbed by air being pulled across the condenser fins by the centrifugal fan and then expelled through the exhaust air duct ILL00551 00 4 4 Capillary Tube High Temp High Pressure The capillary tube is a long thin tube that Liquid Refrigerant utilizes line flow resistance as an expansion Esp 1 valve The length and the inner diameter of the capillary tube are determined according to the capacity of the refrigeration system operating gt high pressure high temperature liquid An UI MIKIUTE aides refrigerant 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 and therefore evaporates easily 16
20. point during cool mode 4 Room Temperature Shows a blinking set point temperature for 5 seconds then continuously indicates Set Point Display room temperature 5 Temperature Scale LED Illuminates to indicate the current temperature being displayed is either in C or F 6 ON LED Illuminates during fan only mode and cool mode using fan operate mode 7 AUTO LED Illuminates during cool mode using fan stop mode LED Display Indication In normal operation LED displays the following indication Display Indication Conditions 2 Right decimal segment is on Power stand by or during fan only mode 7 Indicates room temperature a when display is solid During cool mode I Lt Left fig Room temp at 78 F o Indicates set point temperature During set point temperature adjustment when display is flashing or cool mode on Left fig Set Point temp at 75 F 5 seconds ILL00557 00 lt NOTE gt The room temperature display range is from 0 F to 109 F When displayed in C the range is from 9 C to 60 C e In 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 34 Operation Section 2 Fan only mode e 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 of
21. the repetitive vacuum method Evacuate the system an additional time on rainy or humid days 10 4 Refrigerant Charging Work 1 Refrigerant charging Valve Setting 4 Remove the charging hose green from the KEEN vacuum pump and connect it to the refrigerant Air Purging cylinder R 410A Open The Valve of Refrigerant Cylinder WA Charging Hose Red Green To Process Tube Fitting 5 Loosen the nut on the gauge manifold side of the charging hose green Open the valve of the charging hose green Open the valve of the Refrigerant Cylinder R 410A refrigerant cylinder After air purging tighten the 1001901 nut and close the valve of the refrigerant cylinder 70 Repair Section Valve Setting 6 Securely place the refrigerant cylinder on a scale a ee with a weighing capacity of 70 Ib 30 kg that is graduated by 0 2 oz 5 g increments Highpress re vave 7 Open the high pressure valve of the gauge Valve of Refrigerant Cylinder Process Tube Fitting manifold and the valve of the refrigerant cylinder High Pressure Charge the system with refrigerant to the a Side Tube specified amount 1001903 Standard Amount of Refrigerant 1 43 Ib 0 65 kg A CAUTION The amount of refrigerant charged has a great effect on the cooling capacity of the unit Charge to the specified amount always observing the scale graduations while char
22. 02CN14CN16 CN15 4 Position Dip Switch Relay Board Fuse 5A OFF Position ILL00556 00 1 Power supply requirements e This unit requires a single phase 115 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 5 A 250 VAC AN 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 Operation Section 3 Input signal e The relay board receives inputs from the control panel sensors and external devices to perform device control Control Panel Input Symbol Indication Function Connector SWI1 ON OFF Button On off control for unit operation Turns the unit on and off Changes the fan control mode between continuous and automatic on off control SW2 FAN Button ir SET TEMP A Increases the set temperature CN17 Button SW4 SET TEMP V Decreases the set temperature Button Sensor Input Specification Symbol Type Connector Characteristic Short Detection Open Detection 5 k ohm at 77 F 181 F 83 C or 29 F 34 C or RTS Room T
23. ET hold down the SET TEMP buttons A V simultaneously for 3 seconds and the controller returns to normal status When the drain tank switch is activated the LED COOL displays FL and the unit turns off automatically Once emptying the drain tank procedure is No 2 RED o completed and ON OFF has been pushed unit Yes No serTEMP A JEY returns to normal operation MOVINCOOL Classic 10 36 Repair Section Indication Condition a eae d When the high pressure switch connected to COOL CNO03 is activated CNO3 input turns open for i igs the first 2 times in 24 hours HP turns on but R L M o goes away as the high pressure switch resets _serteme CANTY If the high pressure switch is activated 3 times in L_MOVINGOOL Classic 10_ 24 hours HP blinks and signal output CN24 Yes No No 3 1 turns on When the high pressure switch is activated 10 times in 24 hours HP turns on and signal output CN24 turns on Yes No To RESET hold down the SET TEMP buttons A V simultaneously for 3 seconds and the controller returns to normal status Improper hose connection including kink or o COOL blockage or a defect in the condensate pump Sarno for more than 180 seconds will display AS on ON AUTO the LED resulting the compressor to stop sETTEMP A V immediately however fan
24. ON SYSTEM REPAIR 10 1 Repair of Refrigeration System e When there is a leak obstruction or problem in the refrigeration system of the unit replace or repair the defective refrigeration component After replacing any refrigeration component all the connections must be brazed 1 Proper brazing techniques e When brazing use a slightly reduced flame Oxyacetylene is commonly used since it is easy to verify and adjust the condition of the flame Unlike gas welding a secondary flame is used for brazing It is necessary to preheat the base metal properly depending on the shape size or thermal conductivity of the brazed fitting The most important point in flame brazing is to bring the whole brazed fitting to a proper brazing temperature Care should be taken to not cause overflow of the brazing filler metal oxidation of the brazing filler metal or to not deterioration due to overheating of the flux 2 Brazed fittings and fitting clearance e In general the strength of the brazing filler metal is lower than the base metal Therefore noon ees in the shape and clearance of brazed fitting a 0 025 0 075 mm are very important As for the shape of Y ry brazed fitting it is necessary to maximize its J ol J J adhesive area The clearance of the brazed fitting must be minimized to facilitate brazing Clearance From The Pipe Fitting and Tubing filler metal to flow into the fitting by capillary t
25. SERVICE MANUAL CLASSIC 10 SERIAL NUMBER FROM FEBRUARY 2011 0211 TO PRESENT MOVINCOOL THE 1 SPOT COOLING SOLUTION DoclID 00G00089E 2012 DENSO SALES CALIFORNIA INC All rights reserved This book may not be reproduced or copied in whole or in part without the written permission of the publisher DENSO SALES CALIFORNIA INC reserves the right to make changes without prior notice MovinCool Office Pro and SpotCool are registered trademarks of DENSO Corporation Table of Contents 3 Table of Contents Operation Section 1 PRECAUTIONS FOR SAFETY 1 1 FORO WOM e a a nace A E OB A AD oT E e tial v6 4 2 5 1 2 Definition of EMOS e a ohne Mak a wlan a EA Ga ae d i d 5 1 3 General Precautions 0 0 0 eee ee aaa 5 2 SPECIFICATIONS 2 1 Exterior Dimension Diagram 0006 cece ee eee 6 2 2 Technical Specifications eee eee 7 239 Characteristics Seen a Saad eae a xoang c a be Paes 8 3 CONSTRUCTION 31 Internal Structure acca lso aaa os Speedie eet pee eed fee nabs pen ede poet pesados 10 4 REFRIGERATION SYSTEM 4 1 Refrigeration System Construcfion HQ HH kh xa 11 4 2 COMPIESSOM ese 21610076 A A ee ee PE Bee PAE ee Warne le 12 4 3 CONGENSER oooh veka et bat SOO A e eA poe e PE SG 1v SH dees 15 44 Capillary TUD otero a a S da ra daw Mae 15 Aor Evapa cite ie a a E256 b i gi ng bi aA ple 0 M n ae be ed bed 16 4
26. Unit Serial Number from February 2011 0211 to October 2011 1011 TB2 Terminal Block2 RB Relay Board CF Capacitor for TB1 Terminal Block 1 Fan Motor CC Capacitor for Compressor ILL00559 00 For Unit Serial Number from November 2011 1111 to Present TB2 Terminal Block2 RB Relay Board CF Capacitor for TB1 Terminal Block 1 Fan Motor CC Capacitor for Compressor ILL00555 00 19 20 Operation Section 1 Capacitor e The capacitor is used to improve the rotational Se power of the fan motor and compressor at startup The specification for each capacitor is shown below ILL00561 00 Rated Model Capacitor Capacitance Voltage For unit serial number from February For Fan Motor 450 V 16 HF 2011 0211 to March 2011 0311 For Compressor 450 V 55 uF For unit serial number from April For Fan Motor 250 V 25 uF 2011 0411 to Present For Compressor 450 V 55 uF Operation Section 21 2 Relay board e The relay board contains the dip switch the compressor and fan relays and a step down transformer that reduces the line voltage from 115VAC to approx 14 VAC This voltage is then rectified from 14 VAC to 12 VDC and used for relay coil activation The 12 VDC voltage is sent to the control panel assembly and further being reduced to 5 V for the system logic CN23 CN22 CN21 CN24 a DA E A al O qu k maok Ed ES CN13 CN12 CN11 arr ae CN
27. al E and E The controller is equipped with a normal open input signal which can be connected directly from the fire alarm control panel When receiving the signal from the fire alarm control panel the unit turns off and does not turn back on until it has been reset Connecting fire alarm control panel to controller 1 Remove service panel from the rear of the unit 2 Squeeze the inner latches and push out the black cap from inside the panel See drawing of Cap and inner latch shapes 3 Insert the fire alarm signal wire through the hole in the rear panel Use recommended warning signal wire size from 16 AWG to 26 AWG for a solid wire or 16 AWG to 22 AWG for a stranded wire with ring terminal for 6 stud size 4 Connect warning device to terminal E and E according to its polarities lt Cap gt Unit Terminal Fire Alarm Device Latch Sener ILL00080 00 ILL00078 00 Operation Section 33 7 OPERATION 7 1 Operation of Control Panel 1 Control panel Before operating the unit it is important to be familiar with the basic operation of the control panel 6 M Ga ott ha Ln aa SET TEMP V O MOVINCOOL Classic 10 1 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 3 SET TEMP Buttons A V Increases decreases the temperature set
28. drain water water RESET the controller Loose drain switch Recomnect the drain connection switch and check the connection RESET the controller Defective Drain Switch Replace the drain switch RESET the controller 1 2 Display code AS Optional condensate pump Remove any blockage or stops pumping water due to kinks from the drain line or any kinks blockage in the improve hose installation drain line or due to improper RESET the controller routing of the drain line Control panel Control panel Detective condensate pump Replace the condensate LED display display shows pump RESET the turns off error codes controller Missing jumper connector at Insert the pump the pump connector connector and check the connection RESET the controller 3 Display code AL with beep Signal is input from the Check the fire alarm sound fire alarm system and confirm there is no input signal to the unit then RESET the controller 4 Display code E1 Loose or defective room Reconnect or replace thermistor room thermistor RESET the controller 5 Display code E2 Loose or defective freeze Reconnect or replace protection thermistor freeze protection thermistor RESET the controller 1 To RESET the controller press SET TEMP A V buttons simultaneously for 3 seconds 40 Repair Section Condition Possible Cause Remedy Unit
29. erruption 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 Fan mode Fan operation mode fan on or fan stop mode fan auto 26 Operation Section 6 Temperature control e During cool mode temperature control changes the 52CM compressor on off relay status according to RTS temperature in the available range 4 F to 140 F 20 C to 60 C 52CM Compressor Relay OFFL 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 1002624 7 Fire alarm signal control e 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 Operation Section 2 5 4 Compressor 1 Compressor motor The compressor motor is a single phase motor and is contained within the same housing as the compressor Specifications Rated Voltage 115V Rated Output 700 W 1002355 2 Compressor overload relay e An external compressor overload relay is used to protect the compressor motor This relay is ee mounted within the connector housing that attaches to the top of the compressor The Points relay
30. ey and then remove the evaporator fan Nuts 4 Fan Motor Harness Clamp ILL00577 00 Repair Section 5 Take out the four 4 nuts and then remove the fan motor S 54 Repair Section 2 For Unit Serial Number From April 2011 0411 to Present 8 gt Housing for Evaporator Fan V PN gt a y Condenser Fan Evaporator Fan Partition Plate Motor Bracket Fan Motor Ring Housing for Condenser Fan ILL00576 00 Condenser Fan Set Screw WI AL HA 1002361 Housing for Condenser an Motor Bracket ILL00574 00 Set Screw Evaporator Fan I001740 Repair Section 99 1 Loosen the set screw with a hex key and then remove the condenser fan AN CAUTION e Set Screw Torque Value for Installation 10 80 2 17 ftelbf 14 7 3 0 Nem 2 Take off the thee 3 nuts and then remove the condenser fan housing 3 Take off the four 4 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 56 Repair Section Fan Motor ILL00575 00 5 Take out the four 4 bolts and then remove the fan motor 9 4 Removal of Electrical Components WARNING Disconnect power supply from the unit before performing any service Beware that some
31. f and only the fan is in operation When the FAN button is pressed again the fan stops 3 Cool mode e 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 e 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 If room temperature reaches the set temperature during cooling operations the compressor stops and only the fan continues to operate Fan operate mode is a default setting from the manufacturer 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 23 During cooling operations when in the fan stop mode the FAN AUTO LED illuminates 4 Change temperature mode C and F e The temperature display can be switched between C and F by holding the SET TEMP arrow buttons A
32. g is complete close the high pressure valve 5 Open the valve of the refrigerant cylinder and perform air purging in the charging hose green Then tighten the nut 6 Check carefully for gas leaks inside the refrigeration system using the gas leak tester 7 Repair any leak AX WARNING Any repair on a charged system should be performed by a licensed professional only Z WARNING Before checking for gas leaks confirm that there is nothing flammable in the area to cause an explosion or fire Contact of refrigerant with an open flame generates toxic gas Repair Section 69 5 Evacuation repeat Valve Setting 1 Close the valve of the refrigerant cylinder Then Gauge EAER EZ remove the charging hose green from the gt 30 inHg 100 kPa or larger refrigerant cylinder and connect it to the Low Pressure Valve High Pressure Gauge refrigerant recovery machine High Pressure Valve lt NOTE gt gt High Pressure Keep the high pressure valve and the low Side Tube Vacuum Pump in Operation pressure valve of the gauge manifold closed 1002227 2 Using the procedure under Evacuation evacuate the system until the high pressure gauge indicates 30 inHg 100 kPa or higher For 15 minutes or more 3 After evacuation is complete close the high and the low pressure valves of the gauge manifold AN CAUTION Make sure to evacuate the system twice or more using
33. ging 8 Close the high pressure valve of the gauge manifold and the valve of the refrigerant cylinder 2 Removal of gauge manifold 1 Crimp the pinch off tube with a pinch off tool Pinch Off Tool To Gauge 2 Remove the gauge manifold and the process Manifold Side Pinch Off Tube EA tube fitting Crush the end of the pinch off tube 3 Braze the end of the pinch off tube Charging Hose 4 Ensure that a gas leak is not present at the To Refrigerant Cycle Side pinched off portion and the brazed end Process Tube Fitting 1002185 Repair Section 71 11 REASSEMBLY 11 1 Reassembly of Unit e Reassemble the unit in the reverse order of removal Described below are the parts that require special care in reassembling the unit Perform all wiring or rewiring as referenced in the wiring diagram 11 2 Compressor Installation Nut 3 ae Washer 3 gt lt gt a Cushion 3 amp Collar 3 Compressor ILL00605 00 Plastic Cover Mc S MCC oLC 3 eae ILL00598 00 1 Install three 3 cushions and three 3 collars to the bolts and mount the supplied compressor to the unit lt NOTE gt Cushions and collars are packaged in the supplied compressor assembly 2 Insert three 3 washers and tighten three 3 nuts Z CAUTION e Tightening torque 8 3 2 1 ftelbf 11 3 2 9 Nem 3 Remove the plas
34. hen remove the cooling air duct 4 Take out the seven 7 screws and then remove the service panel 5 Remove the two 2 power supply lines from the terminal block 1 and remove the ground wire ET l Screws 13 j EN a 1002602 Rear Panel Screws 2 Upper Panel Screws 4 Screws 4 Screws 2 Upper Panel Screws 2 Housing for Condenser Fan 1002603 ON Room Thermistor Harness Connector Repair Section 49 6 Take out the thirteen 13 screws and then remove the rear panel 7 Take out the fourteen 14 screws and then remove the upper panel Z CAUTION The two screws 2 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 50 Repair Section eae Connectors Board Clamp Upper Panel ge Control Panel AA 1001731 Left Side Panel Screws 6 NEL 1002604 Air Filter 1001733 Screw 1 Screw 1 la V 2 Screws e si Right Side Panel 1002358 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 7 screws a
35. hermistor CN11 25 C more less Freeze Protection 5k ohm at 77 F 181 F 83 C or 29 F 34 C or CTS CN12 Thermistor 25 C more less External Input Signal Specification Symbol Signal Specification Function Connector i On Activates Defect control Fire On Between 10 to 20 Contact Normally open AUX2 Alarm mA at DC12 V CN15 o Off No signal LED shows AL Output signal ON P f g On board buzzer sound On Between 10 to 20 Off Activates Defect control TANK Tank Full mA at DC12 V Contact Normally closed CN16 FULL S W Switch f Off No signal LED shows FL Output signal ON External On Between 101020 ON xterna n Between o 1 From 1 to 180 seconds Compressor stops AUX1 Pump mA at DC12 V CN13 Fail Off No signal 2 After 180 seconds Compressor stops ailure 9 LED shows AS Output signal turns ON High On Between 0 4 to 1 0 Off Activates Defect control Pressure mA at DC 5V Contact Normally closed HPBS Switch Off No signal 1 Activates 3 times in 24 hours CN08 LED shows blinking HP 2 Activates 10 times in 24 hours LED shows HP Output signal ON 1 For unit serial number from November 2011 1111 to Present Operation Section 23 4 Dip switch setting e The controller is equipped with a four position dip switch that defaults in the OFF position The dip switch can be set to c
36. i PIN 33333333 8333335 PI lt lt SS PIN Besess El PI II lo N Beseses RARER RY RRR RRR 29 POR A RY o RRR KR RR KIN Mo PO X3 XVX9XA0I N q POR A I LO POR X3 A I A PI RRR RORY RYH RAR RRR RRR RRR PR 4 RR b E o o o o iagram D pogogggogg ooooooo ooooooo ooooooo 2000000 Ooooooo Ooooooo 1 1 CODO DPODODOO 1 1 1 OoOooooo 20200200A Ooooooo 1 1 E111 ooooooo imension 2 SPECIFICATIONS 2 1 Exterior D ILL00548 00 Unit inch Operation Section 7 2 2 Technical Specifications SPECIFICATIONS Electronic Features Operation Digital Programmable Operating Voltage Max Range i tarting Current cmoo gt gt 8 PIPIS 3 3 D 3 2 2 T T in D KA N Electrical Characteristics Voltage Requirement Cooling Capacity and Power Consumption 1 GR A A A A Evaporator 95 F 35 C 60 RH Condenser 95 F 35 C 60 RH Evaporator Condenser A F Signal Connection Fire Alarm Input Signal Type No voltage contact input e Contact resistance less than 100 ohm 2 Aat 30 V DC AC or less resistive load 14 AWG 3 core x 10 ft 3 0 m 493 x 673 x 1054 mm Weight Temperature Sound Level Safety Devices ignal Input Output e Specifications are subject to change without notice lt NOTE gt 1 One motor rotates both the evaporator and the co
37. in order to prevent injury to the user during installation or unit operation CAUTION Describes precautions that should be observed in order to prevent damage to the unit or its components which may occur during installation or unit operation if sufficient care is not taken NOTE Provides additional information that facilitates installation or unit operation 1 3 General Precautions AN WARNING All 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 e 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 e The power supply for this unit should be a dedicated single outlet circuit with a UL recognized short circuit and ground fault protective breaker to prevent electrical shock from the unit e When brazing any tubing always wear eye protection and work only in a well ventilated area Operation Section e gt p zi Ko A z 5 ZA REX ER RX RX RE RX RR RR RR RR RN BER RARER RY RY RAR RRR RY YR 393939393939 PORRA PIN OR NNN Bos WISSSSSosesed XX GON ESSS 38333333333 PI X3 Besos ISS 33359 S
38. ing and remedies 38 Repair Section Condition Possible Cause Insufficient Cooling Check Area Cause Remedy 1 Usage conditions high temperature Operation near usage limits Review the installation place 2 Dirt in condenser or Insufficient 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 ae ae 1 Compressor coil resistance Short or open circuit Replace compressor 0 ohm or o ohm In case of short check the compressor relay on the relay board Compressor y does not 2 Compressor on off relay Open circuit or insufficient Replace relay board operate 52CM on the relay board contact 3 Capacitor for compressor Capacitor malfunction Replace capacitor and fan motor 4 Compressor overload relay Overload relay fault Replace overload relay 5 Voltage Low voltage Repair power supply Defective high pressure Replace high pressure 6 High Pressure Switch switch short or open switch Loose high pressure switch Reconnect high pressure connection switch and check connection 1 Coil resistance of fan motor Short or open circuit Replace fan motor 0 ohm or ohm
39. installed or repaired Use an electronic gas leak tester to inspect the system See page 68 3 Insufficient refrigerant e When the unit is not producing sufficient cooling follow the troubleshooting chart on page 38 to confirm the cause of the problem Then charge the system with the refrigerant to the specified amount as indicated on page 70 Repair Section 47 9 DISASSEMBLY AN WARNING Disconnect power supply from the unit before performing any service Beware that some residual voltage may remain in the unit immediately after the power is disconnected 9 1 Parts Construction Room Thermistor Upper Panel Cooling Air Duct Control Panel Right Side Panel Air Filter Housing for Condenser Fan Housing for Evaporator Fan Condenser Fan and Motor Left Side Panel Rear Panel Drain Pan g Drain Tank Service Panel Power Cord Locking Swivel Caster Caster ILL00604 00 48 Repair Section 9 2 Disassembly Cooling Air Duct ee Screws 4 Drain Tank 1002600 7 1002601 TB1 Terminal Block 1 Ground Wire Power Supply Lines 2 ILL00568 00 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 4 screws and t
40. n 25 4 Compressor time delay control compressor protection e 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 Specifications Time Delay 120 seconds 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 a0 Controller Status OFF Compressor ON Status i 52cm OFR less than 5 sec Pelay Time No Delay Time for rs 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 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 event of a power loss Status of memory during power int
41. n Tank Drain Water ILL00593 00 Operation Section 31 6 CONNECTION AND SETTING 6 1 Warning Signal Connection Output Signal Terminal L and L e The controller is equipped with a warning signal output relay type Form C normal open dry contact which can be used to monitor the failure conditions Relay contactor is closed if any of the following conditions has occurred Tank Full Temperature sensor fails High pressure switch error 1 lt NOTE gt 1 For unit serial number from November 2011 1111 to Present e The relay output contactor is rated 2 A at 30 VDC or 2 A at 30 VAC resistive load and it is compatible with various warning devices such as alarm speaker light indicators etc Connecting warning signal from controller 1 Remove service panel from the rear of the unit 2 Squeeze the inner latches and push out the black cap from inside the panel See drawing of cap and inner latch shapes 3 Insert the warning signal wire through the hole in the rear panel Use recommended warning signal wire size from 16 AWG to 26 AWG or a solid wire or 16 AWG to 22 AWG for a stranded wire with ring terminal for 6 stud size 4 Connect warning device to terminal L and L according to its polarities lt Cap gt Unit Terminal Warning Device Latch Input Signal ILL00079 00 ILL00078 00 32 Operation Section 6 2 Fire Alarm Control Panel Connection Input Signal Termin
42. nd then remove the left side panel CAUTION The screw 1 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 eleven 11 screws and then remove the right side panel AN CAUTION The screw 1 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 Fan Motor Removal Repair Section 1 For Unit Serial Number From February 2011 0211 to March 2011 0311 Condenser Fan Fan Motor Ring Housing for Condenser Fan Y gt gt Y gt gt Motor Bracket Housing for Evaporator Fan Evaporator Fan a Plate ILL00576 00 51 52 Repair Section Set Screw WIZ AL ON Condenser Fan 1002361 Housing for Condenser Fan Motor Bracket ILL00574 00 Evaporator Fan 1001740 1 Loosen the set screw with a hex key and then remove the condenser fan Ax CAUTION e Set Screw Torque Value for Installation 10 80 2 17 ftelbf 14 7 3 0 Nem 2 Take off the thee 3 nuts and then remove the condenser fan housing 3 Take off the four 4 nuts and then remove the fan motor together with the motor bracket 4 Loosen the set screw with a hex k
43. ndenser fans 2 Measured at 3 feet 1 0 m from surface of the unit 3 For unit serial number from November 2011 1111 to Present 8 Operation Section 2 3 Characteristics 1 Cooling capacity curve at 115 V 13 9 Cooling Capacity x103 Btu h 6 0 104 40 WN 95 35 86 30 N 77 25 59 68 77 86 15 20 25 30 Dry Bulb Temp F C Wet Bulb Temp F C ILL00563 00 2 Power consumption curve at 115 V 1 2 x 14 o E ae 2 1 0 O g 0 9 b Oo a 0 8 2 104 40 t d 9568 2 0 E o 86 30 e a gt 77 5 68 77 86 95 20 25 30 85 Wet Bulb Temp F C ILL00564 00 Operation Section 3 Cool air temperature difference curve Temperature Difference Delta T F C Between Inlet and Outlet 27 0 15 25 2 14 23 4 13 21 6 12 19 8 11 18 0 10 16 2 9 14 4 8 12 6 7 at 115 V 40 50 60 70 Relative Humidity ILL00565 00 10 Operation Section 3 CONSTRUCTION 3 1 Internal Structure Condenser Air Outlet Housing for Condenser Fan Condenser Fan and Motor Condenser Compressor and Accumulator Control Box e Relay Board Capacitor
44. o CN21 e If the measured resistance is not equal to the CF2 standard values listed above replace the fan ILL00562 00 motor 8 7 Capacitor Inspection For Fan Motor and Compressor 1 Ohmmeter method e Set the ohmmeter to the 10 M ohm 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 0 indicating that the capacitor is charging If the reading indicates infinity immediately open ILL00567 00 or the ohmmeter fails to move from O ohm shorted replace the capacitor 2 Capacitance tester method Use a capacitance tester to check the capacitors for the values indicated below If the value tested is not within 10 of the indicated capacitance replace the capacitor Rated Unit Serial Number Capacitor Capacitance Voltage From February 2011 0211 For Fan Motor 450 V 10 UF to March 2011 0311 For Compressor 450 V 55 HF From April 2011 0411 For Fan Motor 250 V 25 uF to Present For Compressor 450 V 55 HF AN WARNING e 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 8 8 Full Drain Switch Inspection e Depress the full drain switch to check for continuity If there is no continuity replace the swi
45. onfigure the following functions ON ae Symbol Item Function On Disable onboard buzzer DSW4 B S JEEE Off Enable onboard buzzer DSW3 N A DSW2 N A Change Fan Mode DSW1 Fan Mode On Fan stop mode Fan AUTO Off Fan operate mode Fan ON 1002623 24 Operation Section 5 3 Control Specifications 1 Fan control e When the FAN button is pressed the 52ID fan motor on off relay on the relay board turns on operating the fan Specifications 521D Fan motor On Off relay contact rating 5 A at 250 VAC 2 Compressor start control e When the ON OFF button is pressed the 52CM relay on the relay board turns on operating the compressor Specifications 52CM Compressor On Off relay contact rating 20 A at 250 VAC 3 Anti freeze control e 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 e Compressor on recovery conditions CTS temperature gt 59 F 15 C ON 52CM OFF 29 F 59 F gt CTS temperature 1 5 C 15 C Evaporator out temperature 1001687 Operation Sectio
46. rox 1 92 ohm ILL00603 00 If the measured resistance is not equal to the 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 Overload relay inspection e Check for continuity across two terminals of the overload relay At normal temperature there should be continuity across the terminals Operating Temperature OFF open contacts ON closed contacts 302 F 150 C 142 F 61 C 1001701 e If there is no continuity across the terminals replace the overload relay 8 6 Fan Motor Inspection 1 For unit serial number from February 2011 0211 to March 2011 0311 Measure resistance across the terminals of the fan motor Resistance at 68 F 20 C CF1 TBT CF2 TBT Approx 7 06 ohm Approx 8 73 ohm If the measured resistance is not equal to the 1001702 standard values listed above replace the fan motor 4 Repair Section 2 For unit serial number from April 2011 0411 to Present e Measure resistance across the terminals of the fan motor Resistance at 68 F 20 C CF1 CN21 3 CF2 CN21 3 Approx 8 2 ohm Approx 9 8 ohm y
47. s a ES ES RE J 5 O E E Ka S Jumper 2 Q Q Su Line CTS RTS Drain Tank SW HPRS 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 CC Capacitor for Compressor HPRS High Pressure Switch OLC Overload Protector ILL00553 00 18 Operation Section For Unit Serial Number from November 2011 1111 to Present Dip Switch ON R z y z OFF Default tt Couey a C 1 ON Fan Stop Mode Fan Auto OFF Fan Operate Mode Fan On OLC 2 N A T 3 N A al 4 ON The Buzzer Sound Disabled ji TB2 Y Output Signal L 1 L R f E 1 Es Fine Alarm On Board Input Controller i o CN9 Ground G 3 L l y O 520D2 520D1 Dip Switch AC115V 1PHASE 2 60Hz lly A es E Eos Control Box a O O 3 a Jumper CTS RTS Drain Tank SW ET HH TB1 Terminal Block1 Connector for Option F CN PUMP 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 CC Capacitor for Compressor HPRS High Pressure Switch OLC Overload Protector ILL00554 00 Operation Section 5 2 Control Box For
48. s white from the E capacitor for compressor in the control box TB1 Terminal Disconnect TBT wire black from the terminal block 1 e e Block 1 in the control box Control Box Z WARNING CC1 wire Disconnect power supply from the unit before S z CC Capacitor performing any service Beware that some residual oor E for Compressor voltage may remain in the unit immediate after the power is disconnected ILL00600 00 Insulators 2 Remove the insulators from pipe 2 and accumulator Pipe 2 Accumulator ILL00567 00 3 Braze at point A and B E 7 B Pipe 2 ILL00598 00 4 Remove three 3 nuts and three 3 washers and Nut 3 gt 9 keep them for installation then remove the compressor Washers P Remove three 3 cushions and three 3 collars and E discard Cushion 3 Collar 3 gt Compressor ILL00599 00 Repair Section 65 10 3 Charging the System with R 410A Refrigerant Always ensure that the refrigeration system has been properly evacuated before charging with the specified amount of R 410A e Equipments is for R 410A only e Liquid charge no gas charge e Make sure not to use more than 90 of the initial weight of R 410A in the cylinder NX WARNING When handling refrigerant R 410A the following precautions should always be observed Always wear proper eye protection while handling refrigerant Maintain the temperature of the refrigerant container below 104 F 40 C
49. s 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 Accumulator ws Strainer 7 Terminal E Stator Rotor Cylinder Blade S vi gS Valve Roller Lubricator 1001675 2 Basic compressor operation e The roller compression mechanism is set eccentrically with a certain distance given from the axis of the center of the cylinder A spring 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 roller by means of spring force The blade partitions the space between the suction side Operation Section Discharge Hole Discharge Valve 1000510 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 13 14 Operation Section 3 Operation Discharge Valve Roller 1001676 Discharge Valve
50. tch e Normally Continuity across 1 and 2 e Switch Depressed Continuity across 1 and 3 8 9 Thermistor Inspection e Use an ohmmeter to check the resistance across the 2 pin connector at normal temperature 77 F 25 C Specification Type Characteristic Room Thermistor RTS 5 k ohm at 77 F 25 C Freeze Protection Thermistor 5 k ohm at 77 F 25 C CTS Repair Section Full Drain Switch 1001745 1001695 8 10 Wiring Connection Inspection e Refer to the wiring diagram on page 17 to 18 and check the connection of each wire A 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 45 46 Repair Section 8 11 Refrigeration System Inspection In most cases the causes for insufficient cooling is a clog in the system a leakage or an incorrect amount of refrigerant In such cases inspect the system according to the following procedure 1 Clogged refrigeration system e Check the component parts of the refrigeration system including piping that could be clogged with refrigerant If clogged with refrigerant only the clogged part is partially frosted If this occurs change the part in question see page 63 2 Refrigerant leak e Carefully check all connections and each component for leaks whenever the refrigeration system is
51. tic cover wires and overload relay from the compressor before brazing 4 Braze pipe 1 at point A and I then braze pipe 2 at point B and H lt NOTE gt Pipe 1 and pipe 2 are packaged in the supplied compressor assembly 5 Re install overload relay wires and plastic cover after brazing 72 Repair Section Insulator Pipe 2 Accumulator ILL00602 00 0 06 in 0 06 in 1 5 mm 1 5 mm or more or more 1002608 11 4 Wiring Notice 5 Apply insulators to the accumulator and pipe 2 lt NOTE gt Insulators are packaged in the supplied compressor assembly e Install the evaporator fan and condenser fan Allow a clearance of 0 06 inch 1 5 mm or more between the evaporator fan and the fan casing A CAUTION e Tightening torque 10 69 1 04 ftelbf 14 5 1 4 Nem e Secure the wires using clamps so that they do not come into contact with the edges of the structure etc Secure the wires using clamps in the same position they were before removal DENSO SALES CALIFORNIA INC Long Beach CA 90810 www movincool com P N SV0069 00 First Issue March 2012
52. ts evaporator inlet temperature as a resistance value e The freeze protection thermistor CTS is installed in the evaporator outlet piping and detects low temperature on the evaporator as a resistance value Operation Section 29 1001695 Specification Type 5 Characteristic Short Detection Open Detection Room Thermistor RTS 5 k ohm at 77 F 25 C 181 F 83 C or more 29 F 34 C or less Freeze Protection Thermistor CTS 5 k ohm at 77 F 25 C 181 F 83 C or more 29 F 34 C or less 30 Operation Section 5 7 Drain Tank Switch e The drain switch activates and stops 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 e 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 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 Evaporator Portion A Full Drain Switch Drain Pan Relay Board Z Drain Tube CN16 H Drai
53. ua k A KA a K AE ete ae 45 8 10 Wiring Connection lnspecftion tenes 45 8 11 Refrigeration System lnspection teens 46 9 DISASSEMBLY 9 1 Parts Constructora tan deans a a lane A wag 108 lan Aachen ad 47 9 2 T DISASSEMDIY ec NE 48 93 Fan Motor Removal fa nasaan aaae da aeaa a a a a a a A A a E a a aA 51 9 4 Removal of Electrical Components 0000 ct tenes 56 9 5 Full Drain Switch Removal n ene eae 60 10 REFRIGERATION SYSTEM REPAIR 10 1 Repair of Refrigeration System 2 0 0 0 cet tet xa 61 10 2 Removal of Refrigeration System Components 63 10 3 Charging the System with R 410A Refrigerant 0 0 0 00 ccc ce eee 65 10 4 Refrigerant Charging Work tee tees 69 11 REASSEMBLY Tih Reassembly of the Unit 20 tee eae b3 N ae en bees Oe ee bee Aare da ee e 71 11 2 Compressor Installation tte tees 71 TLS Fan Assembly iia a aes Peet a 0g u Aa tae 72 11 4 7 Wiringlnformatlon 20c ee dee ede 2x v ene ng 72 Operation Section 5 1 PRECAUTIONS FOR SAFETY 1 1 Foreword e This manual has been published to service the MovinCool Classic 10 Please use this service manual only when servicing this unit 1 2 Definition of Terms WARNING Describes precautions that should be observed
54. will continue to MOVINCOOL Classic 10 operate Nasa Normal condition is resumed when condensate 07 No 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 COOL shorted display shows E1 and cool mode operation is off Display and cool mode Noss RD o Operation are returned to normal operation after ee No serTEMP AN condition is corrected MOVINCOOL Classic 10 When freeze protection thermistor becomes COOL open or shorted display shows E2 and cool mode operation is off Display and cool mode NoE RD o Operation are returned to normal operation after 295 No set temp ANY condition is corrected MOVINCOOL Classic 10 1 For unit serial number from November 2011 1111 to Present Repair Section 37 8 3 Troubleshooting Chart To accurately troubleshoot the problem it is important to carefully confirm the nature of the problem Common problems are Insufficient cooling Unit does not operate Overflow of drain water Abnormal noise or vibrations Others 1 Insufficient cooling This problem may occur from electrical components mechanical components environmental condition or installation location Refer to the troubleshooting chart on the next page for possible causes of insufficient cool
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