SERVICE MANUAL - Classic Plus 26
Contents
1. Removal of Drain Tank B Remove 8 screws from the ducts then remove the 2 ducts C Remove 4 screws from the Service Panel D Disconnect and remove O Green Wire ground O White Wire R Terminal Black Wire T Terminal Remove the power cord 22 TROUBLESHOOTING AND REPAIR E Remove remaining 13 screws and the back panel Removal of Back Panel Screws 4 backside F Remove 14 screws from the Top Panel Se R DANN 2 ER e X R ON NY SY X 5 gt SY ER X X gt x DA RR ER m 3 Y gt lt gt gt gt gt X Ky m X gt Y gt X gt x KX gt gt gt gt gt gt gt X Q lt gt x A Y x 2 2 gt gt 338 ER 25252 2522 2529 O 9 8 2 x gt gt gt 2 gt gt N x INN 2 X AO gt gt gt X IN ER 2222525 0 SS 5252252 NA XX 52x Se 55 2 5 x X Removal of Top Panel Screws G Top Panel 4 Removal of Top Panel 23 TROUBLESHOOTING AND REPAIR Attachment Plug Terminal Block Control Board2. Jogsimuuoeu 929914 yms UMS aunssa d YBIH JO 104224014 Peopiano JossaJduuo JO 1019301 PEOHSAO f sor ZOT Torf rxnv 8 f HLY JOSSAUAUUO 5 103 5 uey 5 40SSaJduuo 5 Jo30 N paeog peog onuo 109 9 Al 5 I 40 DENSO DENSO SALES CALIFORNIA INC TECHNICAL SERVICE DEPARTMENT First Issue May 1999 DSCA P N LA990009 0549 Printed in U S A 800 264 9573 www movincool com DSCA P N LA990009 0549
3. 5 volts for the system logic The relay board also contains the DIP S witch The DIP S witch is used to change the Fan Mode operation from Stop to Operate and DIP Switch change the Set Point temperature display from F to C NOTE Ther elay boar d mustbe ser viced as a com plete assembly Ithas only one serviceable compo nent the fuse Relay Board Fuse s O a Relay Board Fuse NOTE Ther elay boar d fuse is the only serviceable CO component onther elay boar d assembly This fuse provides protection against damage to the step down transformer It must be replaced with the exact type of fuse or an equivalent Fuse Specifications 2 10A 250V ACAUTION Failure to use the exact type of fuse could result indamage to the unit and or to com Relay Board ponents It willalso void the warranty of the unit 16 3 Fan Motor The fan motor is a single phase induction type two speed motor The motor rotates fans on the evaporator side and the condenser side at the same time Specifications Rated Voltage 230 volts 60 Hz Rated Output 559 watts 355 watts 4 Compressor Motor The compressor motor is a single phase motor It is contained within the same housing as the compressor Specifications Rated Voltage 230 volts Rated Output 1600 Watts NOTE An inter naloverlo
4. 4 Connect the charging hose green at the center of the gauge manifold to the vacuum pump B Evacuation 1 Open the high pressure valve HI and the low pressure valve LO of the gauge manifold 2 Turn on the vacuum pump to start evacuation Evacuate the system for approximately 15 minutes 3 When the low pressure gauge indicates 750mmHg 29 55 in Hg or more turn off the vacuum pump and close the high and low pressure valves of the gauge manifold C Checking Vacuum 1 Leave the high pressure valve and the low pressure valve of the gauge manifold closed for five minutes or more and confirm that the gauge pointer does not return to zero 2 If the gauge pointer returns gradually to zero there is a leak somewhere in the system this could also include gauge manifold Perform leak check according to procedure indicated in D Once leak has been found and repaired evacuate the system once more and confirm system holds vacuum High Pressure Side Tube Blue Hose Low Pressure Vacuum Pump at a stop Connection of Gauge Manifold Valve Setting Low Pressure Gauge io Tm 10 Open Open Closed Closed A 750 mmHg or larger V High Pressure Gauge High Pressure c Side Tube Vacuum Pump lin Operation Evacuation Valve Setting Leave valves closed for 5 minutes or more Pointer of low pressure eee gauge returning to zero indicates Closed Closed here is a l
5. SS hi Ss Operation of Drain Switch When the drain tank is removed or the drain tank is emptied the top of the drain tank base plate returns to its original position by the tension of the coil spring Then contacts 1 2 of the drain tank switch close This provides a ground to the microprocessor through the J 103 connector To re start the unit press one of the fan mode buttons or the Cool On Off button The unit will return to the previous Temperature Set Point 17 ELECTRICAL SYSTEM 6 10 11 Condensate Pump Kit optional The Classic Plus 26 model comes standard with a drain tank which collects the water that forms on the evaporator during normal cooling operation If the unit is required to operate continuously without periodic emptying of this tank a condensate pump may be needed A condensate pump kit CP K 4 is available for the Classic Plus 26 model Automatic Restart After Power Interruption The program within the microprocessor of the Classic Plus 26 contains a feature that will automatically restart the unit after power is lost and then regained The unit also has memory in order to return itself back to the operating mode including temperature set point it was in prior to the loss of power Compressor Pptection There is a Time Delay program within the microprocessor This prevents a heavy load from being applied on the Compressor Motor when restarting the u
6. E Relay Board DIP Switch 4i S Relay Board Fuse Terminal Block Compressor Capacitor Fan Motor Capacitor Electrical System and Control Box for Classic Plus 26 14 ELECTRICAL SYSTEM 1 Basic Operation of Classic Plus 26 Electrical Circuit There are two basic components used to control the operation of the Classic Plus 26 Electrical System Control Panel Assembly Control Box The Control Panel Assembly contains the Control Panel Control Board with inputs for the freeze and room temperature thermistors drain switch and a microprocessor Fan Only Mode Low Fan Mode When the Low Fan Mode button on the control panel is pressed the microprocessor turns on the button s LED and activates the Fan On Relay Relay Board sending line voltage 208 230 VAC to the N C Normally Closed contacts of the fan mode relay This output is connected to the J 5 terminal relay board where the LOW SPEED wire of the fan motor is connected High Fan Mode When the High Fan Mode button on the control panel is pressed the microprocessor turns on the button s LED and activates both the Fan On Relay and Fan Mode Relay This sends line voltage 208 230 VAC from the Fan On Relay to the N O Normally Open contacts of the Fan Mode Relay This output is connected to the J 6 terminal Relay Board where the HIGH SPEED wire of the Fan Motor is connected Cool Mode In Addition to Fan Only Mode as
7. Relay Board Fan Motor Compressor Motor Capacitor for Fan Capacitor for Compressor IOLC IOLF HPRS DS THS RTH G J 8 AUX1 DIP Switch Compressor Capacitor Removal of Electrical Parts in the Control Box 24 Internal Overload Protector of Compressor Internal Overload Protector of Fan Motor High Pressure Switch Full Drain Warning Switch Freeze Protection Thermistor Room Thermistor Ground Auxiliary Connector C PK 4 Relay Board Relay Board Fuse Terminal Block Fan Motor Capacitor TROUBLESHOOTING AND REPAIR Pin 42 Compressor To Terminal Block To Fan Motor Overload Relay R Terminal High Speed To Terminal Block Motor Relay Board Ground T Terminal Low Speed not used DIP Switch Temperature Scale Display Switch CF Fan Mode Control Switch Relay Board Fuse STOP OPERATE Main Wiring Harness Jumper or 2 Pin Connector of Relay Board to Control Panel optional Condensate Pump Kit CPK 4 Connections to Relay Board High Pressure Switch Drain Tank Switch NOT USED Freeze Thermistor o 5 ey e 5 e 5 N o 5 Room Thermistor Main Wiring Harness Control Panel to Relay Board Connections to Control Board 25 TROUBLESHOOTING AND REPAIR 9 Removal of Electrical Parts 1 Condenser fan 5 Middle Frame 2 Blower housing condenser 6 Evaporator
8. 29 5kg cm G 420 PSIG Reset pressure 20 5kg cm G 291 PSIG Inspection of Wiring Connection CA Refer to the Wiring Diagrams pg 40 and check for connection of each wire Inspection of Thermistor s Using an Ohmeter check the resistance value across the 2 Pin connector At normal temperature 77 F 25 either thermistor Room or Freeze should measure approx 10 000 or 10k ohms Inspection In most cases the probable cause for insufficient cooling is a clogged system leakage or an incorrect amount of refrigerant In such cases inspect the system according to the following procedure A Inspection of Clogged System Check the component parts of the refrigerant system including piping that could be clogged with refrigerant If clogged with refrigerant only the clogged part is frosted partially In such a case change the part in question B Inspection of Refrigerant Leak Carefully check all connections and each component for leaks whenever the refrigerant system is installed or repaired Use an electronic gas leak testerto inspect the system C Insufficient Refrigerant In case the unit is judged to be deficient in cooling capacity be sure to perform the inspections in A and B to confirm the cause of trouble After that charge the system with refrigerant to the specified amount Repair of Refrigerant System In case there is a leak obstruction ortrouble in the refrigerant system of the Spot Cooling System repl
9. as a guide for categorized problem remedies Detailed information is contained in the OPERATION MANUAL supplied with the unit 4 Troubleshooting C hart Probable Cause Probable Unit does not operate at all Unit starts but stops immediately Unit operates but stops after a few minutes Water leakage from the unit Abnormal noise and or shaking Insufficient Air Flow Check for Power at Receptacle Check for Power at Terminal Board Check for Power at Relay Board Check all wire connections Defective Drain Tank Switch Check Relay Board Fuse Defective Relay Board Defective Control Board High Pressure Switch activated disconnected defective Jumper on Relay Board 8 not installed correctly Defective Condensate Pump optional Defective Fan Motor Defective Compressor Motor Defective Relay Board Room and Freeze Thermistor connectors are reversed on control board Defective Compressor Motor Defective Fan Motor Drain Tank Full Fan Mode Switch is set to Stop and compressor cycled off Drain Tank not installed Drain Tank is defective cracked Drain Pan hole is obstructed Loose Compressor mounting nut Deformed or worn rubber grommet on the compressor mounting bolt Internal interference with other components Damaged or out of balance fan and scroll Fan mode switch on Low Defective fan motor Insufficient Air Flow cont d Insufficient Cooling Compressor not oper
10. described above When the Cool On Off button on the control panel is pressed the microprocessor turns on the button s LED and if the Temperature Set Point is less than the current room temperature activates the Compres sor Relay Relay Board This sends line voltage 208 230 VAC to the J 4 terminal Relay Board where the wire from the Compressor wire harness is connected 15 ELECTRICAL SYSTEM 2 Control Box A Capacitors The capacitors are used to temporarily boost the power output available to the fan motor and the compressor at start up Relay Board DIP Switch a n Relay Board Fuse The specifications of each capacitor are listed Terminal Block below CAPACITOR VOLTAGE CAPACITANCE APPLICATION RATING uf Compressor Capacitor Fan Motor 440 12 5 Compressor 370 40 Capacitor Control Box B Relay Board The Relay Board receives signals and outputs from the control board that contains a micro processor The relay board contains the compressor fan on and fan mode speed relays It also contains a step down trans former that converts the line voltage 208 230 VAC to 12 volts This is then converted from SEN AC to DC and used for relay coil activation Temperature Scale qu uet The 12V DC power is sent to the Control Fan Mode Control Switch Panel Assembly where it is further reduced to
11. microprocessor will restart the fan and compressor automatically However if the unit has been off for less than 130 sec the fan will start before the compressor time delay program B Coolto Operate When the DIP Switch is set in the up or Operate position the microprocessor controls the fan opera tion using control panel inputs only The fan will operate continuously during Fan Only and Cool Modes This is the Factory Default setting Temperatue Scale Display Switch When the DIP Switch is set in the down or C position the Set Point Temperature will be displayed in degrees Celsius The LED that indicates will also be illuminated When the DIP Switch is set in the up or F position the Set Point Temperature will be displayed in degrees Fahrenheit The LED that indicates T will also be illuminated This is the Factory Default setting 18 Before troubleshooting the system the following inspection should be performed TROUBLESHOOTING AND REPAIR 1 Inspection of Power Source Voltage Check the voltage of the power source Single phase 208 230 volts 60Hz Check the operation and condition of the fuse or circuit breaker in the power source 2 Inspection of Air Filters Remove the air filters and check the element If the element is dirty wash it as described in the OPERA TION MANUAL supplied with the unit 3 Inspection of Drain Tank Be sure tank is fully drained The following chart is provided
12. pressure valve of the gauge manifold and the valve of the refrigerant cylinder Charge the system with refrigerant to the specified amount Standard Amount of Refrigerant 1 87165 0 85kg If the system cannot be charged with the specified amount of refrigerant under this condition follow the steps below a Close the high pressure valve of manifold b Operate the refrigerant system c Slowly open the low pressure valve while observing the scale reading d When the scale reads the specified amount immediately close the low pressure valve e Bring the system to a stop ACAUTION 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 charging 5 Close the high pressure valve of the gauge manifold and the valve of the refrigerant cylinder 38 Valve Setting to H Closed Closed e Air Purging Open The Valve of Refrigerant Cylinder Blue Charging Hose green Red To Process Tube Fitting Evacuating Air Inside Charging Hose Valve Setting to Ciosed Ciosed Process Tube Fitting High Pressure 22 Side Tube 32 Low Pressure S Side Tube gt Welght Charging with Refrigerant lt gt NE i E Refrigerant 22 27 B 1 i TROUBLESHOOTING AND REPAIR B Removal of Gauge Manifold 1 Crimp the pinch off tube with a
13. 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 MANUFOLD GAUGE STEP 2 EVACUATE THE SYSTEM 750 mmHg 29 55 inHg WHEN LEAK IS FOUND REPAIR 15 MINUTES OR MORE OR MORE OF VACUUM THE CONNECTION OR COMPONENTS STOP EVACUATING THE SYSTEM LEAVE FOR FIVE MINUTES CHECK THE VACUUM gt STEP 3 CONNECT TO REFRIGERANT SOURCE STEP 4 TEST THE SYSTEM FOR LEAKS STEP 5 CHARGE THE SYSTEM WITH R 22 SEE SPECIFICATIONS ON PAGE 6 STEP 6 REMOVE MANIFOLD GAUGE A Connection of Gauge Manifold 1 Properly remove the crushed end of the pinch off tube at the high pressure side X and the low pressure side of the refriger Refrigerant Cycle ant cycle with a pipe cutter Side 2 Fitthe process tube fitting to the pinch off tube on both sides Pinch off Tube Mounting of Process Tube Fitting 35 TROUBLESHOOTING AND REPAIR 3 Connect the charging hoses red high pressure side blue low pressure side of the gauge manifold to the process tube fittings Low Pressure Valve Closed _ High Pressure Valve Closed Green Hose 4 _ Red Hose NOTE Connect the hoses using care not to mistake the high pressure side for the low pressure side and vice versa Process Tube Fitting
14. the spine fins for any dirt dust lint or debris that may have caused poor cooling performance of the unit If cleaning of the spine fins is necessary it is recommended that this service be performed by a qualified service technician Examination of Operating Environment Operating environments will vary depending on location climate and surrounding conditions Installation location also can cause operational problems Consult your reseller concerning operational environment requirements Inspection of Cooling Capacity Measure the difference in temperature between the inlet of the evaporator and the cool air duct Ifthe difference is out of the range given in the graphs on page 8 proceed with the remedy suggested in the troubleshooting chart on page 19 Spine Fins Operating Environment COOL AIR THERMOMETER EVAPORATOR lt AIR IN Inspection of Cooling Capacity 20 8 Disassembly Disassembly TROUBLESHOOTING AND REPAIR Control panel Upper panel Right side panel Air filter Blower housing condenser Condenser fan Rear panel Drain Switch Caster 21 Front panel Blower housing evaporator Drain pan Left side panel Drain tank Service panel Room thermistor Freeze thermistor TROUBLESHOOTING AND REPAIR A Remove Drain Tank
15. SERVICE MANUAL CLASSIC PLUS 26 MOVINCOOL Pioneering New Solutions With Portable Air Conditioning 1999 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 registerd trademark of DENSO Sales California Inc SERVICE MANUAL CLASSIC PLUS 26 MOVINCOOL Pi ioneering New Solutions With Portable Air Conditioning FOREWORD This manual has been published to service the MovinCool Classic Plus 26 Please use this service manual only when servicing the Classic Plus 26 DEFINITION OF TERMS AWARNING Describes precautions that should be observed 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 GENERAL PRECAUTIONS AWARNINGS All electrical work if necessary 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
16. ace or repair the part in question After replacing any component all connections must be brazed A Proper Brazing Techniques It is desirable to use a slightly reducing flame Oxyacetylene is commonly used since it is easy to judge and adjust the condition of the flame 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 brazing filler metal oxidization of brazing filler metal or deterioration due to the overheating of flux 32 TROUBLESHOOTING AND REPAIR BRAZEDFITTING AND ITS CLEARANCE Clearance In general the strength of brazing filler metal 0 025 0 075 mm is lower than that of the base metal So the shape and clearance of the brazed fitting are quite important As for the shape of the brazed fitting it is necessary to maximize its adhesive area The clearance of the brazed fitting must be minimized to facilitate brazing filler metal to flow into it by capillary action CLEANING OF BRAZING FILLER METAL Form The Pipe Fitting with Tubing Tool AND PIPE When the refrigerant system has been Brazed Fitting and Clearance opened up exposure to heat may have caused brazing filler metal to stick to the inside and outside of the pipe Br
17. ad r elay is used to pr otectthe compr essor motor and fan motor This relay is built into the compr essor motorand fan motor and will inter ruptthe flow of cur rent when ther eis an over currentsituation orifabnor mally high temperatur e builds up inthe compr essormotororfan motor 5 Drain Switch The Classic Plus 26 is equipped with a drain tank switch When the drain tank accumulates ap proximately 4 0 gallons 15 liters of condensate water in the drain tank the drain tank switch sends a signal to the microprocessor The micro processor stops all operation of the unit and flashes the Tank Full LED This system utilizes a 1 AMP 250 VAC micro switch for this function When drain water accu mulates approximately 4 0 gallons 15 liters in the drain tank the drain tank base plate which is supported at its fulcrum is pushed down in the direction of the arrow as shown in the figure below When the drain tank base plate is forced down the top of the drain tank base plate opens the contacts 1 2 of the micro switch This causes the ground signal at the J 103 connector of the control panel assembly to go open When the microprocessor detects this event it turns the unit off and flashes the Tank Full LED ELECTRICAL SYSTEM Green Yellow Fan Motor 4 EVAPORATOR 201 DRAIN PAN 4 DRAIN TUBE c j AA SPRING gt BR ir S NE
18. ating Fan Motor not operating 19 Clogged spine fins or Evaporator or Condenser running unit without filter s Environmental conditions exceed design specifications Clogged air filter Clogged spine fins Set point temperature exceeds room temperature Defective room temperature thermistor Leak in refrigerant system Restriction in refrigerant System Compressor not operating Set point temperature exceeds room temperature Unit is operating in Fan Only Mode Cool Mode not activated Jumper on Relay Board 8 not installed correctly Defective Condensate Pump optional Defective Compressor Capacitor Defective Thermistor Defective Compressor Motor Check wiring connections Defective Relay Board Defective Control Board Fan mode switch is set to Stop and current Set Point Temperature exceeds Room Temperature Fan mode switch is set to Stop and unit has been equipped with optional Condensate Pump that is defective Fan mode switch is set to Stop and J umper on Relay Board 8 is not installed correctly Check wire connections Defective fan motor capacitor Defective fan motor Defective Relay Board Defective Control Board TROUBLESHOOTING AND REPAIR In case of trouble perform the following inspection before disassembly 5 Inspection of Spine Fins To inspect the spine fins of either the evaporator or condenser you must remove the air filters After removal of the air filters inspect
19. ationary spiral Gas enters the outer openings as one of the spirals orbits 2 The open passages are sealed off as gas is drawn into the spiral 3 Asthe spiral continues to orbit the gas is compressed into two increasingly smaller pockets 10 11 REFRIGERANT SYSTEM 4 Bythe time the gas arrives at the center port discharge pressure has been reached 5 Actually during operation all six gas passages are in various stages of com pression at all times resulting in nearly continuous suction and discharge NOTE Upon compressor shut off the compressor may run backward for a moment or two until internal pressures equalize This has no effect on compres sor durability but may cause an unexpected sound after the compressor is turned off and should not be diagnosed as a malfunction 2 Condenser The condenser is a heat exchanger whose copper tubes are covered with thin aluminum projections called spine fins 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 REFRIGERANT SYSTEM 3 Capillary Tube The capillary tube is a long thin tube and its line flow resistance serves as an expansion valve The length and the inner diameter of the capillary tube are determined according to the capacity of refrigeration system operating conditions and the amount of refrigerant The capillary tube causes the high pressure high te
20. azing filler metal may also be compounded with oxygen Vertical Down Joint in the air to form oxide film Fats and oils Brazing Filler Metal may stick to the pipe from handling All these factors will reduce effectiveness of brazing It is necessary to eliminate excess brazing filler B metal using sand paper and by cleaning thoroughly with a solvent such as Trichlene USEOFDRY NITROGEN GAS During brazing the inside of the pipe under goes an oxidative reaction due to the brazing flame Introduce dry nitrogen gas 1 liter min adjust with the flow regulator through the pinch off tube of the refrigerant cycle to prevent oxidation NOTE Take care not to allow dirt water oil etc to enter into the pipe VERTICAL J OINT Heat the whole brazed fitting to a proper brazing temperature Bring the brazing filler metal into contact with the fitting so that the brazing filler metal starts flowing by itself Stop heating the fitting as soon as the brazing filler metal has flown into the clear ance Since the brazing filler metal flows easily into the portion heated to a proper Brazing Filler Metal temperature it is essential to keep the whole fitting at a proper brazing temperature Vertical Up J oint 33 TROUBLESHOOTING AND REPAIR B Removal of Refrigeration Cycle Components ACAUTION 1 Before any refrigeration cycle component can be replaced it is necessary to recover the refrigera
21. e Thermistor J 101 2 pin 4 Freeze Thermistor J 102 2 pin 5 High Pressure Switch J 104 2 Pin Removal of Control Panel Assembly NOTE Mark each of the 2 pin connectors with a different color marker to ensure the correct orienta tion when they are re connected 29 TROUBLESHOOTING AND REPAIR J Remove the five 5 screws from the control board on the control panel assembly Remove the control board Removal of Control Board 11 Inspection of Capacitor Fan Motor and Compressor Ohmeter Method Set the ohmeter to the 100K o range Place the two probes against the two terminals of the capacitor At first the ohmeter should indicate then the reading should gradually increase towards infinity lt This indicates that the capacitor is charging If the reading indicates infinity right away shorted or the ohmeter fails to move from open replace the capacitor 12 Capacitance Tester Method Using a capacitance tester and the chart on page Inspection of Capacitor 15 test the capacitor for the value indicated If the value tested is not within 1096 of indicated capacitance replace the capacitor A Warning Properly discharge the capacitor s before testing and after testing has been com pleted Failure to do so could cause damage to test equipment or the unit and or result in per sonal injury electrical shock or death 30 Green Yellow Inspection of Fan Motor Inspection of Comp
22. e switch Capillary tube Modulating tank These parts are all connected by copper piping All the connections have been brazed Condenser Compressor High Pressure Switch Flow of Refrigerant Pressure Switch Modulating Tank Compressor Evaporator Refrigerant System REFRIGERANT SYSTEM 1 Compressor The compressor used for the unit is hermetically sealed The compressor and the compressor motor are in one casing A Compressor Theory of Operation The scroll utilizes an involute spiral which when matched with a mating scroll form generates a series of crescent shaped gas pockets between the two members During compression one scroll remains stationary fixed scroll while the other form orbiting scroll is allowed to orbit but not rotate around the first form As this motion occurs the pockets between the two forms are slowly pushed to the center of the two scrolls while simultaneously being reduced in volume When the pocket reaches the center of the scroll form the gas which is now at a high pressure is discharged out of a port located at the center During compression several pockets are being compressed simultaneously resulting in a very smooth process Both the suction process outer portion of the scroll members and the discharge process inner portion are continuous B Compressor Operation 1 Compression in the scroll is created by the interaction of an orbiting spiral and a st
23. eak Low Pressure Gauge Brazing of Piping Checking Vacuum TROUBLESHOOTING AND REPAIR Valve Setting D Checking Gas Leak 101 Closed Closed 1 Remove the charging hose green from AM the vacuum pump and connect the hose Air Purging 45 to the refrigerant cylinder R22 Open The Valve 2 Loosen the nut on the gauge manifold of Refrigerant N side of the charging hose green Cylinder Blue Charging Hose green Red AUT ES To Process Tube Fitting E Refrigerant Cylinder R 22 i Evacuating Air Inside Charging Hose Valve Setting PT 3 Open the high pressure valve of the o na gauge manifold Charge the system with refrigerant until the low pressure gauge gt 57 psiG indicates 57 PSIG 4 kg cm G After SN charging is complete close the high Low Pressure Valve ROD er valve P 298 6 amp id Open High Pressure Valve 4 Check carefully for gas leaks inside the refrigerant system using the gas leak oF Pl tester 5 Repair any leak Sa Side Tube Valve of Refrigerant Cylinder 7 Refrigerant P 22 a Cylinder R AWARNING Do not attempt any repair ona Charging with Refrigerant for Gas Leak Check charged system AWARNING Before checking for gas leaks fully confirm that there is nothing flammable in the area to cause an explosion or fire Contact of refrigerant with an op
24. en fire generates toxic gas E Evacuation Repeat 1 Close the valve of the refrigerant cylinder Then remove the charging hose green from the refrigerant cylinder and connect it to the refrigerant recovery machine Yete senig NOTE Keep the high pressure valve and the low Low Pressure Gauge pressure valve of the gauge manifold closed io Tm 10 Open Open Closed Closed A 750 mmHg or larger 2 Using procedure B evacuate the system until the low pressure gauge indicates 750mmHg 29 55 inHg or more for 15 minutes or more on High Pressure Gauge 3 After evacuation is complete close the High Pressure high and the low pressure valves of the 5222 Side Tube gauge manifold ACAUTION Be sure to evacuate the system twice T Vacuum Pump or more using the repetitive vacuum method Evacuate the system an additional time on rainy Evacuation repeat or humid days 37 TROUBLESHOOTING AND REPAIR 22 Refrigerant Charging Work A Refrigerant Charging 1 Remove the charging hose green from the vacuum pump and connect it to the refrigerant cylinder R 22 NA lt 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 3 Securely place the refrigerant cylinder on a scale with a weighing capacity of 70 lbs 30 kg that is graduated by 0 2 oz 5 g Open the high
25. fan 3 Fan motor 7 Blower housing evaporator 4 Motor bracket 8 Air flow guide Disassembly of Blower 26 TROUBLESHOOTING AND REPAIR 10 Removal of Blower Assembly A Loosen the set screw using an allen wrench and then remove the centrifugal fan B Remove the two 2 nuts on the inside of the housing in the locations shown A NUT Removal of Blower Housing C Remove two nuts and two screws as de picted Then remove the motor bracket together with the fan motor A NUT SCREW Removal of Fan Motor Assembly 27 TROUBLESHOOTING AND REPAIR SET SCREW D Remove the centrifugal fan by loosening the set screw on the shaft Remove the fan motor by loosening A nuts All gt n 0 0 qmd Removal of Fan Motor E Remove 7 screws from Left Side Panel Removal of Left Side Panel Screws F Remove 7 screws from Right Side Panel Removal of Right Side Panel Screws 28 TROUBLESHOOTING AND REPAIR G Remove 2 screws from Control Panel Assembly Right Stay Removal of Right Stay Screws H Remove 2 screws from Control Panel Assembly Left Stay Removal of Left Stay Screws l Disconnectthe following connectors from the control board 1 Wire Harness Relay Board to Control Board J 201 10 pin 2 Drain Tank Switch J 103 2 pin 3 Room Temperatur
26. hen the drain tank reaches a level of approximately 4 0 gallons 15 liters CONSTRUCTION SPECIFICATIONS amp DATA Rating Conditions dry bulb wet bulb humidity Specifications power frequency line voltage single phase power consumption current consumption power factor starting current power cord Cooling Unit cooling capability cooling system Blower type of fan air volume Evaporator high speed Condenser high speed motor output high speed low speed Compressor type output refrigerant type refrigerant capacity Safety Devices compressor overload protector fan motor protector anti freezing thermistor full drain tank switch automatic restart power interruption compressor time delay program Dimensions amp Weight WxDxH in W x D x H mm weight Ibs kg Operating Conditions inlet air relative humidity Control Device temperature control two speed fan Specifications 95 F 35 C 83 F 28 3 60 60Hz 208 230V 3 37 3 24 Kw 16 8 14 6 Amps 97 62A 12 3 core AWG 6 500 Kcal hr 26 000 Btu hr direct expansion centrifugal fan 708 cfm 1680 cfm 59 63 Kw 54 56 Kw hermetic scroll 1 6kw R 22 1 87 lbs 0 85 kg included included included included included included 19 4 x 28 7 x 47 2 492 x 730 x 1200 235 107 113 F 45 C lt 50 70 F 21 1 C gt 5096 included included Specifications are subject to change with
27. igh the snap disk moves down to push the pin down causing the internal contacts to open This interrupts the ground signal at the Control Board 104 connec tor which turns the compressor off Possible causes of this trouble include A The condenser air filter is dirty restricting air flow B The condenser blower is defective 12 High Temp High Press Liquid Refrigerant Low Temp Low Press Gas and Liquid Mixture Capillary Tube From Evaporator Modulating Tank p ad To Evaporator Inlet To Compressor Modulating Tank Pressure of Refrigerant Movable Snap Disk Stationary Point Case Terminal Molding by Resin Lead Wires High Pressure Switch Condenser Inlet Pipe Compressor Discharge Pipe Compressor Outlet Pipe Compressor Suction Pipe insulated Refrigerant System Piping 13 REFRIGERANT SYSTEM Evaporator Inlet Pipe Evaporator Outlet Pipe Capillary Tube Connecting Tube condenser to capillary tube Connecting Pipe evaperator to compressor ELECTRICAL SYSTEM Attachment Plug Internal Overload Protector of Compressor Terminal Block Internal Overload Protector of Fan Motor Control Board High Pressure Switch Relay Board Full Drain Warning Switch Fan Motor Freeze Protection Thermistor Compressor Motor Room Thermistor Capacitor for Fan Ground Capacitor for Compressor J8 AUX1 Auxiliary Connector CPK 4
28. mperature liquid refriger ant sent from the condenser to expand 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 become low and mist like and therefore it evaporates easily Capillary Tube Dimensions Purpose of Use 1 0 mm Length mm 4 Evaporator The evaporator like the condenser is a heat exchanger covered with spine fins Heat is removed from the air being pulled across the evaporator by the centrifugal fan and the resulting cool air is expelled through the cooling air ducts Modulating Tank The modulating tank consists of a copper pipe and tank sections each being separated from the other The pipe connects to the evaporator outlet at one end and to the compressor at the other the tank connects to the evaporator inlet The modulating tank is covered with insulation to reduce thermal effects of ambient temperature It varies the quantity of refrigerant in the refrigerat ing cycle for optimum operating condition it stores part of refrigerant under light load and delivers additional refrigerant to the cycle under heavy load High Pressure Switch The high pressure switch prevents the condenser and compressor from being damaged by exces sively high pressure in the high pressure line of the refrigeration cycle The switch is normally closed The snap disk responds to variations in pressure and if pressure is abnormally h
29. nit Cool Mode after a very short period of time This delay is in effect any time when the compressor is turned on by either the Cool On Off button temperature set point thermostatic control or power interruption restart Time Delay Program Specifications 120 10 sec Temperatue Contiol The compressor operation Cool Mode is controlled by the microprocessor which receives input signals from the room temperature thermistor evaporator inlet air and the setting of the Temperature Set Point The Temperature Set Point desired room temperature can be adjusted by pressing the A Y buttons on the Control Panel The adjustment range of the Temperature Set point is 70 to 95F 21 to 35 C Fan Mode Contol Switch The fan motor operation is controlled by relays on the relay board through a microprocessor in the control panel assembly The fan program in the microprocessor can be changed by a DIP Switch on the left side of the Relay Board located in the Control Box There are two settings A Coolto Stop When the DIP S witch is set to the down or Stop position the microprocessor controls the fan motor using the same room temperature thermistor that it uses to control the compressor In this case both the fan and the compressor stop when the microprocessor receives a sufficiently low intake air room temperature signal from the thermistor equal to or less than the set point When the temperature increases exceeds the set point the
30. nt using standard recovery procedures and equipment 2 To prevent oxidation dry nitrogen should be conducted flow rate 1 liter min through the pinch off tube during any brazing operation 3 During any component replacement involving brazing shield nearby parts with a steel plate asbestos etc to protect them from the flame 1 Evaporator 2 Capillary tube 3 Condenser 4 Compressor NOTE Hold the compressor body not the tube when carrying the compressor Removal of Refrigerant Cycle Components Refer to 20 B PART REPLACED DISCONNECT AT Compressor A amp B Condenser A amp C Capillary tube D amp E Evaporator E amp F Refrigeration Cycle Components 34 TROUBLESHOOTING AND REPAIR 21 Charging the System with R 22 Refrigerant Always ensure that the refrigerant system has been properly evacuated before charging with the specified amount of R 22 AWARNING When handling refrigerant R 22 the following precautions should always be observed Always wear proper eye protection while handling refrigerant Maintain the temperature of the refrigerant container below 40 C 104F 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 Be careful the liquid refrigerant does not come in contact with the skin If liquid refrigerant
31. out notice CONSTRUCTION SPECIFICATIONS amp DATA CONSTRUCTION SPECIFICATION S amp DATA At 230 volt 8 31 7 gt 7 27 8 3 e 8 6 123 8 ej 8 5 19 8 O 4 15 9 x10 KCalh 3111 9 BTU h 45 113 q RUN NE KY ZINN un 59 68 77 186 F Wet Bulb Temp Cooling Capability Curve high speed only F 15 27 0 Ar D 14 25 2 5 13 23 4 S 9 117098 10 18 0 al portes 9116 2 7 T TUS 40 50 60 70 96 Relative Humidity Of Inlet Air Temperature Difference Between Inlet And Cool Air Temperature Difference Curve high speed only At 230 volt E Y 77 866 958 104 F Wet Bulb Temp Power Consumption Curve high speed only REFRIGERANT SYSTEM The component parts of the refrigerant system include the following e Compressor Evaporator Condenser High pressur
32. 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 To Refrigerant Cycle Sid 4 Ensure that a gas leak is not present at ycle Side the pinched off portion and the brazed end Removal of Gauge Manifold 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 23 Compressor Mounting Mount the compressor on the frame using cushions steel collars spring washers plate washers and nuts Q Compressor Mounting 24 Blower Assembly Install blower fans for evaporator and con denser Tightening torque 10 84 2 17 Ibfeft 150 30 kgf cm 0 06 inches 0 06 inches 1 5 mm 1 5 mm NOTE After reassembling the gap between blower or more or more fan and housing should be 0 06 inches 1 5 mm or more 25 Wiring Notice Secure the wires using clamps so that they do Blower Assembly Mounting not come into contact with the edges of the structure etc Secure the wires using clamps in the same position they were before removal 26 Perform the inspection of cooling capacity and check for abnormal noise or abnormal vibration 39 TROUBLESHOOTING AND REPAIR 27 Schematic Fidd 10329uuo JOISULISOUL
33. 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 Donotexpose 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 any tubing always wear eye protection and work only in a well ventilated area Table of Contents FOREWORD DEFINITION OF TERMS GENERAL PRECAUTIONS GENERAL DESCRIPTION CONSTRUCTION SPECIF REFRIGERANT SYSTEM ELECTRICAL SYSTEM ICATIONS amp DATA ue 3 TROUBLESHOOTING AND REPAIR U U U nnn 19 GENERAL DESCRIPTION Generally speaking conventional air conditioners cool the entire enclosed environment They act as heat exchangers requiring an interior unit evaporator to blow cool air into the interior and an exterior unit condenser to exhaust exchanged heat to the out doors Unlike conventional air conditioners the MovinCool Spot Cooling System is a spot cooler which directs cool air to particular areas or objects MovinCool Spot Cooling Systems have the following features EVAPORATOR CONDENSER INDOOR UNIT OUTDOOR UNIT Conventional Air Conditioner 1 Compact Design Cool Air Out The innovative design of MovinCool has
34. r Filter it Evaporator Service Panel Rear Panel Drain Tank Construction Diagram of Classic Plus 26 CONSTRUCTION SPECIFICATIONS amp DATA Cool Air Out Exhaust Air Out Cool Air Duct Filter Condenser Air In Air Flow Basic Construction The MovinCool Spot Cooling System is compact in construction because the con denser and the evaporator are enclosed in one unit The interior is divided into three sections The upper front face is equipped with the evaporator while the lower front face contains the drain tank The rear section contains the condenser the compressor and the control box Air Flow Air drawn from the right side face passes through the condenser which extracts the heat This hot air is blown out through the upper exhaust air duct Air taken in from the front face is cooled by the evaporator and then blown through the cool air duct which can be turned in any direction All the air inlets are equipped with filters while the exhaust air outlet is protected by wire mesh Compressor and Fans The compressor is hermetically sealed A two speed fan motor is used with two cen trifugal fans to draw air across the evaporator and condenser Drain Tank The capacity of the drain tank is 5 0 gallons 19 liters The unit is equipped with a Tank Full LED and a device to automatically stop the operation of the unit w
35. ressor Motor 6 High Black TROUBLESHOOTING AND REPAIR 31 13 14 15 Inspection of Drain Switch Check for continuity between terminals 1 and 2 Continuity should exist With switch depressed continuity should not exist between terminals 1 and 2 If continuity is not as specified above replace the switch Inspection of Fan Motor Measure resistance across the terminals of the fan motor Terminals at 77F 25 J6 CF1 Approx 6 80 J5 CF1 Approx 1050 CF1 CF2 Approx 19 00 If the measured resistance is not equal to these standard values replace the fan motor Inspection of Compressor Motor Measure resistance across the terminals of the compressor motor Terminals at 77 25 C R C Approx 0 940 C S Approx 1 960 S R Approx 2 900 If the measured resistance is not equal to these standard values replace the compressor The compressor has a built in overload relay The overload relay should be operational if the above resistance is obtained under normal temperature TROUBLESHOOTING AND REPAIR 16 17 18 19 20 Inspection of High Pressure Switch Check for continuity across both terminals of the high pressure switch or the J 104 connector With pressure equalized when the unit is stopped there should be continuity across both terminals and the J 104 connector If there is no continuity open circuit replace the high pressure switch Specifications Cut off pressure
36. resulted in one compact unit replacing the Exhaust Air Out need for two separate units 2 Easy Transportation and Installation Cool iji With the whole cooling system built into one Air Duct Is 3 compact unit MovinCool requires no piping and can be easily transported and installed 3 Energy Conservation MovinC ool is economical because it cools only the area or objects which need to be Condenser led Airin cooled Filter Evaporator Air In Filter Air Flow of MovinCool Spot Cooling System GENERAL DESCRIPTION CONSTRUCTION SPECIFICATIONS amp DATA EXHAUST AIR OUTLET CENTRIFUGAL FAN HOUSING FOR CONDENSER FAN COMPRESSOR CONDENSER SERVICE PANEL OF CONTROL BOX CASTER Construction of Classic Plus 26 ES COOL AIR DUCTS HOUSING FOR EVAPORATOR FAN EVAPORATOR N CAPILLARY TUBE DRAIN PAN AS HIGH PRESSURE SWITCH diu N S V NIE A DRAIN SWITCH CONTROL BOX CONSTRUCTION SPECIFICATIONS amp DATA Side Panel High Pressure Switch Blower Housing Evaporator A AD Evaporator Fan 4 Condenser Side Panel Upper Panel Modulating Tank Blower Housing Condenser Fan Motor Accord Front Panel r lt oC Condenser Fan s EHERILE Pa EPEPIHNN gt f j Bes coo E t EU i 4 b i i 4 d i 901001000 CHEE EE wo Ly Air Filter Condenser T SCIRE a Ai
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