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MovinCool CM12 Service Manual - H

1. ILLO0959 00 56 Repair Section 2 For unit serial number from 0211XXXXC12 to 0315XXXXC12 Please refer to page 2 for the position of the name plate showing the serial number on the unit Capacitor for Condenser Condenser Relay Terminal for Power Terminal for Signal d Capacitor for Condenser Fan Motor ES a Capacitor for Evaporator Fan Motor Relay Board ILL00545 01 Repair Section 57 3 Relay Board To Terminal Block1 Power Source CNO1 nooo B G C 2 Qe Support ume ae Support To Terminal Block2 Fire Alarm Input To Float Switch Relay Board Fuse 250 V 5A To Terminal Block2 External Output Not Use LAM ce m Support CN24 Support 4 To Auxiliary Relay To Terminal Block2 E LA Wall Thermostat CNO3 To Evaporator Inlet Air Thermistor Bee Aq eee M CN21 a To Condenser Fan Motor ef gece ooaqad Co To Freeze Protection To Evaporator CN22 CN T Thermistor Fan Motor H d CN12 Dip Switch CN23 i CNT 31 l CN25 CN17 7 l To Condenser see
2. Open High Pressure Valve Process Tube Fitting High Press Side Tube ure 1002228 Repair Section 67 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 charging 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 N WARNING Any repair on a charged system should be performed by a licensed professional only N 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 5 Evacuation repeat Valve Setting 1 Close the valve of the refrigerant cylinder Then Gauge aed 257 remove the charging hose green from the 30 inHg 100 kPa or larger refrigerant cylinder and connect it to the
3. Screws 9 Screws 4 1002764 mui Connector f 55 Hose Clip 1002766 Repair Section 49 3 Take out the eighteen 18 screws and then remove the top panel 4 Take out the sixteen 16 screws and then remove the front panel 5 After disconnected from the relay connector white two pin either the drain pump assembly or only the drain pump itself can be removed Repair Section 50 1002787 Pump 1002765 a To remove the drain pump assembly Take off the three 3 nuts and remove the drain hose b To remove the only the drain pump Take out the four 4 screws and remove the drain pump Repair Section 51 8 3 Removal of Evaporator Fan Assembly 1002773 1002767 Evaporator Fan Assembly ILL00647 00 1 Disconnect the three connectors two white two pin connectors one white three pin connector and then take out the two 2 screws and the two 2 nuts 2 Disconnect the motor connector white six pin from circuit board CN23 and remove the evaporator fan assembly Repair Section 52 Straight Surface Set Screw 1002774 0 12 in 3 mm i or more 0 12 in 3 mm or mo
4. High pressure switch Dust buildup on the surface of the condenser air inlet Remove dust with a vacuum cleaner Loose high pressure switch connection Reconnect the high pressure switch and check the connection Defective high pressure switch short or open Replace high pressure switch Operating outside of the operating temperature range Check environmental condition Do not operate the unit outside the operating condition range See page 12 Refrigerant is over charged in the field Charge the correct amount of refrigerant See page 69 Thermistor Defective thermistor short or open Replace thermistor Loose thermistor connection Reconnect the thermistor and check the connection 40 Repair Section T Alarm Condition Check Area Possible Cause Remedy Pattern Unit does 2 Drain hose Drain hose clogged Remove any blockage or excessive not operate for internal drain pump kinks preventing water flow RESET Drain hose trap position is too Improve hose installation high to pump up condensation Refer to the operation manual of this water for internal drain pump unit RESET Internal drain pump Internal drain pump is not Reconnect the internal drain pump working and check connection RESET If the internal drain pump still does not work replace it 3 Refrigeration system Refrigeration system proble
5. 50 59 68 77 86 95 104 133 122 0 5 10 15 20 25 30 35 40 45 50 Temp F C 1003204 46 Repair Section 7 9 Inspection of Wiring Connection Refer to the wiring diagrams on page 21 and check the connection of each wire N CAUTION Secure the wires using clamps to prevent contact with the edges of the structure etc Secure the wires in the same position as prior to removal 7 10 Refrigeration System 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 1 Clogged refrigeration system Check the component parts of the refrigeration system including piping that could be clogged with refrigerant If clogged with refrigerant only the clogged part is partially frosted In such cases change the part in question 2 Refrigerant leak Carefully check all connections and each component for leaks whenever the refrigeration system is installed or repaired Use an electronic gas leak tester to inspect the system See page 59 to 70 3 Insufficient refrigerant When the unit is not producing sufficient cooling follow the troubleshooting chart on page 41 to confirm the cause of the problem Then charge the system with the refrigerant to the specified amount as indicated on page 69 Repair Section 8 DISASSEMBLY
6. Low Pressure Valve High Pressure Gauge refrigerant recovery machine High Pressure Valve lt NOTE gt 5 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 Use the procedure under Evacuation evacuate the system until the high pressure gauge indicates 30 inHg 100 kPa or larger For at least 15 minutes 3 After evacuation is complete close the high and the low pressure valves of the gauge manifold N CAUTION Make sure to evacuate the system twice or more using the repetitive vacuum method Evacuate the system an additional time on rainy or humid days 9 4 Refrigerant Charging Work 1 Refrigerant charging Valve Setting LO Closed Air Purging Y N Open The Valve of Refrigerant A Cylinder To Process Tube Fitting Charging Hose Green Refrigerant Cylinder R 410A 1001901 Valve Setting Specified Amount LO HI Closed Open Valve of Refrigerant Cylinder of Refrigerant al LO HI Closed Closed p High Press Side Tube High Pressure Valve Process Tube Fitting ure 1001903 Repair Section 69 1 Remove the charging hose green from the vacuum pump and connect it to the refrigerant cylinder R 410A 2 Loosen the nut on the gauge manifold side of the charging hose green Open the valv
7. 3 1 Technical Specificatlons sis secant bat eb epe el PER S d dA A 11 3 2 Characteristics 5 nos a ds e alae fad Et ah ROPA e EUR ag Tod EAR RAN BPO LEER A Poe s 14 4 REFRIGERATION SYSTEM 4 1 Refrigeration System Construction lisse en 15 4 2 COMPIESSOR i oce as AA A RH Eee oie iere A ee et ee e ree ra 16 4 3 Condenser vecinita eR esq D bea pps Au te e add 18 4 4 Capillary TUDE s zudem nete Re eth eat gate Re aep E Gina Ea 19 4 5 EVaporator zs eum ePMETARR ERU eee RR IE EVA IE RE TINI Den IESU 19 4 6 Accumulator xar Eee A Eigene edite d ce eee a eee Rh deep De rd 19 4 High Pressure With a T Ed T TR A ATRE SA E N e NAAT N TR d L R TR NE RL TN e AR 20 5 ELECTRICAL SYSTEM 5 1 Circuit DIagtatm on eset cese ede Red ERI x eres a 21 9 2 Control BOX sas sco ee REG ean aan te ek atu ute tet nil m RM ML n e AL RAE 22 S MEMO C 24 5 4 Relay Board osi ve da ad ia 25 5 5 Compressors 4 it edad t dtu E E teat E d 27 5 0 Fan Motor nort ERE dee deese PR GE ch ERE 28 buf Capacitor 22d eer A tree i Ranh A ote fd A ed ah Aug tera til 29 5 8 Temperature TherMistOr oooooooooooo eel rs 29 LK EH Draim BUMD eese Seti wordy E xm E Ed eum oe ite artem ea a DLE 29 5 10 Float S with ok detentus ltd A eor ice ane cue e a des PR e stie ee 30 Table of Contents 6 CONNECTION AND SETTING 6 1 Power Supply Requirements tee eee 31 6 2 MMillivolt Wall Thermostat Connection s 33 6 3 Warning Signal Con
8. Cold Air Exhaust 10 in Dia Flange Condenser Hot Air Exhaust Drain Pipe for Pump Evaporator Room Air Inlet 10 in Dia Flange lt Mounting Brackets Condensate Pan Drain for Maintenance Thermistor Condenser Air Inlet P Service panel y Override Stop Switch Signal Input and CO Output Wires Thermostat Wires Power Cord Inlet 1LL00642 00 Operation Section 2 3 Internal Structure Evaporator Capillary Tube Condenser Evaporator Fan Evaporator Fan Motor Drain Pump Control Box Accumulator Condenser Fan Condenser Fan Motor ILL00533 01 Operation Section 2 4 Basic Construction e The MovinCool CM 12 is compact in Control Box Condenser construction due to the condenser and Evaporator evaporator being enclosed in one unit The interior of the unit is divided into two sections One section contains the evaporator which cools room interior air The other section is comprised of the condenser compressor and y Condenser Evaporator q control box Motor Motor ILL00649 00 2 5 Air Flow Air drawn from the rear face passes over the Condenser condenser which extracts heat from the Intake Condenser refrigerant The hot air is blown out through the Exhaust front exhaust air vent Air taken in fr
9. UUUHDUDULUL UDULU ina Inlet Air Thermistor Busk Support Not Use Not Use 1LL00539 00 Removal of Relay Board 1 Disconnect the power at the source 2 Take out the four 4 screws and then remove the service panel See page 48 3 Disconnect all connectors from relay board 11 connectors two connections on the relay and ground wire Refer to the figure Relay Board to identify the relay connections and the connectors marked as CN To ensure easy reinstallation be sure to label each connector wire as you remove them 4 Remove relay board from plastic supports 6 locations Use needle nose pliers to squeeze all the supports before removing the relay board lt NOTE gt In case there is no room to remove and replace the relay board take out the eighteen 18 screws and then remove the top panel 58 Repair Section Replacement of Relay Board 1 Replace the new relay on existing supports Make sure all stand offs are aligned horizontally Change the support if damaged during removal process Make sure that the dip switches on the new relay board are all set to off positions 2 Reconnect all 11 connectors to the new relay board and make sure connector label 52CM3 is connected to terminal 3 and connector label 52CM4 is connected to terminal 4 of the relay Also connect the ground wire and make sure they are all properly connected Refer to the figure Relay Board to identify the connectors that need to
10. 54 10 5 Wiring Notice Secure the wires using clamps so that they do not come into contact with the edges of the structure Secure the wires using clamps in the same position they were before removal 10 6 Perform an Inspection Perform an inspection of cooling performance and check for abnormal noise or vibration DENSO DENSO PRODUCTS AND SERVICES AMERICAS INC Long Beach CA 90810 www movincool com P N SV0068 02 Third Issue April 2015
11. OFF open contacts ON closed contacts 302 F 150 C 142 F 61 C If there is no continuity across the terminals 1001701 replace the overload relay 7 7 Inspection of Fan Motor 1 Evaporator fan motor Measure resistance across the terminals of the fan motor Between terminals at 77 F 25 C Black White Approx 24 5 ohm Black Blue Approx 36 5 ohm Black Red Approx 39 0 ohm Repair Section 45 If the measured resistance is not equal to the standard values listed above replace the fan motor 2 Condenser fan motor Measure resistance across the terminals of the fan motor Between terminals at 77 F 25 C Black White Approx 8 8 ohm Black Blue Approx 7 0 ohm Black Red Approx 18 6 ohm If the measured resistance is not equal to the ILLO0619 00 standard values listed above replace the fan motor 7 8 Inspection of Thermistor Using an Ohm meter check the resistance value across the 2 pin connector At normal temperature 77 F 25 C all thermistors evaporator inlet air freeze protection or condenser inlet air should measure approximately 5 k ohm Thermistors Evaporator inlet air thermistor RTS Condenser inlet air thermistor ODS Freeze protection thermistor CTS Resistance k ohm N o E a o al Thermistor Specification 0 32 41
12. Turn on the vacuum pump to start evacuation Evacuate the system for approximately 15 min 3 When the high pressure gauge indicates 30 inHg 100 kPa or larger turn off the vacuum pump and close the high pressure valves of the gauge manifold 66 Repair Section 3 Checking vacuum Valve Setting Leave valves closed for 5 minutes or more Pointer of pressure gauge returning to zero indicates there is a leak Pressure Gauge Pipe Brazing 1003203 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 a 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 4 Checking gas leak Valve Setting LO Closed Air Purging A N R Open The Valve of Refrigerant Cylinder To Process Tube Fitting Charging Hose Green Cylinder R 410A Refrigerant 1001901 Valve Setting Low Pressure Valve Closed Refrigerant Cylinder Valve Open Refrigerant ier Lo HI Lo HI Closed Open Gauge Reading Closed Closed Oylinder R 410A 57 psi 390 kPa
13. be connected 3 Reconnect the power at the source and turn on the unit to verify the function and operation of the unit Turn off the unit 4 Close the service panel and secure with four 4 screws Repair Section 9 REFRIGERATION SYSTEM REPAIR 9 1 Repair of Refrigeration System 1 2 3 In case there is a leak obstruction or problem in the refrigeration system replace or repair the part in question After replacing any component all connections must be brazed 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 Brazed fittings and fitting clearance In general the strength of brazing filler metal is Clearance lower than that of the base metal So the 0 001 0 003 in shape and clearance of the brazed fitting are a 0 025 0 075 mm quite important As for the shape of the brazed l fitting it is necessary to maximize its adhesive Jol
14. signal at the relay board which turns the compressor off Operation Section 5 ELECTRICAL SYSTEM 5 1 Circuit Diagram IDFM ODFM 3 3 DP K y A SE ile a CN OOOO Fire Alarm INPUT EXTERNAL AC115 V OUTPUT 520D2 520D1 1PHASE 60Hz G1 G CN12 EN CNO3 Y 9 OF 1 0 RC D O LEAL CONTROLBOX 7 i E NI Edd s OD RTS HPRS FLTS TB1 Terminal Block 1 RTS Room Thermistor Evaporator Inlet Air Thermistor TB2 Terminal Block 2 CF1 Capacitor For IDFM Capacitor For Evaporator Fan Motor RB Relay Board CF2 Capacitor For ODFM Capacitor For Condenser Fan Motor IDFM Indoor Fan Motor Evaporator Fan Motor CC Capacitor For Compressor ODFM Outdoor Fan Motor Condenser Fan Motor OL Overload Protector MC Compressor Motor DP Drain Pump RX Auxiliary Relay SW Switch For Emergency Override Stop Switch ODS Outdoor Thermistor Condenser Inlet Air Thermistor FLTS Float Switch CTS Freeze Protection Thermistor G Ground HPRS High Pressure Switch ILLOO536 01 Operation Section 22 5 2 Control Box 1 For unit serial number from 0415XXXXC12 to Present Please refer to page 2 for the position of the name plate showing the serial number on the unit CC Capacitor for Compressor RB Relay Board RX Auxiliary Relay TB1 Terminal Block1 CF1 Capacitor for Evaporator Fa
15. signal is ON the evaporator fan comes ON G G Orange When the signal is OFF the evaporator fan goes OFF When the G1 signal is ON the evaporator fan speed switches to Lo G1 G1 Yellow When the signal is OFF the evaporator fan speed switches to Hi Thermostat CM 12 Unit Orange Wire OG Red Wire i OY Brown Wire Yellow Wire Use only with thermostat that has Fan Hi Lo Speed control ILL00615 00 NOTE Use thermostat that is compatible with millivolt system Do not connect thermostat to AC power source 34 Operation Section 5 Install the wall thermostat to the proper location inside the room where it can be conveniently accessed Do not install the wall thermostat where unusual heating condition may occur i e hot stove hot pipe fireplace direct sunlight and etc Most thermostats provide these basic functions Fan Mode On Auto Selects the desired fan mode System Cool Heater Selects Cool only 6 3 Warning Signal Connection The CM 12 s controller is equipped with a warning signal output relay type Form C normally open dry contact which can be used to monitor the failure condition Relay contactor is closed if the following condition has occurred Condensation Overflow Temperature Sensor fails Cooling Function fails The relay output contactor is rated 5 A at 30 VDC or 5 A at 250 VAC resistive load and it is compatable with various warning device
16. the unit If cleaning of the fins is necessary it is recommended that P d this service be performed by a qualified service Q technician Q 3 Operating environment inspection 1001780 Operating environments can vary depending on location climate and surrounding conditions Installation location also can cause operational problems Consult your reseller concerning operational environment requirements 4 Operating environment examination Measure the temperature difference between Condenser the evaporator inlet and the cooling air duct Condenser outlet If the difference is out of the range Exhaust shown in the graphs on page 14 proceed with the remedy suggested in the troubleshooting chart on page 39 Cool Air a Supply Evaporator Air Intake 1002841 Repair Section 43 7 5 Inspection of Capacitor For Fan Motor and Compressor 1 Ohm meter method Set the ohm meter to the 10M range Place the two probes against the two terminals of the capacitor At first the ohm meter should indicate small value then the reading should gradually increase towards infinity This indicates that the capacitor is charging If the reading indicates infinity right away open or the ohm meter fails to move from 0 shorted replace the capacitor 2 Capacitance tester method CC Capacitor for Compressor Control Box CF1 Capacitor for
17. 8 1 Parts Construction Right Side Panel Top Panel Capillary NS S a Tube Condenser High Pressure ae Freeze Inlet Air 7 Protection Thermistor Condenser Thermistor ODS CTS N Evaporator Inlet Air Thermistor RTS Evaporator Fan Sy Control Box Front Panel Service Panel oft Side Panel ILL00430 01 Repair Section 48 8 2 Disassembly Screws 4 1002761 Power Ground Supply Line Line ILL00958 00 i LAS Power Ground O Supply Line ILL00541 00 1 Take out the four 4 screws and then remove the service panel 2 Disconnect the two power supply lines from the terminal and disconnect the ground line N CAUTION Ground tightening torque 0 74 0 15 ftelbf 1 0 0 2 Nem a For unit serial number from 0415XXXXC12 to Present Please refer to page 2 for the position of the name plate showing the serial number on the unit b For unit serial number from 0211XXXXC12 to 0315XXXXC12 Please refer to page 2 for the position of the name plate showing the serial number on the unit Screws 3 Top Panel aa Screws 2 Screws 4 g lt Screws 5 1002763 Front Panel Screws 3
18. A S pp Wire Connection ILL00544 00 3 Take out the four 4 screws and then remove the ring Loosen the set screw with an Allen wrench and remove the fan Z CAUTION When assembling the ring ensure that the straight surface of the ring is facing forward 4 When assembling the fan ensure that the screws align with the motor axis positioning holes N CAUTION Tightening torque 10 80 2 17 ftelbf 14 7 x 3 0 Nem Verify the clearance between the fan and case ring After installing the fan and fan motor ensure that the clearance between the fan and case ring is at least 0 12 in 3 mm 5 Take out the four 4 screws and then remove the fan motor N CAUTION When assembling the motor ensure that the wire connection ends are facing down Repair Section 55 8 5 Removal of Electrical Parts N WARNING Disconnect the power supply from the CM 12 unit before performing any service Beware that some residual voltages may remain in the unit immediately after the power is disconnected 1 For unit serial number from 0415XXXXC12 to Present Please refer to page 2 for the position of the name plate showing the serial number on the unit Capacitor for Condenser Condenser Relay Wire E gt Support y S 2 pp Relay Board a Terminal for Terminal for Signal i B Power e Capacitor for Capacitor for Condenser Evaporator Fan Motor oe Fan Motor
19. Consumption Curve 1 6 ANC c c S 2 2 E 5 E 2 5 8 O c 9 g 0 8 T 37 35 95 p gt AS a Uf s 30 86 E pe a Y o o E I 25 77 2 a E Sus e gt LY a 20 25 30 35 a 20 25 30 35 68 77 86 95 68 77 86 95 Wet Bulb Temp C F Wet Bulb Temp C F ILL00650 00 Operation Section 15 4 REFRIGERATION SYSTEM 4 1 Refrigeration System Construction The component parts of the refrigeration system include the following Compressor Evaporator Condenser Accumulator Capillary tube High pressure switch These parts are all connected by copper tubing All the connections have been brazed Connecting Pipe Compressor Discharge Pipe Evaporator Inlet Pipe Capillary Tube Evaporator Outlet PipeAssy p p a E Evaporator High Pressure Switch Ps Pa gt Condenser m di k Outlet P d Condenser Inlet Pipe Condenser Accumulator Compressor Connecting Tube Refrigerant Flow gt Accumulator Capillary Tube Compressor IIS Sy Suction Pipe Insulated 9 3 S3 ILL00534 00 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 2 The construction of a rotary type compressor is divided into two mechanisms the drive mechanism compressor motor and the compression mechanism com
20. E J area The clearance of the brazed fitting must be minimized to facilitate brazing filler metal to Clearance From The Pipe Fitting and Tubing flow into it by capillary action 1002225 Cleaning brazing filler metal and pipe When the refrigeration system has been opened up exposure to heat may have caused brazing filler metal to stick to the inside and outside of the pipe Brazing filler metal may also be compounded with oxygen in the air to form oxide film Fats and oils may stick to the pipe from handling All these factors can reduce effectiveness of brazing It is necessary to eliminate excess brazing filler metal using sand paper and by cleaning thoroughly with a solvent such as trichlene N CAUTION Do not use chlorine cleaner 60 Repair Section 4 Use of dry nitrogen gas 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 lt NOTE gt Take care not to allow dirt water oil etc to enter into the pipe 5 Vertical joints Heat the whole brazed fitting to a proper Vertical Down Joint Brazing Filler Metal brazing temperature Bring the brazing filler metal into contact with the fitting so that the Burner brazing filler metal starts flowing by itself Stop heating the fitting as soo
21. Evaporator Fan Motor CF2 Capacitor for Condenser Fan Motor ILLO0546 01 Using a capacitance tester and the chart on page 29 test the capacitor for the value indicated If the value tested is not within 10 of indicated capacitance replace the capacitor Capacitor Application Voltage Rating Capacitance Evaporator Fan Motor 250 V 8 UF Condenser Fan Motor 250 V 14 uF Compressor 450 V 60 uF Z WARNING e Properly discharge the capacitor s before testing and after testing has been completed Failure to do so could cause damage to test equipment or the unit and or result in personal injury electrical shock or death Repair Section 7 6 Inspection of Compressor 1 Compressor motor Measure resistance across the terminals of the compressor motor Between terminals at 77 F 25 C R C Approx 0 49 0 8 ohm C S Approx 1 9 3 3 ohm If the measured resistance is not equal to the 1002770 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 see chart on page 27 2 Overload relay Check for continuity across two terminals of the overload relay At normal temperature there should be continuity across the terminals Operating Temperature
22. SERVICE MANUAL CM 12 Unit Serial Number Range 0211XXXXC12 to Present MOVINCOOL THE 1 SPOT COOLING SOLUTION DoclD 00G00088EB SERIAL NUMBER LOCATION AND IDENTIFICATION Nameplate Label A A 1 COOLING AMPS WITH PUMP COMPR OUTPUT REFRIGERANT TOTAL CHARGE DESIGN PRESSURE LO HI PART NO WEIGHT SERIAL NO A A LU XXXX HH Nameplate Label Position Month x E Model Year Sequential Number O 2015 DENSO PRODUCTS AND SERVICES AMERICAS 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 PRODUCTS AND SERVICES AMERICAS INC reserves the right to make changes without prior notice MovinCool Office Pro and SpotCool are registered trademarks of DENSO Corporation Table of Contents Table of Contents Operation Section 1 PRECAUTIONS FOR SAFETY 1 1 FOorewotd 322 o doh banat reb a ala a tid tal alado s aiaa e ty abies 6 12 Definitionor Termis c eu a A A uoce Mate SAN IG EIN AR Gus 6 1 3 General Precautions oia ei oa de an Eu tow e o O aa 6 2 CONSTRUCTION 2 1 Exterior DIMENSIONS wortd 000 eed eee ee A A ed AA 97 7 22 ExteriorOveniew eis iaa ir ri adea ge edd lad den mld bes 8 2 3 Antermal Structure Typ an estaa cce pe sada deal be AS de Sige ada aa a RR GA eae 9 24 Basic Construction o 10 ES tean T H TTT 10 3 SPECIFICATIONS
23. Unit 2 OE oe ee ce be ee a eee 71 10 2 Compressor Installation lille n 71 10 3 Evaporator Fan Assembly K 0 K K K R RR eh m rn 72 10 4 Condenser Fan Assembly e eee hh 72 10 5 Wiring NOtlGe e no ox ees EROR os ei GREG e M eei e ERES 72 10 6 Perform an Inspection 00000 cc rns 72 6 Operation Section 1 PRECAUTIONS FOR SAFETY 1 1 Foreword This manual has been published to service the MovinCool CM 12 Please use this service manual only when servicing the CM 12 1 2 Definition of Terms N WARNING Describes liada thal enol be gaal 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 1 3 General Precautions N 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 Before replacing any refrigeration components recover the refrigerant using standard recovery procedures and equipment When h
24. Voltage 115 V Rated Output 890 W 2 Compressor overload relay An external compressor overload relay is used to protect the compressor motor This relay is mounted within the connector housing that attaches to the top of the compressor The relay interrupts the flow of current when there is an overload condition such as high current draw and or high temperature buildup in the compressor Specifications Temperature Overcurrent Contact 302 F 150 C 17 A 30 min Open at 212 F 100 C Contact 142 F 61 C Close Operation Section 27 1002753 Bimetal a Terminal 1001691 28 Operation Section 5 6 Fan Motor 1 Evaporator Fan Motor The evaporator fan motor is a single phase induction type two speed motor Specifications Rated Voltage 115 V 60 Hz Rated Output High 44 5 W Low 14 3 W Rotational Speed High 1100 rpm Low 760 rpm NOTE 1000520 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 buildup in the fan motor 2 Condenser Fan Motor The condenser fan motor is a single phase induction type two speed motor Specifications Rated Voltage 115 V 60 Hz Rated Output High 91 2 W Low 68 7 W R
25. a vacuum cleaner 2 Check environmental condition Do not operate the unit outside the operating condition range See page 12 3 Reconnect the high pressure switch and check the connection 4 Replace high pressure switch 5 Charge the correct amount of refrigerant See page 69 Insufficient air volume Air filter is clogged Clean or replace air filter Condenser air intake or outlet in the ceiling is blocked Check for any blockage and remove it Dust buildup on the surface of the condenser air intake Remove dust with a vacuum cleaner Leak or clogged on the duct connection Repair duct connection Using longer duct length or smaller duct diameter than recommended Change the duct to proper size Fan is locked Check for any foreign object causing fan lock Operating outside of the operating temperature range Check environmental condition Do not operate the unit outside the operating condition range See page 12 Repair Section 7 4 Basic Inspection Perform the following inspections before disassembly 1 Power supply voltage inspection Check the power supply voltage Single phase 115 V 60 Hz Check the operation and condition of the fuse or circuit breaker for the power source 2 Inspection of plate fins Inspect the plate fins for any dirt dust lint or debris that may have caused insufficient cooling performance of
26. andling refrigerant always wear proper eye protection and do not allow the refrigerant to come in contact with your skin Do not expose refrigerant to an open flame The 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 When brazing any tubing always wear eye protection and work only in a well ventilated area Disconnect power before servicing unit Be careful of any sharp edges when working on unit Operation Section 2 CONSTRUCTION N 2 1 Exterior Dimensions Ground Screw M6 With Washer E S 6 e 96 p lo E E o S Fixing Hole M4 For Optional Outlet Ring See 8 5 Mount Bracket t 0 08 2 3 6 3 2 0 Q3 69 Ez Ligh T L a e gt al E 1 3 2 i z tt P1 SEE i 3 IS O o 9o 9 e e o gt Sta 2 o IS y v9 y H ty A 0 6 0 7 l S 3 5 DIA 10 0 e 8 1 15 4 x DIA 0 6 2 8 19 9 ee 15 8 zx 9 gt o Y rr a 1 0 UNIT inch ILL00532 00 Operation Section 2 2 Exterior Overview
27. e of the charging hose green Open the valve of the refrigerant cylinder After air purging tighten this nut and close the valve of the refrigerant cylinder 3 Securely place the refrigerant cylinder on a scale with a weighing capacity of 70 Ib 30 kg that is graduated by 0 2 oz 5 g increments 4 Open the high 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 23 Ib 0 56 kg Ax 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 charging 5 Close the high pressure valve of the gauge manifold and the valve of the refrigerant cylinder Repair Section 2 Removal of gauge manifold Pinch Off Tool To Gauge Manifold Side To Refrigerant Cycle Side 1002185 1 Crimp the pinch off tube with a pinch off tool 2 Remove the gauge manifold and the process tube fitting Crush the end of the pinch off tube 3 Braze the end of the pinch off tube 4 Ensure that a gas leak is not present at the pinched off portion and the brazed end Repair Section 10 REASSEMBLY 10 1 Reassembly of Unit Reassemble the unit in the reverse order of removal Described below are the parts that require special care in reassembling the unit Perform a
28. ely prevents bearing temperature increases and offers high aca 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 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 1002754 Operation Section 4 4 Capillary Tube The capillary tube is a long thin tube utilizing l High Temp High Pressure line flow resistance to serve as an expansion Liquid Refrigerant valve The length and the inner diameter ofthe gt capillary tube are determined by the capacity of the refrigeration system specified operating conditions and the amount of refrigerant The C capillary tube causes the high pressure high bow Tam llow Presse Ey temperature liquid refrigerant sent from the Gas and Liquid Mixture 1001887 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 becomes low and mist like respectively causing it to evaporate easily 4 5 Evaporator The evaporator is a heat exchanger covered with plate fins Heat is removed from the air being pulled acr
29. enser inlet air temperature is Condenser Inlet 73 F 77 approx 73 F 23 C or less Air Temperature 23 C 25 C Condenser fan speed switches to low 1LL00643 00 lt NOTE gt However when the 52lD relay is ON and the ODS temperature is 73 F 23 C or less the condenser fan will switch to low speed after running in high speed for 5 seconds 4 Anti frost control Anti frost controls turns the 52CM relay on in accordance with the Freeze Protection Thermistor CTS temperature in order to turn the compressor on and off to prevent a decrease in cooling performance resulting from a buildup of frost on the evaporator Compressor off conditions Freeze protection thermistor CTS temperature x 30 F 1 C Compressor on recovery conditions CTS temperature gt 50 F 10 C and continuous anti frost control for 15 minutes Operation Section 25 5 Compressor protection Compressor time delay control Compressor protection consists of a time delay program within the microprocessor which 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 when the compressor is turned on by either the COOL ON OFF button after the Y signal goes OFF once and then comes back ON or power interruption restart automatic recovery Specifications Time Delay 120 sec 6 Automatic re
30. from 0211XXXXC12 to 0315XXXXC12 Please refer to page 2 for the position of the name plate showing the serial number on the unit Power Cord 0 0 9 4 Circuit Breaker with R gt 3 Ground Fault Protective i bara mate d b e a E CM 12 Terminal Block Ground Eo Terminal R T G 1LL00538 00 Operation Section 33 6 2 Millivolt Wall Thermostat Connection 1 Use with a single stage wall thermostat Thermostat type Millivolt System 2 Set the wall thermostat to cooling system mode since most wall thermostats are designed for both heating and cooling 3 Prepare the wire harness for connection from the unit to the thermostat The recommended wire size is Wire Type Thermostat cable Solid wire 16 26 AWG 4 Identify the thermostat connectors labeled G G1 Y and RC G Fan On Off G1 Fan Speed Hi Lo Y Cooling On Off and RC Cooling Transfer Common Connecting Thermostat to CM 12 Unit Millivolt System LACS H HT g OHHOHM A 9 Remove Factory Installed Jumper Wall Thermostat CM 12 WIRES l Function Connector Name Label Name Color RC RC Brown Common line for thermostat connection Y Y Red When both Y and G signals are ON the compressor comes ON When the G
31. gh 0 04 kw Low 0 01 kw Operation Section ITEM SPECIFICATIONS Condenser Type of Condenser Plate Fin Type of Fan Centrifugal Fan Air Flow High 700 CFM 1190 m3 h Low 370 CFM 630 m3 h Max External Static Pressure 0 12 IWG 30 Pa Motor Output High 0 09 kW Low 0 06 kw Refrigerant Refrigerant Control Capillary Tube Type R 410A Amount 1 59 Ib 0 72 kg Signal Connection Fire Alarm Input Signal Type No voltage contact input Contact resistance less than 100 ohm Warning Signal Output 2 A at 30 V DC AC max with resistive load Dimension WXDXH Without Flange and 32 0 X19 9 X 15 2 in Mounting Bracket 813 x 505 X 386 mm With Flange and 34 8 X 22 7 X 15 8 in Mounting Bracket 884 x 577 X 401 mm Weight Net 123 Ib 56 kg Shipping 137 Ib 62 kg Condensate Pump Pump Rate 5 0 gal h 19 L h Capacity Max Head 4 ft 1 2 m Operating Condition Evaporator Air Inlet Max 95 F 35 C 50 RH Range Min 65 F 18 C 50 RH Condenser Air Inlet Max 113 F 45 C Min 65 F 18 C Maximum Duct Length Cold Duct 20 ft 6 1 m Hot Duct 10 ft 3 0 m Maximum Sound Level High 52 dB A Low 52 dB A Safety Devices Compressor Overload Protector Included Fan Motor Overload Protector Included Freeze Protection Thermistor Included Full Drain Pan Switch Included Automatic Resta
32. it Operation Section 2 Dip switch setting The controller is equipped with a four position dip switch that defaults in the OFF position The dip switch can be set to configure the following functions Switch Setting Name Function DSWA Alarm Setting When DSW 4 is ON the buzzer sound function is disabled DSW3 Compressor Time Delay Cut When DSW 3 is ON the compressor delay timer function is disabled DSW2 Cooling Test Operation When DSW 2 is ON the compressor evaporator and condenser fan motor will turn ON This function is used for test purposes and verification DSW1 Discharge Air Test Operation When DSW 1 is ON the evaporator and condenser fan motor will turn ON This function is used for test purposes and verification 4 Position Dipswitch O fren a aj eae oe Sa OlBe lt gt O E a E mo yA E S Relay Board Fuse 5A KN E ot OFF Position O IO E o 9 9 O 1002759 5 5 Compressor 1 Compressor motor The compressor motor is a single phase motor and is contained within the same housing as the compressor Specifications Rated
33. k ohm 93 2 F 34 C or above 566 k ohm 181 4 F 83 C 2 Condensation overflow When the float switch is ON continuously for 60 seconds Water leak detection Cooling function failure When the following occurs 3 times 3 Refrigeration cycle abnormality When 20 minutes from the start of operation has elapsed RTS CTS 23 F 5 C continuously for 1 minute 4 Fire alarm When receiving fire alarm signal input Repair Section 39 7 3 Troubleshooting Chart To accurately troubleshooting 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 Unit does not operate or stops operation Condition Alarm Pattern Check Area Possible Cause Remedy Unit does not operate Voltage Power failure Repair power supply Turn the circuit breaker on Ground fault breaker trip Ground fault or defective ground fault Repair ground fault section Reset or repair circuit breaker Fuse Fuse is blown Replace fuse on the relay board Wall thermostat Incorrect connection Connect the wires correctly Battery depleted by the thermostat Change battery Override Stop switch Override Stop switch is in the STOP position Turn the override stop switch to OPERATE
34. ll wiring or rewiring as referenced in the wiring diagram 10 2 Compressor Installation Compress eo Nut 3 9 Washer 3 Cushion 3 Collar 3 ILL00624 00 Plastic Cover MC S MCC goic3 ILLO0625 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 N CAUTION Tightening torque 8 3 2 1 ftelbf 11 3 2 9 Nem 3 Remove the plastic cover wires and overload relay from the compressor before brazing 72 Repair Section ILLO0626 00 Insulators Accumulator ILL00627 00 10 3 Evaporator Fan Assembly 4 Braze pipe at point A and G then braze at point B lt NOTE gt Pipe is packaged in the supplied compressor assembly 5 Re install overload relay wires and plastic cover after brazing 6 Apply insulators to the accumulator and pipe 2 lt NOTE gt Insulators are packaged in the supplied compressor assembly Install evaporator fan Allow a clearance of 0 12 in 3 0 mm or more on each side of the evaporator fan See page 52 10 4 Condenser Fan Assembly Install condenser fan Allow a clearance of 0 12 in 3 0 mm or more on each side of the condenser fan See page
35. m Check for leakage Check compressor relay Check for refrigerant blockage RESET 4 Fire alarm system Signal is input from the fire Check the fire alarm system and alarm confirm there is no signal input to the unit then RESET lt NOTE gt 1 To RESET reset power source or turn the wall thermostat off and on 2 Insufficient cooling Repair Section 41 Condition Check Area Possible Cause Remedy Unit Air is not cool Compressor start delay 120 seconds Compressor starts after 120 seconds operates is activated automatically Freeze protection is activated Condition Compressor stops while the condenser fan runs Compressor starts automatically when evaporator outlet pipe temperature rises more than 60 F 15 6 C Clean the filter on the evaporator inlet air grill Make sure evaporator fan external static pressure and evaporator inlet air temperature are within operating condition range See page 11 to 12 High pressure switch is activated Condition Compressor stops while the condenser fan runs During this time the compressor may cycle on and off periodically 1 Dust buildup on the surface of the condenser air inlet 2 Operating outside of the operating temperature range 3 Loose high pressure switch connection 4 Defective high pressure switch short or open 5 Refrigerant is over charged in the field 1 Remove dust with
36. n Motor CF2 Capacitor for Condenser Fan Motor ILL00956 00 Operation Section 2 For unit serial number from 0211XXXXC12 to 0315XXXXC12 Please refer to page 2 for the position of the name plate showing the serial number on the unit 23 CC Capacitor for Compressor RB Relay Board 4 Position Dipswitch RX Auxiliary Relay OFF Position TB1 Terminal Block1 CF1 Capacitor for Evaporator Fan Motor CF2 Capacitor for Condenser Fan Motor 1LL00537 00 24 Operation Section 5 3 Operation 1 Basic operation When a Y signal is input the 52CM relay located on the relay board comes ON and the compressor operates When a G signal is input both the 52ID relay and the RX auxiliary relay come ON and the evaporator and condenser fans operate However when the G signal is OFF both the 52CM and 521D relays go OFF stopping the compressor as well as the fans 2 Evaporator fan speed control With a G signal on the fan will start at high speed When a G1 signal is input relay 521D will become active and fan speed changes from high to low 3 Condenser fan speed control Air Volume Control Condenser fan air volume is controlled by the ODS condenser inlet air thermistor When condenser inlet air temperature is aet approx 77 F 25 C or greater Condenser F n A l Condenser fan speed switches to high High When cond
37. n as the brazing filler metal has flown into the clearance Since the brazing filler metal flows easily into the portion heated to a proper temperature it is 1000564 essential to keep the whole fitting at a proper brazing temperature Vertical Up Joint Burner Brazing Filler Metal 1001725 Repair Section 9 2 Removal of Refrigeration System Components N WARNING 61 Before replacing any refrigeration component recover the refrigerant using standard recovery procedures and equipment When recovering the refrigerant use the pinch off tube as shown in figure below N CAUTION 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 During any component replacement involving brazing to protect them from the flame shield nearby parts with a steel plate etc Evaporator Capillary tube Condenser Compressor High pressure switch ANNE xf BAN RAE Part to Replace Disconnect at Compressor See page 62 Condenser A amp C Capillary Tube C D amp E Evaporator B amp C High Pressure Switch F ILL00547 01 62 Repair Section 1 Removal of compressor assembly 1 Disconnect CC1 black and CC2 white wires from the capacitor for compressor in the control box Discon
38. nd discard ILLO0623 00 64 Repair Section 9 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 Equipments is for R 410A only Liquid charge no gas charge Make sure not to use more than 90 of the initial weight of R 410A in the cylinder AX 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 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 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 E 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 Leave for 5 minutes or comp
39. nect TBR wire white from the terminal block 1 in the control box AX WARNING Disconnect power supply from the unit before performing any service Beware that some residual voltage may remain in the unit immediate after the power is disconnected a For unit serial number from 0415XXXXC12 CC1 wire IE E D Present CC2 wire I M to Present 2 Please refer to page 2 for the position of the a Control l CC Capacitor 5 Lac Box name plate showing the serial number on the for CJ s Compressor y unit TBR wire TB1 Terminal ele 3 Block1 ILLO0960 00 ef b For unit serial number from 0211XXXXC12 wire e o e UE pue Tu to 0315XXXXC12 2 Please refer to page 2 for the position of the N Control l CC Capacitor 5 Lar Box name plate showing the serial number on the for Compressor E unit TBR wire TB1 Terminal S Block1 ILLO0620 00 Repair Section 63 2 Remove the insulators from pipe and accumulator Insulators ILLO0621 00 3 Disconnect at point A and B ILLO0622 00 4 Remove three 3 nuts and three 3 washers Nut 3 gt 9 Washer 3 _ and keep them for installation then remove the A compressor Cushion 3 8 Remove three 3 cushions and three 3 collars Collar 3 a
40. nection 6 4 Fire Alarm Control Panel Connection Table of Contents Repair Section 7 TROUBLESHOOTING Fob Troubleshooting oss ia ya a e ath eR XR Ghee a pa EOE Rode a 36 eE ANNAN eeu SE ON RO Ea 37 13 Troubleshooting Chart skull ha te eee kad EVAN a bate 39 LA Basic INSPECtON ves dev BN A a Boe Ak ces 42 7 5 Inspection of Capacitor For Fan Motor and Compressor s eee ee eeaee 43 7 6 Inspection of COMpressor 00 0c eee eee 44 T Inspection of Fan Motors sssri ia iio na gad da neds ded deed emet kei 45 719 Inspecti n of Thermistor orcas ka Ga coh m SoG aie adn heats Wane Galea ise ae bale 45 7 9 Inspection of Wiring Connection 0 6 eee eee 46 7 10 Refrigeration System Inspection 0 00 0 tees 46 8 DISASSEMBLY 9 1 Parts Construction isset pase reebbdd dia eeid ode Sam eb ERR Nr peed Eid 47 39 2 Disassemibly gt exe cota ed yq Aa en ad aie ble PM ales wate pe dale AL EQ HERUM Bee ee 48 8 3 Removal of Evaporator Fan Assembly 0 000 eee eae 51 8 4 Removal of Condenser Fan Assembly ssas auauua aaaea 53 8 5 Removal of Electrical Parts R RN N N a a A E tee eee 55 9 REFRIGERATION SYSTEM REPAIR 9 1 Repair of Refrigeration System 0 0 eee ee 59 9 2 Removal of Refrigeration System Components 000 cee eae 61 9 3 Charging the System with R 410A Refrigerant 0 0 0000 eee eee 64 9 4 Refrigerant Charging Work sses stii 00 cents 69 10 REASSEMBLY 10 1 Reassembly of
41. om the right side face is cooled by the evaporator and then blown through the front cool air duct Cool Air Supply j Evaporator Air Intake 1002841 3 SPECIFICATIONS 3 1 Technical Specifications Operation Section ITEM SPECIFICATIONS Electronic Features Control Millivolt Thermostat Field supplied Electrical Characteristics Voltage Requirement Single Phase 115 V 60 Hz Operating Voltage Max 127 V Range Min 104 V Starting Current 50A Recommended Fuse Size 15A FLA 11 2A MCA 14 9A MOP 20A LRA 50A Cooling Capacity and Power Consumption Evaporator 80 F 27 C 50 RH Condenser 95 F 35 C 50 RH Total Cooling Capacity 10500 Btu h 3090 W Sensible Cooling Capacity 7200 Btu h 2100 W Power Consumption 1 23 kW Current Consumption 1 11 2A EER 8 5 Power Factor 96 Evaporator 72 F 22 C Total Cooling Capacity 9300 Btu h 2730 W 50 RH Sensible Cooling Capacity 7 7000 Btu h 2040 W bend gor Power Consumption 1 22 kW Current Consumption 1 11 1A EER 7 6 Power Factor 96 Compressor Type Hermetic Rotary Output 0 91 kW Evaporator Type of Evaporator Plate Fin Type of Fan Centrifugal Fan Air Flow High 324 CFM 550 m3 h Low 228 CFM 390 m3 h Max External Static Pressure 0 16 IWG 40 Pa Motor Output Hi
42. onents 3 Check the vacuum Step 3 Connect to refrigerant source Step 4 Test the system for leaks Charge the system with R 410A Step 5 See Technical Specifications for the specified amount Step 6 Remove manifold gauge ILL00084 00 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 gt Side Tube when stopped 1000568 2 Evacuation Valve Setting LO HI a LO HI Gauge Closed Open Closed Closed 30 inHg 100 kPa or larger Low Pressure Valve High Pressure Gauge High Pressure Valve High Pressure Side Tube Vacuum Pump in Operation 1002227 Repair Section 65 1 Properly remove the crushed end of the pinch off tube at the high pressure side of the refrigerant cycle with a pipe cutter 2 Fit the process tube fitting to the pinch off tube 3 Connect the charging hoses red high pressure side for the gauge manifold to the process tube fitting 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
43. oss the evaporator by the centrifugal fan and the resulting cool air is expelled through the cool air vent ILL00535 00 4 6 Accumulator The accumulator is mounted on the suction F rom Evaporator gas piping between the evaporator and the compressor The accumulator separates the liquid refrigerant from the gas refrigerant A allowing only the gas refrigerant to enter the 1 compressor In the accumulator suction gas is led into a cylindrical vessel where the speed of To Compressor the gas is decreased This process separates 1000514 the refrigerant contained in the gas by the force 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 20 Operation Section 4 7 High Pressure Switch e 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 V Snap Disk Movable Point CY ZA Pin Lead Wires la 1001768 Stationary Point Terminal Case EN Molding by Resin ground
44. otational Speed High 1100 rpm Low 975 rpm NOTE ILL00594 00 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 buildup in the fan motor Operation Section 29 5 7 Capacitor The capacitor is used to improve the rotational power of the fan motors and compressor at Se startup The specification for each capacitor is shown below Rated Capacitor Capacitance Voltage Evaporator Fan Motor 250 V 7 UF Condenser Fan Motor 220 V 9 uF ILLOO561 00 Compressor 370 V 60 UE 5 8 Temperature Thermistor The evaporator inlet air thermistor RTS is installed upstream of the evaporator and detects evaporator inlet temperature as a resistance value The freeze protection thermistor CTS is installed in the evaporator outlet piping and detects low temperature on the evaporator as a resistance value 1001695 Specification Type Characteristic Short Detection Open Detection Evaporator Inlet A 5 k ohm at 77 F 25 C 181 F 83 C or more 29 F 34 C or less Air Thermistor RTS HR en 5 k ohm at 77 F 25 C 181 F 83 C 29 F 34 C or ohm a Thermistor CTS larma peers 5 9 Drain Pump The drain
45. pressor When the rotor shaft of the motor drive mechanism turns the roller compression mechanism rotates to compress the refrigerant Basic compressor operation 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 1002753 Discharge Hole Discharge Spring Valve Suction Hole Blade Shaft L2 Roller Cylinder 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 3 Operation Discharge Valve Roller 1001676 Discharge Blade 1001677 Discharge Roller 1001678 Discharge Valve 1001679 Operation Section 1 Start of compression 1 The cylinder is filled with low pressure gas 2 Since pressure in the discharge chamber is higher than in the cylinder the discharge val
46. pump evacuates evaporator condensation accumulated in the drain pan The drain pump turns on when the compressor turns on The drain pump turns off when the compressor turns off 1000523 30 Operation Section 5 10 Float Switch A float switch is installed in the drain pan The float switch is a normally closed type switch If evaporator condensation cannot be evacuated and the drain pan becomes full the float rises turning the switch on which then activates the warning signal output and stops the unit s operation This prevents the drain pan from overflowing and alerts the user of the situation 1000524 Operation Section 6 CONNECTION AND SETTING 6 1 Power Supply Requirements The CM 12 requires a single phase 115 V 60 Hz power supply The power supply should be a dedicated single outlet circuit with a UL recognized short circuit and ground fault protective breaker and a maximum fuse size of 20 A 1 For unit serial number from 0415XXXXC12 to Present Please refer to page 2 for the position of the name plate showing the serial number on the unit Circuit Breaker with E gt gt Ground Fault Protective i AA boro a a Fuse 20AMax S S 2eles los CM 12 Terminal Block Ground AS 4 Terminal Power Cord R T 1LL00957 00 32 Operation Section 2 For unit serial number
47. re pue ID 3 Motor Ae 1002775 Bolts 4 Wire Connection ILL00542 00 3 Take out the three 3 screws and then remove the ring Loosen the set screw with an Allen wrench and remove the fan N CAUTION When assembling the ring ensure that the straight surface of the ring is facing forward 4 When assembling the fan ensure that the screws align with the motor axis positioning holes N CAUTION Tightening torque 8 7 1 1 ftelbf 5 0 1 5 Nem Verify the clearance between the fan and case ring After installing the fan and fan motor ensure that the clearance between the fan and case ring is at least 0 12 in 3 mm 5 Take out the four 4 bolts and then remove the fan motor N CAUTION When assembling the motor ensure that the wire connection ends are facing down Repair Section 53 8 4 Removal of Condenser Fan Assembly Frame 1LL00593 00 ILLO0648 00 1 Take off the four 4 nuts 2 Disconnect the motor connector white six pin from circuit board CN22 and remove the condenser fan assembly Repair Section 54 ILL00543 00 0 12 in 3mm or more W Set Screw E Hr 0 12 in 3mm or more Motor Axis 1002780 Bolts 4 NO
48. reaker in the power source 2 Inspection of air filters Remove the air filters and check the element If the elements dirty wash the filters as described in the OPERATION MANUAL which supplied with the unit Repair Section 37 7 2 Alarm An alarm is emitted when a system abnormality is detected stopping the system The type of abnormality can be recognized by the alarm pattern The CM 12 controller is equipped with a warning signal output type relay Form C normally open dry contact which can be used for monitoring the CM 12 abnormality conditions The relay contactor is closed when the following conditions have occurred Temperature sensor failure Condensation overflow Cooling function failure The relay output is rated for 5 A at 30 VDC or 5 A at 250 VAC resistive load The relay can be used to connect to warning devices with compatible outputs such as alarm speakers light indicators etc lt NOTE gt However when dipswitch no 4 on the relay board is OFF an alarm will not sound Pattern 1 Internal thermister failure Pattern 2 Pump or drain problem Pattern 3 Refrigeration system problem Pattern 4 Fire alarm signal input 1002772 38 Repair Section Alarm Cause Detection Details Pattern Temperature sensor failure When an abnormality is detected in either RTS CTS or ODS 1 Thermistor short failure Detection value Below 136 5
49. rt Power Interruption Included High Pressure Interruption Included Compressor Time Delay 120 sec Signal Input Output Included Control Devices Temperature Control Included Two Speed Fan Included Operation Section 13 e Specifications are subject to change without notice lt NOTE gt 1 With two 6 foot 1 8 m ducts containing one 90 bend each supply grill and return grill with filter 0 16 IWG 40 Pa external static pressure on high fan speed 2 When ambient temperature is lower than 65 F 18 C operation may be interrupted due to anti freeze protection activation 3 Confirm pressure drop of duct grills and filter with manufacture s specifications 4 Measured at 3 feet 1 0 m under the ceiling with evaporator duct and ceiling tile Operation Section 14 3 2 Characteristics Cooling Capability Curve 16 Z E 2 Cool Air Temperature Difference Curve D 15 27 0 Z 14 25 2 Condenser Inlet Air Temperature at 95F 5 13 23 4 s o 2 12 21 6 G oO 8 K 0 19 8 S S 10 18 0 9 16 2 i 35 95 O 8 14 4 a 30 86 E 7 12 6 E 30 40 50 60 70 80 a 29077 Relative Humidity 96 2 m ooh SEA ES N YN 10 15 20 25 50 59 68 77 Wet Bulb Temp C F Power Consumption Curve Current
50. s such as alarm speakers light indicators and etc 1 Connect the warning device to CM 12 signal wires label L and L 2 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 Unit Terminal Warning Device ILLO0616 00 Operation Section 35 6 4 Fire Alarm Control Panel Connection The CM 12 s controller is equipped with a normally 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 power source is reset or turns the wall thermostat off and on 1 Connect the fire alarm signal wires to CM 12 signal wires label E and E 2 Use recommended fire alarm signal wire size from 16 AWG to 26 AWG for a solid wire or 16 AWG to 22 AWG for a stranded wire Unit Terminal Fire Alarm Device ILL00617 00 Repair Section 7 TROUBLESHOOTING 7 1 Troubleshooting Before troubleshooting the system the following inspection should be performed N WARNING Disconnect power supply from the unit before performing any service Beware that some residual voltages may remain in the unit immediately after the power is disconnected 1 Inspection of power source voltage Check the voltage of the power source Single phase 115V 60Hz Check the operation and condition of the fuse or circuit b
51. start after power interruption Automatic Recovery Function The program within the CM 12 microprocessor 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 either manual or preset program it was in prior to the loss of power Any preset program will also be retained in the memory in the event power loss occurs 5 4 Relay Board The relay board controls the components such as the compressor and fan motor based on the signals received from the millivolt wall thermostat and other sensors on the unit It also contains a step down transformer that converts the line voltage 115 VAC to 12 V This 12 V is then converted from AC to DC and used for relay coil activation The 12 V DC power is sent to the control panel assembly where it is further reduced to 5 V for the system logic The relay board also contains the DIP switch lt NOTE gt The relay board must be serviced as a complete assembly It has only one serviceable component the fuse see below 1 Relay board fuse 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 5A 250 VAC N CAUTION Failure to use the exact type of fuse could result in damage to the unit and or to components It could also void the warranty of the un
52. ve is kept closed 2 Suction and compression 1 The pressure in the cylinder increases gradually 2 Refrigerant suction begins on the suction side of the cylinder 3 The discharge valve remains closed 3 Discharge 1 The pressure in the cylinder exceeds that in the discharge chamber and the discharge valve opens 2 On the suction side refrigerant suction continues 4 Completion of compression 1 When compression is completed all of the refrigerant has been drawn from the suction chamber 2 Operation then returns to step 1 Start of compression and the above process of suction continues and compression repeatedly in succession Operation Section 4 Compressor lubrication The lubrication system is comprised of a hollow shaft an oil scraper mounted at the end face hollow shaft a shaft journal shaft Rotor bearing and the lubrication groove for the shaft journal The lubrication groove is wider than the oil hole When the shaft turns oil is Hollow Shaft scraped upward by the oil scraper along the Cylinder Eccentric Shaft inside diameter of the hollow shaft The oil is fed through the oil hole by centrifugal force then supplied to the lubrication groove for each shaft journal lubricating the bearing In this lubrication system oil enters into each bearing Oil Feed Groove NS separately and returns to the oil reservoir This Oil Hole Oil Scrapper system effectiv

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