1 SERVICE MANUAL 15SF DocID: 00G00092E
2 2014 DENSO AUTOMOTIVE SYSTEMS AUSTRALIA PTY. LTD. All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher. DENSO AUTOMOTIVE SYSTEMS AUSTRALIA PTY. LTD. reserves the right to make changes without prior notice. MovinCool is a registered trademark of DENSO Corporation.
3 Table of Contents Table of Contents Operation Section 1. PRECAUTIONS FOR SAFETY 1.1 Foreword Definition of Terms General Precautions SPECIFICATIONS 2.1 Exterior Dimension Diagram Technical Specifications Characteristics CONSTRUCTION 3.1 Internal Structure REFRIGERATION SYSTEM 4.1 Refrigeration System Construction Compressor Condenser Capillary Tube Evaporator Accumulator ELECTRICAL SYSTEM 5.1 Circuit Diagram Control Box Control Specifications Compressor Fan Motor Temperature Thermistor Drain Tank Switch OPERATION 6.1 Operation of Control Panel
4 Table of Contents Repair Section 7. TROUBLESHOOTING 7.1 Troubleshooting Self-Diagnostic Codes Troubleshooting Chart Basic Inspection Compressor Inspection Fan Motor Inspection Capacitor Inspection (For Fan Motor and Compressor) Auxiliary Relay Inspection Full Drain Switch Inspection Thermistor Inspection Wiring Connection Inspection Inspection of Refrigeration System DISASSEMBLY 8.1 Parts Construction Disassembly Fan Motor Removal Removal of Electrical Components Full Drain Switch Removal REFRIGERATION SYSTEM REPAIR 9.1 Repair of Refrigeration System Removal of Refrigeration System Components Preparing the System for Charging with R-410A Refrigerant Refrigerant Charging Work REASSEMBLY 10.1 Reassembly of Unit Compressor Installation Fan Assembly Wiring Notice Perform an Inspection
5 Operation Section 5 1. PRECAUTIONS FOR SAFETY 1.1 Foreword This manual has been published to service the MovinCool 15SF. Please use this service manual only when servicing the 15SF. Please forward these instructions to subsequent owners of your MovinCool 15SF. Refer to the 15SF spare parts catalogue for spare parts ordering information. 1.2 Definition of Terms WARNING CAUTION NOTE Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation. 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. Provides additional information that facilitates installation or unit operation.
6 6 Operation Section 1.3 General Precautions 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. This air conditioner uses R-410A refrigerant under high pressure. It is both dangerous and illegal to tamper with the sealed refrigerant system without appropriate licensing and training. Deliberate release of refrigerant is illegal in Australia, New Zealand and other regions. Refrigerant recovery and charging equipment must be specifically rated for use with R- 410A. Observe Refrigerant Handling Code of Practice and all other applicable regulatory requirements. Before replacing any refrigeration components, recover the refrigerant using standard recovery procedures and equipment. When handling refrigerant, always wear proper eye protection and do not allow the refrigerant to come in contact with your skin. Do not expose refrigerant to an open flame. The power supply for this unit should be a dedicated single outlet circuit with short-circuit protection and residual current protective device 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 this unit. Be careful of any sharp edges when working on this unit.
7 Operation Section 7 2. SPECIFICATIONS 2.1 Exterior Dimension Diagram 2100 OBSTACLE Minimum clearance 500 mm DIA. 350 OBSTACLE Minimum clearance 500 mm Minimum clearance 500 mm OBSTACLE Unit: mm ILL
8 8 Operation Section 2.2 Technical Specifications ITEM SPECIFICATIONS Electronic Features Operation Digital Electronic Electrical Characteristics Voltage Requirement 1 Phase, 230 V, 50 Hz Operating Voltage Max. Range Min. Starting Current Recommended Breaker Size V V 25 A 10 A Cooling Capacity and Power Consumption Evaporator: 35 C, 60 %RH Condenser: 35 C, 60 %RH Cooling Capacity Power Consumption 4.4 kw 1.5 kw Current Consumption 6.7 A COP 2.9 Power Factor 97% Compressor Type Hermetic Rotary Output 0.94 kw Evaporator Type of Evaporator Spine Fin Type of Fan Centrifugal Fan Air Flow 800 m 3 /h Motor Output * kw Condenser Type of Condenser Plate Fin Type of Fan Centrifugal Fan Air Flow 1500 m 3 /h Motor Output *1 - Refrigerant Refrigerant Control Capillary Tube Type R-410A Amount 0.75 kg Power Cord Plug AC 250 V, 10 A Wire Length 2.1 m Dimension W D H mm Weight Net 76 kg Shipping 90 kg Drain Tank Capacity 19 L Operating Condition Range Inlet Air Temperature Max. Min. 40 C, 50 %RH 21 C, 50 %RH Sound Level *2 64 db (A)
9 Operation Section 9 Specifications are subject to change without notice. < NOTE > ITEM Safety Devices Compressor Overload Relay Included Fan Motor Overload Relay Freeze Protection Thermistor Drain Warning Switch Automatic Restart (Power Interruption) Compressor Time Delay *1 : One motor rotates both the evaporator and the condenser fans. *2 : Measured at 1.0 m from surface of the unit. SPECIFICATIONS Included Included Included Included 120 sec Control Devices Temperature Control Included
10 10 Operation Section 2.3 Characteristics (1) Cooling capacity curve 5.5 Cooling Capacity. kw Dry Bulb Temp. C Wet Bulb Temp. C ILL (2) Power consumption curve 1.8 Power Consumption. kw Dry Bulb Temp. C Wet Bulb Temp. C ILL
11 Operation Section 11 (3) Cool air temperature difference curve 15 (Delta-T) C Temperature Difference Between Inlet and Outlet Relative Humidity. % ILL
12 12 Operation Section 3. CONSTRUCTION 3.1 Internal Structure Control Panel Evaporator Inlet Air Thermistor (RTS) Condenser Air Outlet Cooling Air Duct Housing for Condenser Fan Housing for Evaporator Fan Condenser Fan and Motor Evaporator Condenser Freeze Protection Thermistor (CTS) Capillary Tube Compressor and Accumulator Drain Tank Control Box Relay Board Capacitor Auxiliary Relay Caster (Rear) Full Drain Switch Locking Swivel Caster (Front) ILL
13 Operation Section REFRIGERATION SYSTEM 4.1 Refrigeration System Construction The component parts of the refrigeration system include the following: Compressor, Evaporator, Condenser, Accumulator, Capillary tube The parts above are all connected by copper piping with brazed connections. Evaporator Outlet Pipe Condenser Evaporator Compressor Discharge Pipe Evaporator Inlet Pipe Capillary Tube Condenser Inlet Pipe Condenser Outlet Pipe Connecting Pipe (Evaporator to Compressor) Compressor Suction Pipe Compressor Condenser Accumulator Connecting Pipe (Condenser to Capillary Tube) Flow of Refrigerant Accumulator Capillary Tube Fan Motor Evaporator Compressor ILL
14 14 Operation Section 4.2 Compressor The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in one casing. (1) Compressor construction The construction of a rotary type compressor is divided into two mechanisms; the drive mechanism (compressor motor), and the compression mechanism (compressor). When the rotor shaft of the motor (drive mechanism) turns, the roller (compression mechanism) rotates to compress the refrigerant. Terminal Stator To Condenser From Evaporator Accumulator Strainer Rotor Cylinder Roller Lubricator Blade Discharge Valve Oil I001675
15 Operation Section 15 (2) Basic compressor operation The roller (compression mechanism) is set Discharge eccentrically with a certain distance given from Hole Spring Discharge the axis of the center of the cylinder. A spring Valve Suction Hole loaded blade is mounted on the cylinder. The Blade roller turns to compress the refrigerant in the space between the cylinder and eccentrically Shaft mounted roller. The blade is in contact with the Roller Cylinder roller by means of spring force. The blade I partitions the space between the suction side and the discharge side to keep compressed refrigerant from returning to the suction side. There is no suction valve. The discharge valve is designed not to open until the pressure of the refrigerant within the cylinder reaches or exceeds discharge side pressure. As a result, the discharge valve prevents the backward flow of refrigerant gas.
16 16 Operation Section (3) Operation Discharge Valve Blade 1) Start of compression 1) The cylinder is filled with low pressure gas. 2) Since pressure in the discharge chamber is higher than in the cylinder, the discharge valve is kept closed. Roller I Discharge Valve Blade 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. Roller I Discharge Valve Blade 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. Roller I Discharge Valve Roller Blade I ) Completion of compression 1) When compression is completed, all of the refrigerant has been drawn from the suction chamber. 2) Operation then returns to step 1) (Start of compression) and the above process of suction and compression continues repeatedly in succession.
17 Operation Section 17 (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 bearing), and the lubrication groove for the shaft journal. The lubrication groove is wider than the oil hole. When the shaft turns, oil is scraped upward by the oil scraper along the inside diameter of the hollow shaft. The oil is fed through the oil hole by centrifugal force, then supplied to the lubrication groove for each shaft journal, lubricating the bearing. In this lubrication system, oil enters into each bearing separately and returns to the oil reservoir. This system effectively prevents bearing temperature increases, and offers high reliability. In addition, the specially treated Rotor Hollow Shaft Eccentric Shaft Cylinder Roller Oil Feed Groove Oil Hole Oil Scraper shaft journal keeps the bearing from being damaged during high temperature operation. ILL 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. I002351
18 18 Operation Section 4.4 Capillary Tube The capillary tube is a long thin tube that High Temp./High Pressure utilizes line flow resistance as an expansion Liquid Refrigerant valve. The length and the inner diameter of the capillary tube are determined according to the capacity of the refrigeration system, operating conditions, and the amount of refrigerant. The high pressure, high temperature liquid Low Temp./Low Pressure refrigerant sent from the condenser expands Gas and Liquid Mixture I rapidly as the refrigerant is sprayed out through the fixed orifice in the capillary tube. As a result, the temperature and state of the refrigerant becomes low and mist-like, and therefore evaporates easily. 4.5 Evaporator The evaporator is a heat exchanger covered with spine fins. Heat is removed from the air being pulled across the evaporator by the centrifugal fan. The resulting cool air is expelled through the cooling air ducts. I Accumulator The accumulator is mounted on the suction From Evaporator gas piping between the evaporator and the compressor. The accumulator separates the liquid refrigerant from the gas refrigerant, allowing only the gas refrigerant to enter the compressor. In the accumulator, suction gas is led into a cylindrical vessel where the speed of To Compressor the gas is decreased. This process separates the refrigerant contained in the gas by the force I 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.
19 Operation Section ELECTRICAL SYSTEM 5.1 Circuit Diagram IOLF MF M 1~ M 1~ MC OLC CF 1 2 CC 1 2 RX A1 A2 CB 11 CN9 1 CN25 52ID 1 52ID 3 CN21 F CN TB2 L2 L1 AC230V 1Φ 50Hz AP 1 5 CN CN17 5 CN RB CN12 CN11 CN CM CN03 52CM Jumper Line Jumper Line t t CTS RTS DS AP TB RB CB MC MF CC Attachment Plug Terminal Block Relay Board Control Board Compressor Motor Fan Motor Capacitor for Compressor CF RX DS RTS CTS OLC IOLF Capacitor for Fan Motor Auxiliary Relay Drain Switch Room Thermistor Freeze Protection Thermistor Overload Relay For Compressor Internal Overload Relay For Fan Motor ILL
20 20 Operation Section 5.2 Control Box RB: Relay Board CN15 CN16 CN14 CN02 CN03 CN04 CN11 CN12 CN13 RB 4 52CM 3 CN17 CN25 CN01 CN24 TB TB: Terminal Block RX: Auxiliary Relay RX L1 L CC: Capacitor for Compressor CC CF CF: Capacitor for Fan Motor ILL (1) Capacitor The capacitor is used to improve the rotational power of the fan motor and compressor at startup. The specification for each capacitor is shown below. Specifications: Capacitor Rated Voltage Capacitance For Fan Motor 400 V 10 µf For Compressor 400 V 35 µf ILL
21 Operation Section 21 (2) Auxiliary relay The auxiliary relay is normally closed when the unit is in operation (fan or cool), and supplies power to the fan motor. When current flows across A1 and A2, terminals 13 and 14, 23 and 24, 33 and 34, 43/41 and 44/42 conduct. Specifications: Rated Voltage Rated Current AC 220 V 25 A 13 A1 14 A2 I001694
22 22 Operation Section (3) Relay board The relay board contains the dip switch, compressor and fan relays, and a step-down transformer that reduces the line voltage from 230 VAC to approximately 12.7 VAC. This voltage is then rectified from 12.7 VAC to 12 VDC and used for relay coil activation. The 12 VDC voltage is sent to the control panel assembly, further being reduced to 5 V for the system logic. CN15 CN16 CN14 CN02 CN03 CN04 CN11 CN12 CN13 4-Position Dip Switch CN17 52CM CN01 CN25 Relay Board Fuse (5A) CN24 CN21 CN22 CN23 OFF Position ILL ) Power supply requirements This unit requires a 1 phase 230 V, 50 Hz power supply. 2) Relay board fuse The relay board fuse is the only serviceable component on the relay board assembly. This fuse provides protection against damage to the step-down transformer. The fuse must be replaced with the exact same part, or a suitable equivalent. Specifications: - 5 A 250 VAC CAUTION Failure to use the exact same fuse may result in damage to the unit and/or components, and will also void the unit warranty.
23 Operation Section 23 3) 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: ON Symbol DSW4 DSW3 DSW2 DSW1 Item Buzzer - - Fan Mode Function On --- Disable onboard buzzer Off --- Enable onboard buzzer N/A N/A Change Fan Mode On --- Fan stop mode (Fan AUTO) Off --- Fan operate mode (Fan ON) I002623
24 24 Operation Section 5.3 Control Specifications (1) Fan control When the FAN button is pressed, the 52ID (fan motor on/off) relay on the relay board turns on, operating the fan. For the 15SF, the 52ID relay turns the auxiliary relay on to operate the fan. Specifications: - 52ID (Fan motor On-Off) relay output: 5 A at AC 250 V (2) Compressor start control When the ON/OFF button is pressed, the 52CM relay on the relay board turns on, operating the compressor. Specifications: - 52CM (Compressor On-Off) relay output: 20 A at AC 250 V (3) Anti-freeze control Anti-freeze controls turns the compressor on and off by turning the 52CM relay on in accordance with the freeze protection thermistor (CTS) temperature. As a result, decreases in cooling performance due to frost buildup on the evaporator are prevented. Compressor off conditions: Freeze protection thermistor (CTS) temperature -1.1 C Compressor on (recovery) conditions: CTS temperature 15.6 C 52CM ON OFF -1.1 C 15.6 C CTS temperature (Freeze protection thermistor temperature) ILL
25 Operation Section 25 (4) Compressor time delay control (compressor protection) Compressor protection consists of a time delay program within the microprocessor. This program prevents a heavy load from being applied to the compressor motor when restarting the unit (cool mode) after a very short period of time. This delay is in effect any time the compressor is turned on by either the COOL ON/OFF button, or power interruption restart (automatic recovery.) Specifications: - Time Delay: 120 seconds [Example] Controller Status Compressor Status (52CM) ON OFF ON OFF 1st Time (After initial set up, reset circuit breaker, etc.) Delay Time (120 sec.) Compressor turns off and on immediately (within 120 sec.) Turn ON Compressor turns off and on more than 120 sec. later No Delay Time (Less than 5 sec.) Delay Time (120 sec. after last turn off) Stop (for Extended Period) No Delay Time (less than 5 sec.) Reference: Initial turn on Within: 120 sec. after (the power cord is connected to) the power supply, the compressor will start with delay timer. After: 120 sec. since (the power cord was connected to) the power supply, the compressor will start without delay timer. I (5) Automatic restart and recovery function The microprocessor contains a feature that automatically restart the unit after power is lost and regained, and also has memory to store and recover operation status in the event of a power loss. Status of memory during power interruption When the input power is off, the status items below are saved in the memory. - Running status (on or off) - Operating mode: Cool mode or fan only mode - Set temperature - Temperature mode ( F or C) - Fan mode: Fan operation mode (fan on) or fan stop mode (fan auto)
26 26 Operation Section (6) Temperature control During cool mode, temperature control changes the 52CM (compressor on/off) relay status according to RTS temperature in the available range (-20 C to 60 C). 52CM (Compressor Relay) ON OFF Set Temp C Set Temp Inlet Air Temperature When compressor operation continues within this range for more than 5 minutes, the 52CM relay stops. ILL
27 Operation Section Compressor (1) Compressor motor The compressor motor is a single-phase motor and is contained within the same housing as the compressor. Specifications: Rated Voltage Rated Power Output 230 V 0.94 kw (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. Points Bimetal Terminal I I Operating Temperature OFF (Open Contacts) ON (Closed Contacts) Non-Operating Limit at 100 C Marking 158 C 75 C 9 A MRA
28 28 Operation Section 5.5 Fan Motor The fan motor is a single phase, induction type. The motor rotates the fan on both the evaporator side and the condenser side at the same time. Specifications: Rated Voltage Rated Power Output 230 V 0.35 kw < NOTE > I 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. 5.6 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. I Type Evaporator Inlet Air Thermistor (RTS) Freeze Protection Thermistor (CTS) Specification Characteristic Short Detection Open Detection 5 k ohm at 25 C 83 C or more -34 C or less 5 k ohm at 25 C 83 C or more -34 C or less
29 Operation Section Drain Tank Switch The drain switch activates and stops the operation of compressor motor and fan motor when approximately 16 L of drain water accumulates in the drain tank. At the same time, control panel display "FL", and compressor and fan operations stop. This system uses a 250 V, 0.1 A rating micro switch for this function. When approximately 16 L of drain water accumulates in the drain tank, the drain tank base plate, which is supported at fulcrum (a), is pushed down in the direction of the arrow. When the drain tank base plate is forced down, portion A, located at the top of the drain tank base plate, turns off micro switch contacts (1)-(2). Portion A Evaporator Full Drain Switch Drain Pan NC (2) Relay Board (CN16) 2 NC 1 NO 3 COM C (1) Drain Tube Spring Drain Water Drain Tank a Base Base Plate I001696
30 30 Operation Section 6. OPERATION 6.1 Operation of Control Panel (1) Control panel Before operating the unit, it is important to be familiar with the basic operation of the control panel COOL ON/OFF Button FAN Button SET TEMP Buttons ( / ) Room Temperature/ Set Point Display Temperature Scale LED ON LED AUTO LED Activates/deactivates the cool mode; turns the unit off. Activates/deactivates the fan only mode; turns the unit off. Increases/decreases the temperature set point during cool mode. Shows a blinking set point temperature for 5 seconds, then continuously indicates room temperature. Illuminates to indicate the current temperature being displayed is either in C or F. Illuminates during fan only mode and cool mode using fan operate mode. Illuminates during cool mode using fan stop mode. [LED Display Indication] In normal operation, LED displays the following indication. Display Indication Conditions Right decimal segment is on Indicates room temperature when display is solid. (Left fig. : Room temp. at 30 C) Indicates set point temperature when display is flashing. (Left fig. : Set Point temp. at 25 C) Power stand by or during fan only mode During cool mode During set point temperature adjustment or cool mode on. (5 seconds) ILL < NOTE > The unit has been preset at the factory to display the temperature in C The room temperature display range is from -9 C to 60 C. (When displayed in F the range is from 0 F to 109 F) In Fahrenheit only, when the display value is greater than 99 F, 100 F, 101 F, and 109 F are displayed as 00, 01, and 09 respectively.
31 Operation Section 31 (2) Fan only mode When the FAN button on the control panel is pressed, the FAN ON LED illuminates, and the fan operates. At this time, the compressor is off, and only the fan is in operation. When the FAN button is pressed again, the fan stops. (3) Cool mode When the COOL ON/OFF button is pressed, the FAN ON LED illuminates, and room temperature is shown on the display. At this time, the compressor and fan begin to operate to provide cooling. When the COOL ON/OFF button is pressed again, the compressor and fan stop. When the COOL ON/OFF button is pressed in fan only mode, room temperature is shown on the display, and the compressor operates to provide cooling. If room temperature reaches the set temperature during cooling operations, the compressor stops, and only the fan continues to operate. (Fan operate mode: * Initial setting) < NOTE > The fan only mode will not operate after the cool mode has been activated. Once the cool mode is activated, the unit cannot be turned off by pressing the fan button. Rather, the COOL ON/OFF button must be pressed. *Fan stop mode - In fan stop mode, if room temperature reaches the set temperature during cooling operations, both the compressor and fan stop. The fan stop mode setting can be changed using the dip switch on the relay board. (For details, refer to page 23). During cooling operations when in the fan stop mode, the FAN AUTO LED illuminates. (4) Change temperature mode C and F The temperature display can be switched between C and F by holding the SET TEMP arrow buttons (, ) and the FAN button down simultaneously for 3 seconds. (5) Diagnostic code Most of the diagnostic codes can be RESET by holding the SET TEMP arrow buttons (, ) down simultaneously for 3 seconds. (For details, refer to page 33.)
32 32 Repair Section 7. TROUBLESHOOTING 7.1 Troubleshooting Before troubleshooting the system, the following inspection should be performed. WARNING Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. (1) Inspection of power supply Check the voltage of the power source. - 1 Phase, 230 V, 50 Hz Test the power supply circuit breaker and residual current device (RCD) before connecting the unit and then at least once a month during operation. (2) Inspection of air filters Remove the air filters and check the filter elements. If the elements are dirty, remove dust with a vacuum cleaner, or rinse in cold or lukewarm water. If the elements are extremely dirty, wash with a neutral detergent. Affer the filter elements have been cleaned, rinse with clean running water, allow to dry, then reinstall. (3) Inspection of drain tank Make sure the tank is fully drained. The following pages (page 33 to 37) are self-diagnostic codes and troubleshooting information.
33 Repair Section Self-Diagnostic Codes Self-diagnostic codes are displayed on the control panel under the following conditions. Refer to the troubleshooting chart on page 35 and 36 for the remedies. Indication Condition Buzzer *1 No. 1 When the drain tank switch is activated, the LED displays FL and the unit turns off automatically. No No. 2 When evaporator inlet air thermistor becomes open or shorted, display shows E1 and cool mode operation is off. No No. 3 When freeze protection thermistor becomes open or shorted, display shows E2 and cool mode operation is off. No < NOTE > *1: Buzzer is located on the relay board.
34 34 Repair Section 7.3 Troubleshooting Chart To accurately troubleshoot the problem, it is important to carefully confirm the nature of the problem. Common problems are: - Insufficient cooling. - Unit does not operate. - Overflow of drain water. - Abnormal noise or vibrations. - Others. (1) Insufficient cooling Cooling system problem generally results from electrical or mechanical components such as fan motor, compressor, and control switch. Condition Possible Cause Insufficient Cooling Check Area Cause Remedy Air volume normal Compressor operates. Compressor does not operate. 1. Usage conditions (high temperature). Operation near usage limits. Review the installation place. 2. Dirt in condenser or Insufficient heat exchange. Clean fins. evaporator. 3. Frost in refrigeration cycle. Clogging at the frost section. Replace clogged section. 4. No temperature difference between evaporator and condenser. Insufficient refrigerant. Check the leaking part, then repair and charge refrigerant. 1. Compressor coil resistance. (0 ohm or ohm Short or open circuit. Replace compressor. (In case of short, check the compressor relay on the relay board) 2. Compressor on/off relay Open circuit or insufficient Replace relay board. (52CM) on the relay board. contact. 3. Capacitor for compressor Capacitor malfunction. Replace capacitor. and fan motor. 4. Compressor overload relay. Overload relay fault. Replace overload relay. 5. Voltage. Low voltage. Repair power supply.
35 Repair Section 35 Condition Possible Cause Insufficient Cooling Check Area Cause Remedy 1. Coil resistance of fan motor. (0 ohm or ohm) Short or open circuit. Replace fan motor. 2. Fan motor on-off relay (52ID) on the relay board. No air. 3. Auxiliary relay in the control box. Insufficient air volume Open circuit or insufficient Replace relay board. contact. Open circuit or insufficient Replace auxiliary relay. contact. No excite coil on the relay Check and replace relay (no voltage). board. 1. Air filter. Clogged air filter. Clean air filter. Insufficient air volume. 2. Evaporator. Clogged evaporator or crushed fins. Repair and clean fins, or replace evaporator. 3. Duct connection state. Improper connection. Repair duct connection. 4. Fan motor. Insufficient rotation. Replace motor. (2) Unit does not operate or stops operation This problem occurs mainly from the safety devices, electrical components, environmental condition, or installation location. Refer to the troubleshooting chart below and page 36 for possible causes of unit does not operate or stops operation and remedies. Condition Possible Cause Remedy Unit does not operate. Check Area Cause 1. Voltage. Power failure. Repair power. Control 2. Ground fault breaker trip. Ground fault or defective Repair ground fault Control panel ground fault breaker. section. panel LED display does Reset or repair breaker. display not show turns off. 3. Fuse. Fuse blown. Repair shorting section. error codes. Repair fuse on the relay board. Condition Possible Cause Unit stops operation. Check Area Cause 1. Display code FL. Drain tank is filled with the drain water. Control Control Loose drain switch panel panel LED connection. display display shows error turns off. codes. Defective Drain Switch. Remedy Discharge the drain water. RESET the controller *1. Reconnect the drain switch and check the connection. RESET the controller *1. Replace the drain switch. RESET the controller *1. *1 : To RESET the controller, press SET TEMP ( / ) buttons simultaneously for 3 seconds.
36 36 Repair Section Condition Possible Cause Remedy Unit stops operation. Check Area Cause Control Control panel panel LED display display shows error turns off. codes. Unit stops Control immediately panel LED after displays starting. normal. 2. Display code E1. Loose evaporator inlet air thermistor. Reconnect the evaporator inlet air thermistor and check the connection. RESET the controller *1. Defective evaporator inlet air thermistor. Replace the evaporator inlet air thermistor. 3. Display code E2. Loose freeze protection thermistor. Reconnect the freeze protection thermistor and check the connection. RESET the controller *1. Defective freeze protection thermistor. Replace the freeze protection thermistor. 1. Fan Motor on/off relay (52ID) on the relay board. 2. Fan Motor insulation resistance. 3. Compressor insulation resistance. Open circuit or insufficient Replace relay board. contact. Insulation failure on fan Replace fan motor. motor. Insulation failure on Replace compressor. compressor. 1. Coil resistance of fan motor. Defective fan motor. Replace fan motor. Unit stops after running for a while. Control panel LED displays normal. 2. Temperature of fan motor Operation of safety device Replace fan motor. abnormally high. (IOLF) due to fan motor malfunction. 3. Temperature of compressor Operation of safety device Replace compressor. abnormally high. (OLC) due to compressor malfunction. 4. Refrigerant leakage. Insufficient refrigerant or gas leakage. Repair and charge refrigerant. 5. Dirt on evaporator. Insufficient cooling of Clean evaporator. evaporator. 6. Duct connection state. Improper connection. Repair duct connection. *1 : To RESET the controller, press SET TEMP ( / ) buttons simultaneously for 3 seconds.
37 Repair Section 37 (3) Overflow of water from the unit Condition Possible Cause Remedy Check Area Cause 1. Drain pan. Cracks in drain pan. Check and replace. 2. Water level in drain pan. Clogged drain hose. Check and repair. Overflow from the unit. 3. Drain hole. Reversed air flow from drain hole. 4. Clogged air filter. Reversed air flow from drain hole due to the excessive negative pressure inside of the unit. Insert a trap on the discharge drain hose. Clean air filter. (4) Abnormal noise or vibration To prevent from abnormal noise or vibration, carefully determine the source of the problem and come up with proper countermeasures to solve the problem so that it does not occur again. Condition Check Area Possible Cause Cause Remedy 1. Fan. Fan interference. Repair interfering section. Abnormal noise or vibration. Fan deformation. Replace fan. 2. Compressor fixing nuts. Loose nuts. Tighten nuts further. 3. Piping. Pipe interference. Repair interfering section. 4. Panel fixing screws. Loose screws. Tighten screws further. (5) Others For any other problems, please contact your MovinCool service representative or DENSO.
38 38 Repair Section 7.4 Basic Inspection Perform the following inspections before disassembly. (1) Inspection of plate fins To inspect the plate fins of the condenser, the air filter must be removed. After removal of the air filters, inspect the plate fins for any dirt, dust, lint, or debris that may have caused insufficient cooling performance of the unit. If cleaning of the fins is necessary, it is recommended that this service be performed by a qualified service technician. I (2) Inspection of spine fins Remove the air filters and inspect the spine fins of the evaporator for any dirt, dust, lint, or debris that may cause poor cooling performance. If spine fin cleaning is necessary, it is recommended that this service be performed by a qualified service technician. I (3) Examination of operating environment Operating environments can vary depending on location, climate and surrounding conditions. Installation location can also cause operational problems. Consult with your reseller concerning operational environment requirements. (4) Cooling capacity inspection Measure the temperature difference between the evaporator inlet and the cooling air duct outlet. If the difference is out of the range shown in the graphs on page 10 and 11, proceed with the remedy suggested in the troubleshooting chart on page 34 to 37. Thermometer Cooling Air Duct Inlet of Evaporator I001699
39 Repair Section Compressor Inspection (1) Compressor motor inspection Measure resistance across the terminals of the compressor motor. Resistance at 25 C C S R R-C Approx ohm C-S Approx ohm If the measured resistance is not equal to the standard values listed above, replace the I compressor. The compressor has an external overload relay. The overload relay should be operational if the above resistance is obtained under normal temperature. For overload relay specifications, refer to the chart below. (2) Overload relay inspection Check for continuity across two terminals of the overload relay. At normal temperature, there should be continuity across the terminals. Operating Temperature OFF (open contacts) ON (closed contacts) 158 C 75 C If there is no continuity across the terminals, replace the overload relay. I Fan Motor Inspection Measure resistance across the terminals of the fan motor. Resistance at 20 C CF1-RX12 Approx.14.4 ohm CF2-RX14 Approx ohm RX14 If the measured resistance is not equal to the standard values listed above, replace the fan motor. CF2 CF1 ILL
40 40 Repair Section 7.7 Capacitor Inspection (For Fan Motor and Compressor) (1) Ohmmeter method Set the ohmmeter to the 10 M ohm range. Place the two probes against the two terminals of the capacitor. At first, the ohmmeter indicates small value, then the reading should gradually increase towards infinity ( ), indicating that the capacitor is charging. If the reading indicates infinity immediately (open), or the ohmmeter fails to move from 0 ohm (shorted), replace the capacitor. (2) Capacitance tester method Use a capacitance tester to check the capacitor for the values indicated below. If the value tested is not within 10 % of the indicated capacitance, replace the capacitor. Capacitor Rated Voltage Capacitance For Fan Motor 400 V 10 µf For Compressor 400 V 35 µf WARNING ILL Properly discharge the capacitor(s) before and after testing. Failure to discharge the capacitor may cause damage to the test equipment and/or unit, and result in personal injury (electrical shock) or death.
41 Repair Section Auxiliary Relay Inspection Check the continuity across the terminals 13 and 14, when the test button is depressed as well as when released. Terminals State of Reset Switch Continuity Depressed Released Continuity No continuity (Reference) Depressed Released Continuity No continuity Depressed Released Continuity No continuity A1 43/41-44/42 Depressed Released Continuity No continuity 14 A2 I Full Drain Switch Inspection Depress the full drain switch to check for continuity. If there is no continuity, replace the switch. Normally: Continuity across 1 and 2. Switch Depressed: Continuity across 1 and 3. Relay Board (CN16) Full Drain Switch NC (2) 2 NC 1 NO 3 COM C (1) I Thermistor Inspection Use an ohmmeter to check the resistance across the 2-pin connector at normal temperature (25 C). Type Evaporator Inlet Air Thermistor (RTS) Freeze Protection Thermistor (CTS) Specification Characteristic 5 k ohm at 25 C 5 k ohm at 25 C I001695
42 42 Repair Section 7.11 Wiring Connection Inspection Refer to the wiring diagram on page 19, and check the connection of each wire. 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 Inspection of Refrigeration System In most cases, the probable cause for insufficient cooling is a clog in the system, a leakage, or an incorrect amount of refrigerant. In such cases, inspect the system according to the following procedure. (1) Clogged refrigeration system Check the component parts of the refrigeration system, including piping, that could be clogged with refrigerant. If clogged with refrigerant, only the clogged part is partially frosted. If this occurs, change the part in question. (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. (3) Insufficient refrigerant When the unit is not producing sufficient cooling, follow the troubleshooting chart on page 34 and 35 to confirm the cause of the problem. If insufficient refrigerant is suspected, refer to Section 9 (Refrigeration System Repair) on page 55.
43 Repair Section DISASSEMBLY WARNING Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. 8.1 Parts Construction Control Panel Evaporator Inlet Air Thermistor Upper Panel Cooling Air Duct Right Side Panel Air Filter Front Panel Housing for Condenser Fan Air Filter Condenser Fan and Motor Housing for Evaporator Fan Left Side Panel Rear Panel Drain Pan Drain Tank Service Panel Full Drain Switch Locking Swivel Caster Caster Power Cord ILL
44 44 Repair Section 8.2 Disassembly Cooling Air Duct Screws (8) 1) Remove the drain tank. 2) Unfasten the two clips and the lower-side hook, and then remove the front panel. 3) Take out the eight (8) screws, and then remove the two cooling air ducts. Front Panel Drain Tank I Service Panel 4) Take out the six (6) screws, and then remove the service panel. Screws (6) ILL ) Remove the two (2) power supply lines from the terminal block, and remove the ground wire. TB: Terminal Block Power Supply Lines (2) Ground Wire ILL
45 Repair Section 45 6) Take out the thirteen (13) screws, and then remove the rear panel. Screws (13) Rear Panel ILL Screws (4) Screws (2) Upper Panel Screws (4) 7) Take out the fourteen (14) screws, and then remove the upper panel. CAUTION The two screws (2*) used on the front side of the upper panel differ from the rest. Ensure that the correct screws are used when attaching the upper panel. Screws (2*) Upper Panel Screws (2) Clamp Housing for Condenser Fan I ) Unfasten the connector on the evaporator inlet air thermistor wiring harness. 9) Remove the wiring harness from the clamp. Evaporator Inlet Air Thermistor Harness Connector ILL
46 46 Repair Section Connectors Upper Panel Control Panel Board Clamp 10) Unfasten the two connectors (11-pin, 5-pin) from the control panel. 11) Remove the wiring harnesses from the clamp and board clamp. Clamp I Left Side Panel Screws (6) Screw (1*) I ) Take out the seven (7) screws, and then remove the left-side panel. CAUTION The screw (1*) on the front side of the left-side panel differs from the rest. Ensure that the correct screw is used when attaching the left-side panel. Air Filter 13) Remove the two air filters from the right-side panel. Air Filter I Screw (1*) Screws (6) Screws (6) Right Side Panel I ) Take out the thirteen (13) screws, and then remove the right-side panel. CAUTION The screw (1*) on the front side of the rightside panel differs from the rest. Ensure that the correct screw is used when attaching the right-side panel.
47 Repair Section Fan Motor Removal Housing for Evaporator Fan Condenser Fan Evaporator Fan Partition Plate Fan Motor Motor Bracket Housing for Condenser Fan ILL
48 48 Repair Section Condenser Fan 1) Loosen the set screw with a hex key, and then remove the condenser fan. CAUTION Set Screw Torque Value (for Installation) ± 3.0 N m Set Screw I Housing for Condenser Fan 2) Take off the two (2) nuts, and then remove the condenser fan housing. Nuts (2) I Nuts (4) 3) Take off the four (4) nuts, and then remove the fan motor together with the motor bracket. Fan Motor Motor Bracket I Set Screw 4) Loosen the set screw with a hex key, and then remove the evaporator fan. Evaporator Fan I001740
49 Repair Section 49 Nuts (4) 5) Take off the four (4) nuts, and then remove the fan motor. Fan Motor I002616
50 50 Repair Section 8.4 Removal of Electrical Components WARNING Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. (1) Removal of control panel 1) Take out the eight (8) screws, and then remove the control panel. Control Panel Screws (8) I002615
51 Repair Section 51 (2) Removal of wire-harness in control box Disconnect all the wires from the electrical parts in control box. 2-P (Red) 3-P (Black) 2-P (Black) 52CM4 (White) CN15 CN16 CN14 CN02 CN03 CN04 CN11 CN12 CN13 52CM3 (White) 5-P RB 4 52CM 3 CN17 CN25 5-P (Black) CN01 11-P RX13 (Black) CN24 TB TBR (White) RXA1 (Black) RX TBT (Black) RXA2 (Black) L1 L2 1 2 CC1 (White) 1 2 CF1 (Black) CC CF ILL
52 52 Repair Section (3) Removal of control box Control Box 1) Take off the three (3) nuts, and then remove the control box. Nuts (3) I002606
53 Repair Section 53 (4) Removal of electrical parts Terminal block (power connection): Remove the two (2) screws from the control box. Auxiliary relay: Remove the relay from the holder. Capacitor for compressor: Remove the two (2) screws from the control box. Capacitor for fan motor: Remove the two (2) screws from the control box. Relay board: Remove the six (6) supports from the relay board. RX: Auxiliary Relay Control Box RB: Relay Board Support TB: Terminal Block CC: Capacitor for Compressor CF: Capacitor for Fan Motor ILL
54 54 Repair Section 8.5 Full Drain Switch Removal 1) Take out the two (2) screws, and then remove the full drain switch cover. Screws (2) Full Drain Switch Cover I Harness Connector 2) Unfasten the wiring harness connector. 3) Take out the two (2) screws, and then remove the full drain switch. Screws (2) Full Drain Switch I002610
55 Repair Section REFRIGERATION SYSTEM REPAIR WARNING This air conditioner uses R-410A refrigerant under high pressure. It is both dangerous and illegal to tamper with the sealed refrigerant system without appropriate licensing and training. Deliberate release of refrigerant is illegal in Australia, New Zealand and other regions. Fully recover all refrigerant before attempting to remove or repair any refrigeration system components. Ensure that the system is free of leaks before charging with refrigerant. Observe Refrigerant Handling Code of Practice and all other applicable regulatory requirements. 9.1 Repair of Refrigeration System When there is a leak, obstruction, or problem in the refrigeration system of this unit, replace or repair the part in question. After replacing any component, all connections must be brazed. (1) Proper brazing techniques It is desirable to use a slightly reduced 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 the brazing filler metal, oxidation of the brazing filler metal, or deterioration due to overheating of flux. (2) Brazed fittings and fitting clearance In general, the strength of the brazing filler metal is lower than the base metal. Therefore the shape and clearance of brazed fittings are quite important. As for the shape of 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. a Clearance a 0.025~0.075 mm Clearance From The Pipe Fitting and Tubing. ILL
56 56 Repair Section (3) Cleaning brazing filler metal and piping When the refrigeration system has been opened up, exposure to the 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 the oxide film. Fat and oils may stick to the pipe from handling. All these factors can reduce the 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. CAUTION Do not use chlorine cleaner. (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 1 L/min; adjust with the flow regulator) through the pinch-off tube of the refrigerant. < NOTE > Take care not to allow dirt, water, oil, etc. to enter into the pipe. (5) Vertical joint 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 clearance. Since the brazing filler metal flows easily into the portion heated to a proper temperature, it is essential to keep the whole fitting at a proper brazing temperature. Tube 45 Vertical Down Joint Brazing Filler Metal Burner I Tube Vertical Up Joint 45 Burner Brazing Filler Metal I001725