MovinCool Office Pro 12 Service manual
Contents
1. 59 68 77 Wet Bulb Temperature C F Cooling Capability Curve Temperature C Power Consumption kW Dry Bulb Temperature C F Cool Air Temperature Difference Curve 0 8 35 95 30 86 25 77 Q 115V 40 50 60 70 Relative Humidity of Inlet Air 96 Q 115V 15 20 25 30 59 68 77 86 Wet Bulb Temperature Power Consumption Curve REFRIGERANT SYSTEM 1 The component parts of the refrigerant system include the following Compressor e Evaporator Condenser e Accumulator Capillary tube These parts are all connected by copper piping All the connections have been brazed A EVAPORATOR CONDENSER A J 4 CAPILLARY TUBE ACCUMULATOR ia COMPRESSOR 6 REFRIGERANT FLOW gt ACCUMULATOR CAPILLAR Refrigerant System REFRIGERANT SYSTEM 2 Compressor The compressor used for the unit is hermetically sealed The compressor and the compressor motor are in one casing A 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 of the compres sor compression mechanism2. DIP Switch 4 ad o 122 gl E w Fan Motor 370 Compressor 370 B Relay Board Terminal Block The Relay Board receives signals and outputs 219 from the control board that contains a micro eek o Fan Motor processor The relay board contains the Capacitor compressor fan on and fan mode speed relays It also contains a step down trans former that converts the line voltage 115 VAC to 12 volts This is then converted from AC to DC and used for relay coil activation The 12V DC power is sent to the Control Panel Assembly where it is further reduced to 5 volts for the system logic Control Box TNT The relay board also contains the DIP Switch The DIP Switch is used to change the Fan c Mode operation from Stop to Operate and change both the Set Point and Room tem perature display from F to C The relay board must be serviced as a complete assembly It has only one service able component the fuse See below Relay Board Fuse The relay board fuse is the only serviceable component on the relay board assembly This fuse provides protection against damage Pelay Board to the step down transformer It must be replaced with the exac
3. High Pressure Gauge 2 Turn on the vacuum pump to start evacuation Evacuate the system for approximately 15 minutes 3 When the low pressure gauge indicates 750mmHg 30in Hg or larger turn off the vacuum pump and close the high and low Wu gt pressure valves of the gauge manifold T 7 Vacuum Pump in operation C Checking Vacuum Leave valves closed for 5 minutes 1 Leave the high pressure valve and the c primera Pointer ef lew low pressure valve of the gauge manifold gauge returning to zero indicates closed for five minutes or more and 4 there is a leak confirm that the gauge pointer does not Low Pressure Gauge return to zero 2 If the gauge pointer returns gradually to zero there is a leak somewhere in the system this could also include gauge manifold Perform leak check according to procedure indicated in 20D Once leak has been found and repaired evacuate the system once more and confirm system holds vacuum Brazing of Piping D Checking Gas Leak Valve 1 Remove the charging hose green from the vacuum pump and connect the hose to the refrigerant cylinder R22 Air Purging 453 of Refrigerant Cylinder 4 Charging Hose green gerant Hed To Process Tube Fitting TROUBLESHOOTING AND REPAIR Valve Setting LO HI Low Pressure LO Hi Closed Open Gauge Reading Closed Closed Low Pressure Gauge
4. CONDENSER INLET PIPE COMPRESSOR SUCTION PIPE EVAPORATOR Insulated OUTLET PIPE 2 gt ASSY COMPRESSOR DISCHARGE PIPE CAPILLARY TUBE CONDENSER CONNECTING TUBE Condenser to Capillary Tube P CONNECTING PIPE Evaporator to Compressor Refrigerant System Piping ELECTRICAL SYSTEM LO HI f VEN J8 AUX1 00000 OO Attachment Plug Overload Relay of Compressor Terminal Block DS Full Drain Warning Switch Control Board THS Freeze Protection Thermister Relay Board RTH Room Thermister Fan Motor SCP Short Circuit Plate Compressor Motor G Ground Capacitor for Fan J8 AUX1 Auxiliary Connector CPK 3 Capacitor for Compressor AUX2 Auxiliary Connector not used RELAY BOARD DIP SWITCH CAPACITOR Electrical System and Control Box for Office Pro 12 ELECTRICAL SYSTEM 1 Basic Operation Of the Office Pio 12 Electrical Circuit There are two basic components used to control the operation of the Cf ce Pro 12 Electrical System Control Panel Assembly Control Box The Control Panel Assembly contains the Control Panel Control Board inputs for the freeze and room temperature thermisters drain switch and a microprocessor Fan Only Mode Low Fan Mode When the Low Fan Mode button on the control panel is pressed the microprocessor turns on the buttons LED and activates the Fan On Relay Relay Board sending l
5. EVAPORATOR INDOOR UNIT GENERAL DESCRIPTION CONSTRUCTION AND SPECIFICATIONS CONSTRUCTION AND SPECIFICATIONS 1 Basic Construction The MovinCool Spot Cooling System is compact in construction because the condenser and the evaporator are enclosed in one unit The interior is divided into three sections The upper front face is equipped with the evaporator while the lower front face contains the drain tank The rear section contains the condenser the compressor and the control box 2 Air Flow Air drawn from the right side face passes through the condenser which extracts the heat This hot EXHAUST air is blown out through the upper exhaust air AIR OUT duct Air taken in from the front face is cooled by the evaporator and then blown through the cool air vent All the air inlets are equipped with filters while the exhaust air duct is protected by wire mesh EVAPORATOR AIR IN 7 CONDENSER AIR IN 3 Compressor and Fans The compressor is hermetically sealed A two speed fan motor is used with two centrifugal fans to draw air across the evaporator and condenser
6. Environmental conditions exceed design specifications Clogged air filter Insufficient Cooling d Compressor not operating Fan Motor not operating e Clogged spine fins e Set point temperature exceeds room temperature Defective room temperature thermister Leak in refrigerant system Restriction in refrigerant system Compressor not operating Set point temperature exceeds room temperature Unit is operating in Fan Only Mode Cool Mode not activated Jumper on Control Board J104 not installed correctly Jumper on Relay Board J8 not installed correctly Defective Condensate Pump optional Defective Compressor Capacitor Defective overload relay Defective Thermister Defective Compressor Motor Check wiring connections Defective Relay Board Defective Control Board Fan mode switch is set to Stop and current Set Point Temperature exceeds Room Temperature Fan mode switch is set to Stop and unit has been equipped with optional Condensate Pump that is defective Fan mode switch is set to Stop and Jumper on Control Board J104 or Relay Board J8 is not installed correctly Check wire connections Defective fan motor capacitor Defective fan motor Defective Relay Board Defective Control Board TROUBLESHOOTING AND REPAIR In case of trouble perform the following inspection before disassembly 5 Inspection of Spine Fins To inspect the spine fins of either the evaporator or cond
7. f 0 06 inches 1 0 06 inches 1 5 mm or more 38 Reassemble the unit in the reverse order of removal Described below are the parts that require special care in reassembling the unit Perform all wiring or rewiring as referenced in the wiring diagram 22 Compressor Mounting Mount the compressor on the frame using cushions steel collars spring washers plate washers and nuts 23 Blower Assembly Install blower fans for evaporator and con denser Tightening torque 10 84 2 17 Ibfeft 150 30 kgfecm 24 Wiring Notice Secure the wires using clamps so that they do not come into contact with the edges of the structure etc Secure the wires using clamps in the same position they were before removal 25 Perform the inspection of cooling capacity and check for abnormal noise or abnormal vibration TROUBLESHOOTING AND REPAIR 26 Schematic pesn zxnv Md9 1012euuo9 Lxnv er 5 HNI HOUS dOS Jeisiugeu 5 uonoejoJd 2 SHL youms Aejay 910 JosseJduijo 104 10112ede uey JOJO 40sse14duio5 4010 N p4eog pieog 1 39 do au 99 91
8. 39 NOTES 40 DENSO DENSO SALES CALIFORNIA INC TECHNICAL SERVICE DEPARTMENT Second Issue November 1998 First Issue October 1998 DSCA P N LA990009 0435 Printed in USA DSCA P N LA990009 0435
9. wash it as described in the OPERATION MANUAL supplied with the unit 3 Inspection of Drain Tank Be sure tank is fully drained The following chart is provided as a guide for categorized problem remedies Detailed information is contained in the OPERATION MANUAL supplied with the unit 4 e s Chart Probable Case Probable Case Unit does not operate at all Unit starts but stops immediately Unit operates but stops after a few minutes Water leakage from the unit Abnormal noise and or shaking Insufficient Air Flow Insufficient Cooling Check for Power at Receptacle Check for Power at Terminal Board Check for Power at Relay Board Check all wire connections Defective Drain Tank Switch Check Relay Board Fuse Defective Relay Board Defective Control Board Defective Overload Relay Defective Fan Motor Defective Compressor Motor Defective Relay Board Defective Compressor Motor Defective Overload Relay Defective Fan Motor Drain Tank Full Fan Mode Switch is set to Stop and compressor cycled off Drain Tank not installed Drain Tank is defective cracked Drain Pan hole is obstructed Loose Compressor mounting nut Deformed or worn rubber grommet on the compressor mounting bolt Internal interference with other components Damaged or out of balance fan and scroll Clogged spine fins or Evaporator or Condenser running unit without filter s Fan mode switch on Low Defective fan motor
10. 0 95 Ibs 430g If the system cannot be charged with the specified amount of refrigerant under this condition follow the steps below a Close the high pressure valve of manifold b Operate the refrigerant system c Slowly open the low pressure valve while observing the scale reading d When the scale reads the specified amount immediately close the low pressure valve e Bring the system to a stop 10 Specified Amount Valve Setting LO HI Closed Low Pressure Valve Valve of Refrigerant Cylinder of Refrigerant Closed Closed High Pressure 22 Side Tube Low Pressure Side Tube ANCAUTION 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 B Removal of Gauge Manifold 1 Crimp the pinch off tube with a pinch off Pinch off Tool tool a To Gauge Manifold Side 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 To Refrigerant Cycle Side Y Charging Hose Process Tube Fitting end 37 TROUBLESHOOTING AND REPAIR pA Cushion Steel Collar
11. Motor Overload Relay R Terminal High Speed To Fan Motor To Terminal Block Low Speed T Terminal Relay Board Ground not used OPERATE F DIP Switch Temperature Scale Display Switch BC Fan Mode Control Switch Relay Board Fuse STOP gt OPERATE F 5 Qo STi Main Wiring Harness Jumper or 2 Pin Connector of Relay Board to Control Panel optional Condensate Pump Kit CPK 3 Connections to Relay Board Jumper Drain Tank Switch NOT USED Freeze Thermistor 5 5 C 5 Room Thermistor Main Wiring Harness Control Panel to Relay Board 0 Connections to Control Board 25 TROUBLESHOOTING AND REPAIR 10 Removal of Blower Assembly Control Panel Right Stay v Control Panel Left Stay wl ye Evaporator Fan Motor Stay e Middle Frame Sub Assy Fan Motor Casing Assy Condenser Fan Ring Sub Assy Disassembly of Blower 26 TROUBLESHOOTING AND REPAIR A Loosen the set screw using an allen wrench and then remove the centifugal fan B Remove the two 2 nuts as shown Then remove the blower housing condenser C Remove the two 2 nuts and two 2 screws as shown Then remove the motor bracket together with the fan motor D Remove the centrifugal fan by loosening the set screw
12. rotates to compress the refrigerant B Basic Compressor Operation DISCHARGE HOLE The roller compression mechanism is set DISCHARGE SPRING eccentrically with a certain distance given VALVE SUCTION from the axis of the center of the cylinder A 5 HOLE 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 It partitions the space between the suction side and the discharge CYLINDER side to keep compressed refrigerant from returning to the suction side Compressor Operation 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 that of the refrigerant on the discharge side It thus prevents the backward flow of discharge gas 3 Condenser The condenser is a heat exchanger whose copper tubes are covered with thin aluminum projections called spine fins Heat is given of and absorbed by air being pulled across the condenser fins by the centrifugal fan and then expelled through the exhaust air duct REFRIGERANT SYSTEM 4 Capillary Tube High Temp High Press The capillary tube is a long thin tube and its line Liquid Refrigerant flow resistance serves as an expansion valve The prs length and the inner diameter of the capillary tube are determined according
13. timer included two speed fan included Specifications Specifications are subject to change without notice CONSTRUCTION AND SPECIFICATIONS EXHAUST AIR VENT gt E r COOL AIR VENT EVAPORATOR CENTRIFUGAL FAN CONDENSER CAPILLARY TUBE DRAIN TANK COMPRESSOR Construction of Office Pro 12 CONSTRUCTION AND SPECIFICATIONS EVAPORATOR FAN CONTROL PANEL TOP PANEL a EXHAUST AIR VENT RIGHT HANDLE 2 COOL VENT 9 L3 SIDE PANEL FRONT PANEL 6 gt FAN MOTOR TL BENE s CONDENSER FAN EVAPORATOR 123 Te COMPRESSOR CAPILLARY TUBE DRAIN TANK 9 ccumutaton 7 CONDENSER 0 POWER CORD Construction Diagram CONSTRUCTION AND SPECIFICATIONS Cooling Capability x10 kcal h BTU h Dry Bulb Temperature C 3 6 14 3 3 2 12 7 2 8 11 1 2 4 9 5 2 0 7 9 35 95 30 86 25 77 Q 115V
14. to the microprocessor through the J103 connector _ BRAIN WATER 13 As amp s joa pit Operation of Drain Switch 7 9 How to re start the unit If the program Run LED is flashing press the Cool On Off button to continue running the program If the program Run LED is illuminated continuously program activated no further steps are necessary If no program exists or the program was deactivated press one of the fan mode buttons or the Cool On Off button The unit will return to the previous Temperature Set Point Condensate Pump Kit optional The Office Pro 12 model comes standard with a drain tank which collects the water that forms on the evaporator during normal cooling operation If the unit is required to operate continuously without periodic emptying of this tank a condensate pump may be needed A condensate pump kit CPK 3 is available for the Office Pro 12 model Automatic Restart after Power Interruption The program within the microprocessor of the Office Pro 12 contains a feature that will automatically re start 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 ELECTRICAL SYSTEM 10 Compressor Piotection There is a Time Delay program with
15. 4 Drain Tank The capacity of the drain tank is 5 0 gallons 19 liters The unit is equipped with a full tank LED and a device to automatically stop the unit operation when the drain tank reaches a level of approximately 4 0 gallons 15 liters CONSTRUCTION AND SPECIFICATIONS Rating Conditions ary bulb 80 F 26 6 C wet bulb 67 F 19 4 C humidity Specifications power frequency line voltage single phase 115 V power consumption 1 28 Kw current consumption power factor starting current power wiring Cooling Unit cooling capability 2 870 Kcal hr 11 480 BTU hr direct expansion Blower type of fan centrifugal fan ar Volume E Evaporator Hi speed 441 ft3 min Condenser Hi speed 823 ft min MOOr outpUl cui tese breue tees eint ive tt 0 14 Kw Hi nS 0 08 Kw Lo Compressor rotary uc 0 8 Kw refrigerant type refrigerant capacity 0 95 Ibs 0 43 kg Safety Devices compressor overload relay included fan motor protector included anti freezing thermister included full drain tank switch included power interruption feature included time delay feature included Dimensions amp Weight W x Dx Hin mm 21 2 x 27 4 x 44 539 x 696 x 1118 weight Ibs kg 165 75 Operating Conditions inlet air relative humidity 95 F 35 lt 50 65 F 18 3 C gt 50 Control Device temperature control included programmable
16. 4 kglcm G 4 kg cm G 57 psiG 157 psiG N Low Pressure Valve A a Open High Pressure Valve closed 49 Process Tube Fitting 1 a High Pressure Side Tube Refrigerant Cylinder open Du Low Pressure Side Tube SS f i Refrigerant vkCylinder ANWARNING Before checking for gas leaks fully confirm that there is nothing flammable in the area to cause an explosion or fire Contact of refrigerant with an open fire generates toxic gas Valve Setting Low Pressure Gauge HL LO HI Open Open losedi Closed 750 mmHg or larger Gauges High Pressure Gauge v 7 Low Pressure zx gt High Pressure Valve High Pressure S gt Side Tube ay Low Pressure Tp Side Tube Vacuum Pump in operation Valve Setting Hi _ Closed Air Purging Open The Valve lt of Refrigerant EX Cylinder Blue Charging Hose green Red To Process Tube Fitting 2 Refrigerant t Cylinder R 22 3 36 2 Loosen the nut on the gauge manifold side of the charging hose green 3 Open the high pressure valve of the gauge manifold Charge the system with refrigerant until the low pressure gauge indicates 57 PSIG 4 kg cm G After charging is complete close the high pressure valve 4 Check carefully for gas leaks inside the refrigerant system using the gas leak tester b Repair any
17. IR B Removal of Refrigerant Cycle Components A CAUTION 1 Before any refrigerant cycle component can be replaced it is necessary to recover the refrigerant using standard recovery procedures and equipment 2 To prevent oxidation dry nitrogen should be conducted flow rate 1l min through the pinch off tube during any brazing operation 3 During any component replacement involving brazing shield nearby parts with a steel plate asbes tos etc to protect them from the flame 1 Evaporator 2 Capillary tube 3 Condenser 4 Compressor NOTE Hold the compressor body not the tube when carrying the compressor PART TO REPLACE DISCONNECT AT Compressor A amp B Condenser A amp C Capillary Tube D E amp G Evaporator E amp F TROUBLESHOOTING AND REPAIR 20 Charging the System with R 22 Refrigerant Always ensure that the refrigerant system has been properly evacuated before charging with the specified amount of R 22 A WARNING When handling refrigerant R 22 the following precautions should always be observed e Always wear proper eye protection while handling refrigerant Maintain the temperature of the refrigerant container below 40 C 104 F 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 e Be care
18. OUBLESHOOTING AND REPAIR A Remove drain tan C Slide upper front panel forward and remove TROUBLESHOOTING AND REPAIR Removal of Air Outlet Louver Removal of Service panel Removal of Power Cord Screws DISCONNECT DISCONNECT DISCONNECT 23 D Louver can be removed from upper front panel by unsnapping it rearward E Remove four 4 screws from service panel F Disconnect the three 3 lead wires of the power cord TROUBLESHOOTING AND REPAIR G Remove thirteen 13 screws fron rear panel H Remove ten 10 screws eight shown from upper rear panel and two 2 screws on top Removal of Back and Upper Rear panel Screws 9 Removal of Electrical Parts ji OO 0000 Attachment Plug Overload Relay of Compressor Terminal Block DS Full Drain Warning Switch Control Board THS Freeze Protection Thermister Relay Board RTH Room Thermister Fan Motor SCP Short Circuit Plate Compressor Motor G Ground Capacitor for Fan J8 AUX1 Auxiliary Connector CPK 3 Capacitor for Compressor AUX2 Auxiliary Connector not used RELAY BOARD FUSE RELAY BOARD gu DIP SWITCH TERMINAL BLOCK COMPRESSOR CAPACITOR e FAN CAPACITOR Removal of Electrical Parts in the Control Box 24 TROUBLESHOOTING AND REPAIR Pin 42 Compressor To Terminal Block To Fan
19. SERVICE OFFICE PRO 12 cock ERI pE mmm STAR mm NO THA SET CL CK MOVIN Pioneering New Solutions With Portable Air Conditioning 1998 DENSO SALES CALIFORNIA INC All rights reserved This book may not be reproduced or copied in whole or in part without the written permission of the publisher DENSO SALES CALIFORNIA INC reserves the right to make changes without prior notice FOREWORD This manual has been published to service the MovinCool Office Pro 12 Please use this service manual only when servicing the Office Pro 12 DEFINITION OF TERMS ANWARNING Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation A CAUTION Describes precautions that should be observed in order to prevent damage to the unit or its components which may occur during installation or unit operation if sufficient care is not taken NOTE Provides additional information that facilitates installation or unit operation GENERAL PRECAUTIONS AWARNINGS e electrical work if necessary should only be performed by qualified electrical personnel Repair to electrical components by non certified technicians may result in personal injury and or damage to the unit All electrical components replaced must be genuine MovinCool purchased from an autho rized reseller e When handling refrigerant always wear proper eye protection and do not
20. allow the refrigerant to come in contact with your skin expose refrigerant to an open flame e The proper electrical outlet for MovinCool units must be equipped with a UL approved ground fault breaker to prevent electrical shock from the unit e When brazing any tubing always wear eye protection and work only in a well ventilated area Generally speaking conventional air conditioners cool the entire enclosed environment They act as heat exchangers requiring an interior unit evaporator to blow cool air into the interior and an exterior unit condenser to exhaust exchanged heat to the outdoors Unlike conventional air conditioners the MovinCool Spot Cooling System is a spot cooler which directs cool air to particular areas or objects MovinCool Spot Cooling Systems have the following features 1 Compact Design The innovative design of MovinCool has resulted in one compact unit replacing the need for two separate units 2 Easy Transportation and Installation With the whole cooling system built into one compact unit MovinCool requires no piping and can be easily transported and installed 3 Energy Conservation MovinCool is economical because it cools only the area or objects which need to be cooled GENERAL DESCRIPTION CONDENSER OUTDOOR UNIT Conventional Ai Office Pro 12 r Conditioner E
21. an overload condition and a high temperature builds up in the compressor Temperature Variance Trip Time seconds Specifications Contacts Open 284 140 41 F 5C 2 12 Contacts Closed 165 F 74 C 48 F 9 6 ELECTRICAL SYSTEM Drain Switch The Office Pro 12 is equipped with a drain tank switch When the drain tank accumulates approximately 4 0 gallons 15 liters of condensate water in the drain tank the drain tank switch sends a signal to the microprocessor The microprocessor stops all operation of the unit and illuminates the full tank LED This system utilizes a 1 AMP 250 VAC micro switch for this function When drain water accumulates approximately 4 0 gallons 15 liters in the drain tank the drain tank base plate which is supported at its fulcrum is pushed down in the arrow direction as shown in the figure below When the drain tank base plate is forced down the top of the drain tank base plate turns off the contacts 1 2 of the micro switch This causes the ground signal at the J103 connector of the control panel assembly to go open When the microprocessor detects this event it shuts the unit off and illuminates the Full Tank LED When the drain tank is removed or the drain tank is emptied the top of the drain tank base plate returns to its original position from the tension of the coil spring Then contacts 1 2 of the drain tank switch close This provides a ground
22. enser you must remove the air filters After removal of the air filters inspect the spine fins for any dirt dust lint or debris that may have caused poor cooling performance of the unit If cleaning of the spine fins is necessary it is recommended that this service be performed by a qualified service technician 6 Examination of Operating Environment Operating environments will vary depending on location climate and surrounding conditions Installation location also can cause operational problems Consult your reseller concerning operational environment requirements 7T Inspection of Cooling Capacity Measure the difference in temperature between the inlet of the evaporator and the cool air vent If the difference is out of the range given in the graphs on page 8 proceed with the remedy suggested in the troubleshooting chart on page 19 Spine Fins Operating Environment 7 1 THERMOMETER E COOL AIR OUT THERMOMETER EVAPORATOR AIR IN Cooling Capacity TROUBLESHOOTING AND REPAIR 8 Disassembly Right Handle Room Thermistor Left Panel Blower Housing evap Blower Housing Condenser Fan lt f gt Drain Assy Rear Panel e Freeze Thermistor Drain Tank Panel Assy Service Panel 7 Disassembly TR
23. ful 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 e Apply clean petroleum jelly to the skin Go immediately to a physician or to a hospital for professional treatment A Connection of Gauge Manifold 1 Properly remove the crushed end of the pinch off tube at the high pressure side and the low pressure side of the refriger ant cycle with a pipe cutter Refrigerant lt p 2 Fit the process tube fitting to the pinch off tube on both sides Pinch off Tube 3 Connect the charging hoses red high pressure side blue low pressure side of Low Pressure ANg the gauge manifold to the process tube Valve Closed 28 High Pressure Valve Closed fittings Green Hose mG P Red Hose NOTE Connect the hoses using care not to mistake Process Tube Fitting the high pressure side for the low pressure side and vice versa MA Em 4 Connect the charging hose green at the ee eer center of the gauge manifold to the Side Tube vacuum pump Vacuum Pump Z at a stop 34 TROUBLESHOOTING AND REPAIR B Evacuation Valve Setting Low Pressure Gauge 1 Open the high pressure valve HI and the low pressure valve LO of the gauge E open besos manifold mmHg or larger
24. 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 Inspection Of Compressor Page 16 30 TROUBLESHOOTING AND REPAIR 16 Inspection of Wiring Connection Refer to the Wiring Diagrams on page 39 and check for connection of each wire 17 Inspection of Thermister Using an Ohmeter check the resistance value across the 2 pin connector At normal temperature 77 F 25 C either thermister room or freeze should measure approximately 10 000 or 10K ohms 18 Inspection In most cases the probable cause for insufficient cooling is a clogged system leakage or an incorrect amount of refrigerant In such cases inspect the system according to the following procedure A Inspection of Clogged System Check the component parts of the refrigerant system including piping that could be clogged with refrigerant If clogged with refrigerant only the clogged part is frosted partially In such a case change the part in question Inspection of Refrigerant Leak Carefully check all connections and each component for leaks whenever the refrigerant system is installed or repaired Use an electronic gas leak tester to inspect the system Insufficient Refrigerant In case the unit is judged to be deficient in cooling capacity be sure to perform the inspections in 18A and 18B to confirm the cause of trouble After t
25. hat charge the system with refrigerant TROUBLESHOOTING AND REPAIR 19 Repair of Refrigerant System In case there is a leak obstruction or trouble in the refrigerant system of the Spot Cooling System replace or repair the part in question After replacing any component all connections must be brazed A Proper Brazing Techniques It is desirable to use a slightly reducing flame Oxyacetylene is commonly used since it is easy to judge and adjust the condition of the flame Unlike gas welding a secondary flame is used for brazing It is necessary to preheat the base metal properly depending on the shape size or thermal conductivity of the brazed fitting The most important point in flame brazing is to bring the whole brazed fitting to a proper brazing temperature Care should be taken to not cause overflow of brazing filler metal oxidization of brazing filler metal or deterioration due to the overheating of flux BRAZED FITTING AND ITS CLEARANCE In general the strength of brazing filler metal is lower than that of the base metal So the shape and clearance of the brazed fitting are Clearance quite important As for the shape of the 0 025 0 075 mm brazed fitting it is necessary to maximize its adhesive area The clearance of the brazed HE posee fitting must be minimized to facilitate brazing 71 filler metal to flow into it by capillary action e CLEANING OF BRAZING FILLER METAL AND PIPE W
26. hen the refrigerant system has been opened up exposure to heat may have Form The Pipe Fitting with Tubing Tool 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 will reduce effectiveness of brazing It is necessary to eliminate excess brazing filler metal using sand paper and by cleaning Brazing Filler Metal thoroughly with a solvent such as Trichlene e USE OF DRY NITROGEN GAS During brazing the inside of the pipe under goes an oxidative reaction due to the brazing flame Introduce dry nitrogen gas 1l min adjust with the flow regulator through the pinch off tube of the refrigerant cycle to prevent oxidation Vertical Down Joint NOTE Take care not to allow dirt water oil etc to enter into the pipe 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 clear ance Since the brazing filler metal flows Burner easily into the portion heated to a proper temperature it is essential to keep the whole fitting at a proper brazing temperature Brazing Filler Metal TROUBLESHOOTING AND REPA
27. in the microprocessor This prevents a heavy load from being applied on 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 Coon On Qf button tem perature set point thermostatic control power interruption restart or Condensate Pump optional opera tion Time Delay Program Specifications 65 10 sec 11 Temperature COntrol The compressor operation Cool Mode is controlled by the microprocessor which receives input signals from the room temperature thermister evaporator inlet air and the setting of theTemperature Set Point The Temperature Set Point desired room temperature can be adjusted by pressing the buttons on the Control Panel The adjustment range of the Temperature Set point is 65 F to 90 F 18 3 C to 32 C 12 Fan Mode Switch The fan motor operation is controlled by relays on the relay board through a microprocessor in the control panel assembly The fan program in the microprocessor can be changed by a DIP Switch on the left side of the Relay Board located in the Control Box There are two settings A Cool to Stop When the Dip Switch is set in the down or stop position the microprocessor controls the fan motor using the same room temperature thermistor that it uses to control the compressor In this case both the fan and the compressor stop when the microprocessor recei
28. ine voltage 115 VAC to the N C Normally Closed contacts of the fan mode relay This output is connected to the J5 terminal relay board where the LOW SPEED wire of the fan motor is connected High Fan Mode When the High Fan Mode button on the control panel is pressed the microproces sor turns on the buttons LED and activates both the Fan On Relay and Fan Mode Relay This sends line voltage 115 VAC from the Fan On Relay to the N O Normally Open contacts of the Fan Mode Relay This output is connected to the J6 terminal Relay Board where the HIGH SPEED wire of the Fan Motor is connected Cool Mode In addition to Fan Only Mode as described above when the Cool On Off button on the control panel is pressed the microprocessor turns on the buttors LED and if the Temperature Set Point is less than the current room temperature activates the Compressor Relay Relay Board This sends line voltage 115 VAC to the J4 terminal Relay Board where the wire from pin 2 of the Compressor Overload Relay is connected to Pin 1 of the Compressor Overload Relay is connected by wire to the compressor ELECTRICAL SYSTEM 2 Control Box A Capacitors The capacitors are used to temporarily boost the power output available to the fan motor and the compressor at start up e Relay Board The specifications of each capacitor are listed below CAPACITOR VOLTAGE CAPACITANCE APPLICATION RATING uf
29. leak ANWARNING Do not attempt any repair on a charged system E Evacuation Repeat 1 Close the valve of the refrigerant cylinder Then remove the charging hose green from the refrigerant cylinder and connect it to the refrigerant recovery machine NOTE Keep the high pressure valve and the low pressure valve of the gauge manifold closed 2 Using procedure 20B evacuate the system until the low pressure gauge indicates 750mmHg 30in HG or greater For 15 minutes or more 3 After evacuation is complete close the high and the low pressure valves of the gauge manifold A CAUTION Be sure to evacuate the system twice or more using the repetitive vacuum method Evacuate the system an additional time on rainy or humid days 21 Refrigerant Charging Work A Refrigerant Charging 1 Remove the charging hose green from the vacuum pump and connect it to the refrigerant cylinder R 22 2 Loosen the nut on the gauge manifold side of the charging hose green Open the valve of the charging hose green Open the valve of the refrigerant cylinder TROUBLESHOOTING AND REPAIR 3 Securely place the refrigerant cylinder on a scale with a weighing capacity of 70 105 30 kg that is graduated by 0 2 oz 5 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 StandardAmount of Refrigerant 15 2 oz
30. on the shaft Remove the blower by loosening the nuts Removal of Blower 27 TROUBLESHOOTING AND REPAIR E Remove seven 7 screws from left side panel Remove seven 7 screws from right side panel G Remove two 2 screws from the control panel stay H Remove two 2 screws from the control panel stay Removal of Control Panel 28 TROUBLESHOOTING AND REPAIR Removal of Connectors from Control Panel Removal of Control Board 11 12 Inspection of Capacitor Disconnect the following connectors from the control board 1 Wire Harness Relay Board to Control Board J201 10 pin 2 Drain Tank Switch J103 2 pin 3 Room Temperature Thermister J101 2 pin 4 Freeze Thermister J102 2 pin NOTE Mark each of the 2 pin connectors with a different color marker to ensure the correct orienta tion when they are re connected J Remove the five 5 screws from the control board on the control panel assembly Remove the control board Inspection of Capacitor for Fan Motor and Compressor Ohmeter Method Set the ohmeter to the 100KQ range Place the two probes against the two terminals of the capacitor At first the ohmeter should indicate 0Q then the reading should gradually increase towards infinity This indicates that the capacitor is charging If the reading indicates infinity right away
31. shorted or the ohmeter fails to move from 0Q open replace the capacitor Capacitance Tester Method Using a capacitance tester and the chart on page 15 test the capacitor for the value indicated If the value tested is not within 1096 of indicated capacitance replace the capacitor ANWARNING Properly discharge the capacitor s before testing and after testing has been com pleted Failure to do so could cause damage to test equipment or the unit and or result in per sonal injury electrical shock or death 29 TROUBLESHOOTING AND REPAIR 13 Inspection of Drain Switch Check for continuity between terminals 1 and 2 Continuity should exist With switch depressed no continuity should exist between terminals 1 and 2 If continuity is not as specified above replace the switch DRAIN SWITCH To J103 Inspection of Drain Switch 14 Inspection of Fan Motor Measure resistance across the terminals of the fan motor Terminals at 77 F 25 C J6 CF1 Approx 6 90 J5 CF1 Approx 8 7Q CF1 CF2 Approx 33 30 If the measured resistance is not equal to these standard values replace the fan motor Inspection of Fan Motor 15 Inspection of Compressor Motor Measure resistance across the terminals of the compressor motor Terminals at 77 F 25 C R C Approx 110 8 Approx 2 70 S R Approx 3 30 If the measured resistance is not equal to these standard values replace the compressor The compressor
32. t type of fuse or its equivalent Fuse Specifications 2 10A 250V A CAUTION Failure to use the exact type of fuse could result in damage to the unit and or its components It will also void the unit s warranty DIP Switch Temperature Scale Display Switch C F Fan Mode Control Switch STOP lt OPERATE DIP Switch ELECTRICAL SYSTEM 3 Fan Motor The fan motor is a single phase induction type two speed motor The motor rotates fans on the evaporator side and the condenser side at the same time Specifications Rated Voltage 115 volts 60 hz Rated Output High 135 watts Low 81 watts 2 1 White UL Listed File Number E 49807 CF2 Brown White NOTE An internal overload relay is used to protect M the fan motor This relay is built into the fan motor GreenYellow and will interrupt the flow of current when there is Fan Motor an overcurrent situation or if abnormally high temperature builds up in the fan motor 4 Compressor Motor The compressor motor is a single phase motor and is contained within the same housing as the compressor Specifications Rated Voltage 115 volts Rated Output 800 watts 5 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 will interrupt the flow of current when there is
33. to the capacity of refrigeration system operating conditions and the amount of refrigerant The capillary tube causes the high pressure high temperature liquid refrigerant sent from the condenser to expand rapidly as the refrigerant is cS Low Temp Low Press sprayed out through the fixed orifice in the Gas and Liquid Mixture capillary tube As a result the temperature and state of the refrigerant become low and mist like Capillary Tube and therefore it evaporates easily 5 Evaporator The evaporator like the condenser is a heat exchanger covered with spine fins Heat is removed from the air being pulled across the evaporator by the centrifugal fan and the resulting cool air is expelled through the cooling air ducts 6 Accumulator The accumulator is mounted on the suction gas piping between the evaporator ond the compres sor The accumulator separates the liquid refriger ant from the gas refrigerant letting only the gas refrigerant enter the compressor In the accumu lator suction gas is led into a vessel having a cylindrical body and the gas speed is decreased inside the vessel This separates the refrigerant iis contained in the gas by the force of gravity From Evaporator causing it to accumulate at the bottom of the vessel This protects the compressor from possible damage caused by the intake of liquid refrigerant To Compressor lt Accumulator REFRIGERANT SYSTEM EVAPORATOR INLET PIPE
34. ves a sufficiently low intake air room temperature signal from the thermister equal to or less than the set point When the temperature increases exceeds the set point the microprocessor will restart the fan and compressor automatically However if the unit has been off for less than 90 sec the fan will start before the compressor time delay feature B Cool to Operate When the Dip Switch is set to the Up or Operate position the microprocessor controls the fan operation using control panel inputs only The fan will operate continuously during Fan Only and Cool Modes This is the factory default setting 13 Temperature Scale Display Switch When the DIP Switch is set in the down or C position the Set PointTemperature will be displayed in degrees Celcius C The LED that indicates C will also be illuminated When the DIP Switch is set in the up or F position the Set PointTemperature will be displayed in degrees Farenheit F The LED that indicates F will also be illuminated this is the factory default setting TROUBLESHOOTING AND REPAIR Before troubleshooting the system the following inspection should be performed 1 Inspection of Power Source Voltage Check the voltage of the power source Single phase 115 volts 60Hz Check the operation and condition of the fuse or circuit breaker in the power source 2 Inspection of Air Filters Remove the air filters and check the element If it is dirty
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