Page 1
SERVICE MANUAL
DocID: 00G00092E
15SF
Page 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.
Page 3
Table of Contents
Table of Contents
Operation Section
1. PRECAUTIONS FOR SAFETY
1.1 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. SPECIFICATIONS
2.1 Exterior Dimension Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. CONSTRUCTION
3.1 Internal Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. REFRIGERATION SYSTEM
4.1 Refrigeration System Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Capillary Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.6 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5. ELECTRICAL SYSTEM
5.1 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Control Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5 Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.6 Temperature Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.7 Drain Tank Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6. OPERATION
6.1 Operation of Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Page 4
Table of Contents
Repair Section
7. TROUBLESHOOTING
7.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2 Self-Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.4 Basic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.5 Compressor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.6 Fan Motor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.7 Capacitor Inspection (For Fan Motor and Compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.8 Auxiliary Relay Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.9 Full Drain Switch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.10 Thermistor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.11 Wiring Connection Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.12 Inspection of Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8. DISASSEMBLY
8.1 Parts Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.3 Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4 Removal of Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.5 Full Drain Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9. REFRIGERATION SYSTEM REPAIR
9.1 Repair of Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.2 Removal of Refrigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.3 Preparing the System for Charging with R-410A Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.4 Refrigerant Charging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10. REASSEMBLY
10.1 Reassembly of Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.2 Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.3 Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.4 Wiring Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.5 Perform an Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Page 5
Operation Section
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
5
WARNING
CAUTION
NOTE Provides additional information that facilitates installation or unit operation.
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.
Page 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.
Page 7
2. SPECIFICATIONS
ILL00698-00
OBSTACLE
OBSTACLE
95 175
326
420
491
525
2100
45
672
1050
284 503 163
100
Unit: mm
DIA. 350
OBSTACLE
Minimum
clearance
500 mm
Minimum
clearance
500 mm
Minimum
clearance
500 mm
2.1 Exterior Dimension Diagram
Operation Section
7
Page 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
Range
Starting Current 25 A
Recommended Breaker Size 10 A
Cooling Capacity and Power Consumption
Evaporator: 35 °C, 60 %RH
Condenser: 35 °C, 60 %RH
Cooling Capacity 4.4 kW
Power Consumption 1.5 kW
Current Consumption 6.7 A
COP 2.9
Power Factor 97%
Max. 254.4 V
Min. 196.6 V
Compressor Typ e Hermetic Rotary
Output 0.94 kW
Evaporator Type of Evaporator Spine Fin
Typ e of Fan Centrifugal Fan
Air Flow 800 m3/h
Motor Output
*1
0.35 kW
Condenser Type of Condenser Plate Fin
Typ e of Fan Centrifugal Fan
Air Flow 1500 m3/h
Motor Output
*1
-
Refrigerant Refrigerant Control Capillary Tube
Typ e R-410A
Amount 0.75 kg
Power Cord Plug AC 250 V, 10 A
Wire Length 2.1 m
Dimension W × D × H 491 × 672 × 1050 mm
Weight Net 76 kg
Shipping 90 kg
Drain Tank Capacity 19 L
Operating Condition
Range
Sound Level
*2
Inlet Air
Temperature
Max. 40 °C, 50 %RH
Min. 21 °C, 50 %RH
64 dB (A)
Page 9
Operation Section
< NOTE >
ITEM SPECIFICATIONS
Safety Devices Compressor Overload Relay Included
Fan Motor Overload Relay Included
Freeze Protection Thermistor Included
Drain Warning Switch Included
Automatic Restart (Power Interruption) Included
Compressor Time Delay 120 sec
Control Devices Temperature Control Included
• Specifications are subject to change without notice.
*1 : One motor rotates both the evaporator and the condenser fans.
*2 : Measured at 1.0 m from surface of the unit.
9
Page 10
10
ILL00720-00
2015 25 30
25
30
35
40
3.0
3.5
4.0
4.5
5.0
5.5
Cooling Capacity. kWDry Bulb Temp. °C
Wet Bulb Temp. °C
ILL00721-00
25 30 3520
25
30
35
40
1.0
1.2
1.4
1.6
1.1
1.3
1.5
1.7
1.8
Power Consumption. kWDry Bulb Temp. °C
Wet Bulb Temp. °C
Operation Section
2.3 Characteristics
(1) Cooling capacity curve
(2) Power consumption curve
Page 11
(3) Cool air temperature difference curve
ILL00722-00
(Delta-T) °C
Relative Humidity. %
40 50 60 70
Temperature Difference
Between Inlet and Outlet
15
14
13
12
11
10
9
8
7
Operation Section
11
Page 12
12
ILL00723-00
Capillary Tube
Condenser
Evaporator
Compressor and
Accumulator
Condenser Fan
and Motor
Housing for
Condenser Fan
Housing for
Evaporator Fan
Control Box
• Relay Board
• Capacitor
• Auxiliary Relay
Condenser Air Outlet
Cooling Air Duct
Freeze Protection
Thermistor (CTS)
Evaporator Inlet Air
Thermistor (RTS)
Drain Tank
Caster (Rear)
Full Drain Switch
Locking Swivel Caster
(Front)
Control Panel
Operation Section
3. CONSTRUCTION
3.1 Internal Structure
Page 13
4. REFRIGERATION SYSTEM
ILL00724-00
Condenser
Flow of
Refrigerant
Capillary
Tube
Compressor
Fan
Motor
Evaporator
Condenser
Condenser
Inlet Pipe
Condenser
Outlet Pipe
Connecting Pipe
(Evaporator to Compressor)
Connecting Pipe
(Condenser to Capillary Tube)
Compressor
Suction Pipe
Capillary Tube
Evaporator Inlet Pipe
Evaporator
Evaporator Outlet Pipe
Compressor
Compressor
Discharge Pipe
Accumulator
Accumulator
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.
Operation Section
13
Page 14
14
I001675
To Condenser
Accumulator
Strainer
From Evaporator
Blade
Discharge Valve
Oil
Lubricator
Roller
Cylinder
Rotor
Stator
Terminal
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.
Page 15
Operation Section
I000510
Discharge
Hole
Cylinder
Blade
Spring
Suction
Hole
Discharge
Val ve
Shaft
Roller
(2) 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
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.
15
Page 16
16
I001676
Blade
Discharge
Val ve
Roller
I001677
Blade
Discharge
Val ve
Roller
I001678
Blade
Discharge
Val ve
Roller
I001679
Blade
Discharge
Val ve
Roller
(3) Operation
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 valve is kept
closed.
2) Suction and compression
1) The pressure in the cylinder increases gradually.
2) Refrigerant suction begins on the suction side of
the cylinder.
3) The discharge valve remains closed.
3) Discharge
1) The pressure in the cylinder exceeds that in the
discharge chamber, and the discharge valve
opens.
2) On the suction side, refrigerant suction continues.
4) Completion of compression
1) When compression is completed, all of the
refrigerant has been drawn from the suction
chamber.
2) Operation then returns to step 1) (Start of
compression) and the above process of suction
and compression continues repeatedly in
succession.
Page 17
(4) Compressor lubrication
ILL00753-00
Oil Feed Groove
Oil Hole
Oil Scraper
Roller
Rotor
Cylinder
Hollow Shaft
Eccentric Shaft
I002351
• 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
Operation Section
17
system effectively prevents bearing
temperature increases, and offers high
reliability. In addition, the specially treated
shaft journal keeps the bearing from being damaged during high temperature operation.
4.3 Condenser
• The condenser is a heat exchanger with
copper tubes that are covered with thin
aluminum projections called plate fins.
• 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.
Page 18
18
I001887
High Temp./High Pressure
Liquid Refrigerant
Low Temp./Low Pressure
Gas and Liquid Mixture
I002352
I000514
From Evaporator
To Compressor
Operation Section
4.4 Capillary Tube
• The capillary tube is a long thin tube that
utilizes line flow resistance as an expansion
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
refrigerant sent from the condenser expands
rapidly as the refrigerant is sprayed out through
the fixed orifice in the capillary tube. As a result, the temperature and state of the refrigerant
becomes low and mist-like, and therefore evaporates easily.
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.
4.6 Accumulator
• The accumulator is mounted on the suction
gas piping between the evaporator and the
compressor. The accumulator separates the
liquid refrigerant from the gas refrigerant,
allowing only the gas refrigerant to enter the
compressor. In the accumulator, suction gas is
led into a cylindrical vessel where the speed of
the gas is decreased. This process separates
the refrigerant contained in the gas by the force
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.
Page 19
5. ELECTRICAL SYSTEM
ILL00725-00
AP Attachment Plug
TB
DS
Terminal Block
RB Relay Board
CB Control Board
MC Compressor Motor
MF Fan Motor
RX Auxiliary Relay
Drain Switch
RTS
CTS Freeze Protection Thermistor
Room Thermistor
OLC Overload Relay For Compressor
IOLF Internal Overload Relay For Fan Motor
OLC
MC
MF
IOLF
AC230V 1Φ 50Hz
AP
Jumper
Line
Jumper
Line
CTS RTS DS
RB
F
CB
CC Capacitor for Compressor
CF Capacitor for Fan Motor
TB2
L2
L1
1
1213
1
12
3
A1
13 14
A2
RX
CF
M
1~
M
1~
12
CC
1
t’ t’
313
4
1
5
1
5
4
3
CN01
CN21
CN03
CN13
CN17
5
1
CN8
1
11
CN25
11
1
CN9
CN12 CN11 CN16
52ID
52ID
52CM
52CM
5.1 Circuit Diagram
Operation Section
19
Page 20
20
ILL00726-00
RB: Relay Board
CF: Capacitor for Fan Motor
TB: Terminal Block
CC: Capacitor for Compressor
RX: Auxiliary Relay
CC
RX
RB
TB
CF
12
21
L2L1
CN13CN12CN11CN04CN03CN02CN14CN16CN15
CN01
CN24
4 52CM
CN17
CN25
3
ILL00561-00
Operation Section
5.2 Control Box
(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
Page 21
(2) Auxiliary relay
I001694
13
14
A1
A2
• 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 AC 220 V
Rated Current 25 A
Operation Section
21
Page 22
22
ILL00591-00
Relay Board Fuse (5A)
4-Position Dip Switch
“OFF” Position
CN15
CN01
CN16 CN02 CN03 CN04 CN11 CN12 CN13
CN21CN24
52CM
CN22 CN23
CN17
CN25
CN14
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.
1) 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.
Page 23
Operation Section
I002623
Symbol
DSW4
DSW3
DSW2
DSW1
Item Function
On --- Disable “onboard buzzer”
Off --- Enable “onboard buzzer”
On --- Fan stop mode (Fan AUTO)
Off --- Fan operate mode (Fan ON)
N/A
N/A
Buzzer
Fan Mode
Change Fan Mode
ON
1234
-
-
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:
23
Page 24
24
ILL00719-00
ON
OFF
52CM
-1.1 °C 15.6 °C CTS temperature
(Freeze protection thermistor temperature)
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
Page 25
Operation Section
I001688
[Example]
1st Time (After initial set up, reset circuit breaker, etc.)
Compressor turns off and on immediately (within 120 sec.)
Delay Time
(120 sec.)
No Delay Time
(Less than 5 sec.)
No Delay Time
(less than 5 sec.)
Delay Time
(120 sec. after last turn off)
Compressor turns off and on more than 120 sec. later
Turn ON
Controller
Status
Compressor
Status
(52CM)
ON
OFF
ON
OFF
Stop
(for Extended Period)
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.
(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
25
(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)
Page 26
26
ILL00727-00
ON
OFF
52CM
(Compressor Relay)
Set Temp. -1.7 °C
Set Temp
Inlet Air Temperature
When compressor operation continues within this range for more
than 5 minutes, the 52CM relay stops.
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).
Page 27
5.4 Compressor
I002355
I001691
Bimetal
Terminal
Points
(1) Compressor motor
• The compressor motor is a single-phase motor
and is contained within the same housing as
the compressor.
Specifications:
Rated Voltage 230 V
Rated Power Output 0.94 kW
(2) Compressor overload relay
• An external compressor overload relay is used
to protect the compressor motor. This relay is
Operation Section
27
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.
Operating Temperature
OFF (Open Contacts) ON (Closed Contacts)
158 °C 75 °C 9 A MRA12154-12027
Non-Operating Limit at 100 °C Marking
Page 28
28
< NOTE >
I001692
I001695
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 230 V
Rated Power Output 0.35 kW
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.
Type
Evaporator Inlet Air
Thermistor (RTS)
Freeze Protection
Thermistor (CTS)
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
Specification
Page 29
Operation Section
I001696
Evaporator
Drain Pan
Full Drain Switch
Portion “A”
Relay
Board
(CN16)
Drain Tube
Drain Tank
a
Base Plate
Base
Spring
1
2
3
NC
COM
NO
C (1)
NC (2)
Drain Water
5.7 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).
29
Page 30
30
< NOTE >
ILL00728-00
Activates/deactivates the cool mode; turns the unit off.
COOL ON/OFF Button
Activates/deactivates the fan only mode; turns the unit off.
FAN Button
Increases/decreases the temperature set point during cool mode.
Shows a blinking set point temperature for 5 seconds, then continuously indicates
room temperature.
Room Temperature/
Set Point Display
Illuminates to indicate the current temperature being displayed is either in °C or °F.
Temperature Scale LED
Illuminates during fan only mode and cool mode using fan operate mode.
ON LED
Illuminates during cool mode using fan stop mode.
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)
AUTO LED
SET TEMP Buttons (/)
1
2
4
5
6
7
[LED Display Indication] In normal operation, LED displays the following indication.
3
Display Indication Conditions
5
6
4
1
2
7
3
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.
• 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.
Page 31
Operation Section
< NOTE >
(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)
31
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.)
Page 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.
Page 33
Repair Section
< NOTE >
7.2 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
When the drain tank switch is activated, the LED displays “FL” and
No. 1
No. 2
No. 3
the unit turns off automatically.
When evaporator inlet air thermistor becomes open or shorted,
display shows “E1” and cool mode operation is off.
When freeze protection thermistor becomes open or shorted,
display shows “E2” and cool mode operation is off.
Buzzer
No
No
No
33
*1
*1: Buzzer is located on the relay board.
Page 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
Air volume
normal
Compressor
operates.
Compressor
does not
operate.
1. Usage conditions
(high temperature).
2. Dirt in condenser or
evaporator.
3. Frost in refrigeration cycle. Clogging at the frost section. Replace clogged section.
4. No temperature difference
between evaporator and
condenser.
1. Compressor coil resistance.
(0 ohm or ohm
2. Compressor on/off relay
(52CM) on the relay board.
3. Capacitor for compressor
and fan motor.
4. Compressor overload relay. Overload relay fault. Replace overload relay.
Operation near usage limits. Review the installation
Insufficient heat exchange. Clean fins.
Insufficient refrigerant. Check the leaking part,
Short or open circuit. Replace compressor.
Open circuit or insufficient
contact.
Capacitor malfunction. Replace capacitor.
Remedy
place.
then repair and charge
refrigerant.
(In case of short, check
the compressor relay on
the relay board)
Replace relay board.
5. Voltage. Low voltage. Repair power supply.
Page 35
Repair Section
35
Condition Possible Cause
Insufficient Cooling Check Area Cause
1. Coil resistance of fan motor.
(0 ohm or ohm)
2. Fan motor on-off relay (52ID)
on the relay board.
No air.
3. Auxiliary relay in the control
box.
Insufficient
air volume
1. Air filter. Clogged air filter. Clean air filter.
2. Evaporator. Clogged evaporator or
Insufficient
air volume.
3. Duct connection state. Improper connection. Repair duct connection.
4. Fan motor. Insufficient rotation. Replace motor.
Short or open circuit. Replace fan motor.
Open circuit or insufficient
contact.
Open circuit or insufficient
contact.
No excite coil on the relay
(no voltage).
crushed fins.
Replace relay board.
Replace auxiliary relay.
Check and replace relay
board.
Repair and clean fins, or
replace evaporator.
Remedy
(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
Unit does not operate. Check Area Cause
1. Voltage. Power failure. Repair power.
Control
panel LED
display
turns off.
Unit stops operation. Check Area Cause
Control
panel LED
display
turns off.
*1 : To RESET the controller, press SET TEMP (/) buttons simultaneously for 3 seconds.
Control
panel
display does
not show
error codes.
Condition Possible Cause
Control
panel
display
shows error
codes.
2. Ground fault breaker trip. Ground fault or defective
ground fault breaker.
3. Fuse. Fuse blown. Repair shorting section.
1. Display code “FL”. Drain tank is filled with the
drain water.
Loose drain switch
connection.
Defective Drain Switch. Replace the drain switch.
Remedy
Repair ground fault
section.
Reset or repair breaker.
Repair fuse on the relay
board.
Remedy
Discharge the drain water.
RESET the controller
Reconnect the drain
switch and check the
connection. RESET the
controller
RESET the controller
*1
.
*1
.
*1
.
Page 36
36
Repair Section
Condition Possible Cause
Unit stops operation. Check Area Cause
2. Display code “E1”. Loose evaporator inlet air
thermistor.
Control
panel LED
display
turns off.
Control
panel
display
shows error
codes.
Defective evaporator inlet air
thermistor.
3. Display code “E2”. Loose freeze protection
thermistor.
Defective freeze protection
thermistor.
Unit stops
immediately
after
starting.
Control
panel LED
displays
normal.
1. Fan Motor on/off relay (52ID)
on the relay board.
2. Fan Motor insulation
resistance.
3. Compressor insulation
resistance.
Open circuit or insufficient
contact.
Insulation failure on fan
motor.
Insulation failure on
compressor.
1. Coil resistance of fan motor. Defective fan motor. Replace fan motor.
Remedy
Reconnect the
evaporator inlet air
thermistor and check the
connection.
RESET the controller
*1
.
Replace the evaporator
inlet air thermistor.
Reconnect the freeze
protection thermistor and
check the connection.
RESET the controller
*1
.
Replace the freeze
protection thermistor.
Replace relay board.
Replace fan motor.
Replace compressor.
2. Temperature of fan motor
abnormally high.
Operation of safety device
(IOLF) due to fan motor
malfunction.
Unit stops
after
running for
a while.
Control
panel LED
displays
normal.
3. Temperature of compressor
abnormally high.
4. Refrigerant leakage. Insufficient refrigerant or gas
Operation of safety device
(OLC) due to compressor
malfunction.
leakage.
5. Dirt on evaporator. Insufficient cooling of
evaporator.
6. Duct connection state. Improper connection. Repair duct connection.
*1 : To RESET the controller, press SET TEMP (/) buttons simultaneously for 3 seconds.
Replace fan motor.
Replace compressor.
Repair and charge
refrigerant.
Clean evaporator.
Page 37
(3) Overflow of water from the unit
Repair Section
37
Condition
Check Area Cause
1. Drain pan. Cracks in drain pan. Check and replace.
2. Water level in drain pan. Clogged drain hose. Check and repair.
3. Drain hole. Reversed air flow from drain
Overflow from the unit.
4. Clogged air filter. Reversed air flow from drain
Possible Cause
hole.
hole due to the excessive
negative pressure inside of
the unit.
Remedy
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
Abnormal noise or
vibration.
Check Area Cause
1. Fan. Fan interference. Repair interfering section.
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.
Possible Cause
Remedy
Fan deformation. Replace fan.
(5) Others
• For any other problems, please contact your MovinCool service representative or DENSO.
Page 38
38
I001780
I000526
I001699
Inlet of Evaporator
Thermometer
Cooling Air Duct
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.
(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.
(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.
Page 39
Repair Section
I002356
C
S
R
I001701
ILL00729-00
RX14
CF2
CF1
7.5 Compressor Inspection
(1) Compressor motor inspection
• Measure resistance across the terminals of the
compressor motor.
Resistance at 25 °C
R-C C-S
Approx. 3.48 ohm Approx. 4.09 ohm
• If the measured resistance is not equal to the
standard values listed above, replace the
compressor. The compressor has an external overload relay. The overload relay should be
operational if the above resistance is obtained under normal temperature. For overload relay
specifications, refer to the chart below.
39
(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.
7.6 Fan Motor Inspection
• Measure resistance across the terminals of the
fan motor.
Resistance at 20 °C
CF1-RX12 CF2-RX14
Approx.14.4 ohm Approx. 12.0 ohm
• If the measured resistance is not equal to the
standard values listed above, replace the fan
motor.
Page 40
40
ILL00566-00
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
• 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.
Page 41
7.8 Auxiliary Relay Inspection
I001694
13
14
A1
A2
I001745
Full Drain Switch
Relay
Board
(CN16)
1
2
3
NC
COM
NO
C (1)
NC (2)
I001695
• 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 Continuity
13-14
Released No continuity
(Reference)
Repair Section
41
23-24
33-34
43/41-
44/42
Depressed Continuity
Released No continuity
Depressed Continuity
Released No continuity
Depressed Continuity
Released No continuity
7.9 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.
7.10 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
Page 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.
7.12 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.
Page 43
Repair Section
ILL00730-00
Upper Panel
Right Side Panel
Air Filter
Air Filter
Rear Panel
Service Panel
Caster
Cooling Air Duct
Front Panel
Drain Pan
Drain Tank
Left Side Panel
Control Panel
Condenser Fan
and Motor
Locking Swivel Caster
Power Cord
Housing for
Evaporator Fan
Full Drain Switch
Evaporator Inlet
Air Thermistor
Housing for
Condenser Fan
8. 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
43
Page 44
44
I002611
Cooling Air Duct
Screws (8)
Front Panel
Drain Tank
ILL00731-00
Screws (6)
Service Panel
ILL00732-00
Power
Supply
Lines (2)
Ground Wire
TB: Terminal
Block
Repair Section
8.2 Disassembly
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.
4) Take out the six (6) screws, and then remove the
service panel.
5) Remove the two (2) power supply lines from the
terminal block, and remove the ground wire.
Page 45
Repair Section
CAUTION
ILL00733-00
Screws (13)
Rear Panel
I002613
Screws (2*)
Upper Panel
Housing for
Condenser
Fan
Screws (4)
Upper Panel
Screws (4)
Screws (2)
Screws (2)
ILL00653-00
Evaporator Inlet Air Thermistor Harness Connector
Clamp
45
6) Take out the thirteen (13) screws, and then
remove the rear panel.
7) Take out the fourteen (14) screws, and then
remove the upper panel.
The two screws (2*) used on the front side of
the upper panel differ from the rest. Ensure
that the correct screws are used when
attaching the upper panel.
8) Unfasten the connector on the evaporator inlet
air thermistor wiring harness.
9) Remove the wiring harness from the clamp.
Page 46
46
CAUTION
CAUTION
I001749
Board Clamp
Clamp
Connectors
Upper Panel
Control Panel
I002614
Screw (1*)
Left Side Panel
Screws (6)
I001751
Air Filter
Air Filter
I002568
Screws (6)
Right Side Panel
Screws (6)
Screw (1*)
Repair Section
10) Unfasten the two connectors (11-pin, 5-pin) from
the control panel.
11) Remove the wiring harnesses from the clamp
and board clamp.
12) Take out the seven (7) screws, and then remove
the left-side panel.
The screw (1*) on the front side of the left-side
panel differs from the rest. Ensure that the
correct screw is used when attaching the
left-side panel.
13) Remove the two air filters from the right-side
panel.
14) Take out the thirteen (13) screws, and then
remove the right-side panel.
The screw (1*) on the front side of the right-
side panel differs from the rest. Ensure that the
correct screw is used when attaching the
right-side panel.
Page 47
8.3 Fan Motor Removal
ILL00734-00
Evaporator Fan
Fan Motor
Motor Bracket
Partition Plate
Condenser Fan
Housing for Evaporator Fan
Housing for Condenser Fan
Repair Section
47
Page 48
48
I002571
Condenser Fan
Set Screw
I002572
Nuts (2)
Housing for
Condenser
Fan
I002573
Fan Motor
Motor Bracket
Nuts (4)
I001740
Evaporator Fan
Set Screw
Repair Section
1) Loosen the set screw with a hex key, and then
remove the condenser fan.
CAUTION
• Set Screw Torque Value (for Installation)
- 14.7 ± 3.0 N•m
2) Take off the two (2) nuts, and then remove the
condenser fan housing.
3) Take off the four (4) nuts, and then remove the
fan motor together with the motor bracket.
4) Loosen the set screw with a hex key, and then
remove the evaporator fan.
Page 49
Repair Section
Fan Motor
Nuts (4)
I002616
49
5) Take off the four (4) nuts, and then remove the
fan motor.
Page 50
50
I002615
Control Panel
Screws (8)
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.
Page 51
(2) Removal of wire-harness in control box
ILL00735-00
CN13CN12CN11CN04CN03CN02CN14CN16CN15
CN01
CN24
4 52CM
CN17
CN25
3
CF1 (Black)
TBT (Black)
TBR (White)
52CM3 (White)
52CM4 (White)
11- P
5-P (Black)
RX13 (Black)
RXA1 (Black)
CC1 (White)
RXA2 (Black)
5-P
2-P (Black)
2-P (Red)
3-P (Black)
CC
RX
RB
TB
CF
12
21
L2L1
• Disconnect all the wires from the electrical parts in control box.
Repair Section
51
Page 52
52
I002606
Control Box
Nuts (3)
Repair Section
(3) Removal of control box
1) Take off the three (3) nuts, and then remove the
control box.
Page 53
(4) Removal of electrical parts
ILL00736-00
TB: Terminal Block
Control Box
RB: Relay Board
CF: Capacitor for Fan Motor
CC: Capacitor for Compressor
RX: Auxiliary Relay
Support
• 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.
Repair Section
53
Page 54
54
I002609
Screws (2)
Full Drain Switch Cover
I002610
Full Drain Switch
Harness Connector
Screws (2)
Repair Section
8.5 Full Drain Switch Removal
1) Take out the two (2) screws, and then remove the
full drain switch cover.
2) Unfasten the wiring harness connector.
3) Take out the two (2) screws, and then remove the
full drain switch.
Page 55
Repair Section
ILL00738-00
Clearance
Clearance From The Pipe Fitting and Tubing.
0.025~0.075 mm
a
a
9. 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.
55
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.
Page 56
56
< NOTE >
I000564
Burner
45°
Tube
Brazing Filler Metal
Vertical Down Joint
I001725
Burner
45°
Tube
Brazing Filler Metal
Vertical Up Joint
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.
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.
Page 57
Repair Section
ILL00737-00
A
C
Pipe 1
Pipe 2
E
Tube 2
B
Tube 1
F
D
Part to Replace Disconnect at
• Compressor
• Condenser
• Capillary Tube
• Evaporator E & D
E & F
A & C
A & B
9.2 Removal of Refrigeration System Components
WARNING
• Before replacing any refrigeration component, recover the refrigerant using standard
recovery procedures.
• When recovering the refrigerant, use the pinch-off tubes at the low pressure side (tube 1)
and high pressure side (tube 2) as shown in figure below.
CAUTION
• To prevent oxidation, dry nitrogen should be conducted (flow rate 1 L/min) through the pinch-off
tube during any brazing operation.
• During any component replacement involving brazing, shield nearby parts with a steel plate to
protect them from the flame.
57
Page 58
58
ILL00754-00
Step 1
Step 5
Step 6
Step 4
Step 3
Step 2
Inspect the refrigerant system and test for leaks using
standard test methods in accordance with local regulations.
1) Evacuate the system.
• To less than 117 Pa (absolute).
2) Stop evacuating the system.
• Leave for at least 60 minutes.
3) Check the vacuum.
•
A rise of more than 13 Pa may indicate a leak or moisture.
•
If necessary, repair the system and repeat steps 1 and 2.
When a leak is found,
repair the connection
or components.
Remove manifold gauge.
Check the operation of the unit.
Charge the system with R-410A.
•
See
“Technical Specifications” for the specified amount.
Connect to refrigerant source.
Repair Section
9.3 Preparing the System for Charging 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.
WARNING
• Any repair to the system should be performed by a licensed professional only.
• 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 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.
- Take caution so that the liquid refrigerant does not come in contact with the skin.
• If liquid refrigerant strikes eye or skin:
- Do not rub the eye or the skin.
- Splash large quantities of cool water on the eye or the skin.
- Apply clean petroleum jelly to the skin.
- Go immediately to a physician or to a hospital for professional treatment.
Page 59
Repair Section
< NOTE >
I002183
Pinch-Off Tube
Seal
Charging Hose
Side
Refrigerant
Cycle Side
ILL00756-00
High Pressure Valve
(Closed)
High Pressure
Side Tube
Vacuum Pump
(Stopped)
Low Pressure
Valve (Closed)
Inlet Hose
Outlet Hose
Process Tube Fitting
ILL00757-00
LO
ClosedHIOpenLOClosedHIClosed
Valve Setting
At least 117 Pa
High Pressure Valve
High Pressure Gauge
Gauge
High Pressure
Side Tube
Vacuum Pump
(Operating)
Low Pressure
Valve
(1) Inspection of the unit before refrigerant recovery
• Inspect the refrigerant system and test for leaks using standard test methods in accordance with
local regulations.
(2) Connection of gauge manifold
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 on
high pressure side.
59
(3) Evacuation
3) Connect the inlet hose (high pressure side) for
the gauge manifold to the process tube fitting.
Connect the hoses with care not to mistake the
high pressure side for the low pressure side
and vice versa.
4) Connect the outlet hose at the center of the
gauge manifold to the vacuum pump.
1) Open the high pressure valve (Hl) of the gauge
manifold.
2) Turn on the vacuum pump to start evacuation.
(Evacuate the system to a vacuum of at least 117
Pa.)
3) When the high pressure gauge indicates a
vacuum of at least 117 Pa, turn off the vacuum
pump and close the high pressure valve of the
gauge manifold.
Page 60
60
ILL00758-00
Return
Pipe Brazing
LO
ClosedHIClosed
Valve Setting
Pressure Gauge
ILL00759-00
Open The Valve
of Refrigerant
Cylinder
To Process Tube Fitting
Inlet Hose
Refrigerant
Cylinder R-410A
Outlet Hose
LO
ClosedHIClosed
Valve Setting
Air Purging
I001903
LO
ClosedHIOpen
LO
ClosedHIClosed
Refrigerant
Cylinder R-410A
Valve Setting
Specified Amount
of Refrigerant
High Pressure Valve
High Pressure
Side Tube
Process Tube Fitting
Valve of
Refrigerant
Cylinder
Weight
Repair Section
(4) Checking vacuum
9.4 Refrigerant Charging Work
(1) Refrigerant charging
1) Leave the high pressure valve of the gauge
manifold closed for at least 60 minutes.
2) If the gauge pointer indicates a rise of more than
13 Pa, there may be a leak or moisture
somewhere in the system (this could also include
gauge manifold). If necessary, repair the system
and repeat "(1) Preparation" to "(4) Evacuation".
1) Remove the hose from the vacuum pump, and
connect it to the refrigerant cylinder (R-410A).
2) Securely place the refrigerant cylinder on a scale
with a weighing capacity of 30 kg that is
graduated by 5 g.
3)
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: 0.75 ± 0.02 kg
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.
4) Close the high pressure valve of the gauge
manifold and the valve of the refrigerant cylinder.
Page 61
(2) Removal of gauge manifold
I002185
Pinch-Off Tube
Pinch-Off Tool
Process Tube Fitting
Charging Hose
To Gauge
Manifold Side
To Refrigerant
Cycle Side
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.
(3) Inspection of the unit after refrigerant charging
• Check the operation of the unit.
Repair Section
61
Page 62
62
< NOTE >
ILL00605-00
Compressor
Nut (3)
Washer (3)
Cushion (3)
Collar (3)
ILL00636-00
Plastic Cover
MC-S
MC-R
MC-C
OLC-3
Overload
Relay
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 all wiring or rewiring as referenced in the wiring
diagram.
10.2 Compressor Installation
1) Install three (3) cushions and three (3) collars to
the bolts and mount the supplied compressor to
the unit.
Cushions and collars are packaged in the
supplied compressor assembly.
2) Insert three (3) washers and tighten three (3)
nuts.
CAUTION
• Tightening torque:
- 11.3 ± 2.9 N•m
3) Remove the plastic cover, wires and overload
relay from the compressor before brazing.
Page 63
Repair Section
ILL00742-00
1.5 mm
or more
1.5 mm
or more
10.3 Fan Assembly
1) Install the evaporator fan and condenser fan.
Allow a clearance of 1.5 mm or more between
the evaporator fan and the fan casing.
CAUTION
• Tightening torque:
- 14.7 ± 3.0 N•m
10.4 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.
63
10.5 Perform an Inspection
• Perform an inspection of cooling performance and check for abnormal noise or vibration.
Page 64
P/N: SV0080-00 First Issue: February 2014
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