Page 1
SERVICE MANUAL
CLASSIC PLUS 14
DENSO SALES CALIFORNIA, INC.
REGISTERED TO ISO 9002
FILE NO. A5537
© 2000 DENSO SALES CALIFORNIA, INC.
All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission
of the publisher. DENSO SALES CALIFORNIA, INC. reserves the right to make changes without prior notice.
MovinCool is a registerd trademark of DENSO CORPORATION.
DSCA P/N: LA990009-0379-E
(800) 264-9573 www.movincool.com
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FOREWORD
This manual has been published to service the MovinCool Classic Plus 14. Please use this service manual only when
servicing the Classic Plus 14.
DEFINITION OF TERMS
WARNING: Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation.
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
WARNINGS:
• All electrical work if necessary, should only be performed by qualified electrical personnel. Repair to electrical components by non-certified technicians may result in personal injury and/or damage to the unit. All
electrical components replaced must be genuine MovinCool, purchased from an authorized reseller.
• When handling refrigerant, always wear proper eye protection and do not allow the refrigerant to come in
contact with your skin.
• Do not expose refrigerant to an open flame.
• The proper electrical outlet for MovinCool units must be equipped with a “UL” approved ground-fault breaker
to prevent electrical shock from the unit.
• When brazing any tubing, always wear eye protection and work only in a well ventilated area.
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 2
Page 3
CONDENSER
(OUTDOOR UNIT)
Conventional Air Conditioner
EVAPORATOR
(INDOOR UNIT)
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:
Air Flow of MovinCool Spot Cooling System
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.
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 3
Page 4
CONSTRUCTION, SPECIFICATIONS & DATA
Cool Air Duct
Exhaust Air Duct
Centrifugal Fan
Housing for
Condenser Fan
Condenser
Compressor
Capillary Tube
Caster with Brake
Drain Switch
Control Box
Caster
Construction of Classic Plus 14
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 4
Page 5
CONSTRUCTION, SPECIFICATIONS & DATA
Cool Air Ducts
Evaporator
Drain Tank
Control Panel
Front Panel
Air Filter
(evaporator)
Evaporator Fan
Control Box
Upper Panel
Fan Motor
Side Panel
Condenser Fan
Air Filter(condenser)
Capillary Tube
Accumulator
Compressor
Air Filter (condenser)
Condenser
Construction Diagram
Power Cord
Casters
Base Panel
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 5
Page 6
CONSTRUCTION, SPECIFICATIONS & DATA
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 air is blown out through the
upper exhaust air duct. Air taken in from the
front face is cooled by the evaporator and then
Air Flow
blown through the cool air duct which can be
turned in any direction. All the air inlets are
equipped with filters, while the exhaust air duct
is protected by wire mesh.
3. Compressor and Fans
The compressor is hermetically sealed. A twospeed fan motor is used with two centrifugal
fans to draw air across the evaporator and
condenser.
4. Drain Tank
The capacity of the drain tank is 5.0 gallons
(19 liters). The unit is equipped with a "Tank
Full" LED and a device to automatically stop
the operation of the unit when the drain tank
reaches a level of approximately 4.0 gallons
(15 liters).
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 6
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CONSTRUCTION, SPECIFICATIONS & DATA
Rating Conditions
dry bulb ...................................................................................................95oF (35oC)
wet bulb ..................................................................................................83oF (28.3 oC)
humidity .................................................................................................. (60%)
Specifications
power frequency .....................................................................................60Hz
line voltage ............................................................................................. single phase 115 V
power consumption ................................................................................1.41 Kw
current consumption ...............................................................................12.3 Amps
power factor ............................................................................................95%
starting current ....................................................................................... 32A
power wiring ........................................................................................... 14 (3-core) AWG
Cooling Unit
cooling capability ....................................................................................3,300 Kcal/hr
................................................................................................................ 13,200 BTU/hr
cooling system ....................................................................................... direct expansion
Blower
type of fan ...............................................................................................centrifugal fan
air volume: Evaporator (Hi speed) ......................................................... 470 ft3/min
Condenser (Hi speed) .......................................................... 882 ft3/min
motor output ...........................................................................................0.24 Kw (High)
................................................................................................................ 0.19 Kw (Low)
Compressor
type ........................................................................................................ rotary
output ..................................................................................................... 0.8 Kw
refrigerant type ....................................................................................... R-22
refrigerant capacity ................................................................................. 1.50 lbs (0.68 kg)
Safety Devices
compressor overload relay...................................................................... included
fan motor protector .................................................................................included
anti-freezing thermister ...........................................................................included
full drain tank switch ............................................................................... included
power interruption restart feature ........................................................... included
time delay feature ................................................................................... included
Dimensions & Weight
W x D x H ............................................................................................... 19.4" x 26.5" x 41.5"
............................................................................................................... 493 x 673 x 1054 (mm)
weight .................................................................................................... 165lbs (75kg)
Operating Conditions
inlet air (relative humidity) ...................................................................... 113oF (45 oC), < 50%
................................................................................................................ 70oF (21.1 oC), > 50%
Control Device
temperature control ................................................................................ included
two speed fan ......................................................................................... included
Specifications Specifications are subject to change without notice.
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 7
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CONSTRUCTION, SPECIFICATIONS & DATA
26.5
21.1
Exterior Dimensions
16.6
12.5
19.4
37.7
3.8
41.5
2.8
20.6
25.6
2.2
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 8
Page 9
@ 115V
40 50 60 70
Relative Humidity of Inlet Air (%)
6 (10.8)
8 (14.4)
10 (18.0)
12 (21.6)
14 (25.2)
Temperature ˚C (˚F)
Cool Air Temperature Difference Curve
25
(77)
30
(86)
35
(95)
40
(104)
30 (86)
25 (77)
35 (95)
40 (104)
45 (113)
Wet Bulb Temperature ˚C (˚F)
Dry Bulb Temperature ˚C (˚F)
Power Consumption (kW)
0.9
1.1
1.3
1.5
1.7
@ 115V
Power Consumption Curve
CONSTRUCTION, SPECIFICATIONS & DATA
4.0 (15.9)
3.6 (14.3)
3.2 (12.7)
kcal/h (BTU/h))
3
Cooling Capability
(x10
2.8 (11.1)
2.4 (9.5)
45 (113)
40 (104)
35 (95)
@ 115V
Dry Bulb Temperature ˚C (˚F)
30 (86)
25 (77)
15
(59)
20
(68)
Wet Bulb Temperature ˚C (˚F)
25
(77)
Cooling Capability Curve
30
(86)
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 9
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REFRIGERANT SYSTEM
1. The component parts of the refrigerant system include the following:
• Accumulator • Capillary tube
• Compressor • Evaporator
• Condenser
These parts are all connected by copper tubing. All the connections have been brazed.
Condenser
Evaporator
Compressor
CAPILLARY
TUBE
Capillary Tube
Accumulator
REFRIGERANT
FLOW
CONDENSER
ACCUMULATOR
FAN
MOTOR
EVAPORATOR
Refrigerant System
COMPRESSOR
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 10
Page 11
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 compressor (compression mechanism) rotates to compress the refrigerant.
B. 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.
REFRIGERANT SYSTEM
The blade is in contact with the roller by
means of spring force. It 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 that of the
refrigerant on the discharge side. This
design prevents the backward flow of
discharge gas.
3. Condenser
The condenser is a heat exchanger with
copper tubes that are covered with thin
aluminum projections called spine fins. Heat
is given off and absorbed by air being pulled
across the condenser fins by the centrifugal
fan and then expelled through the exhaust air
duct.
Compressor Operation
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 11
Page 12
REFRIGERANT SYSTEM
High Temp. / High Press.
Liquid Refrigerant
Low Temp. / Low Press.
Gas and Liquid Mixture
Capillary Tube
4. Capillary Tube
The capillary tube is a long thin tube utilizing
line flow resistance to serve as an expansion
valve. The length and the inner diameter of the
capillary tube are determined by 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 sprayed out through the fixed
orifice in the capillary tube. As a result, the
temperature and state of the refrigerant
become low and mist-like respectively, causing it to evaporate 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 cool
air ducts.
Accumulator
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 letting only the gas refrigerant enter the
compressor. The construction of the accumulator is as shown. In the accumulator, suction
gas is led into a vessel having a cylindrical
body, and the gas speed is decreased inside
the vessel. This separates the refrigerant
contained in the gas by the force of gravity
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
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 12
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Condenser Inlet Pipe
REFRIGERANT SYSTEM
Evaporator
Inlet Pipe
Compressor
Discharge
Pipe
Condenser
Outlet
Pipe
Refrigerant System Piping
Compressor
Suction Pipe
(insulated)
Capillary Tube
Evaporator
Outlet Pipe
Connecting
Pipe (evaporator
to compressor)
Connecting
Tube (condenser
to capillary tube)
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 13
Page 14
ELECTRICAL SYSTEM
AP
G
T R R1 R2
SCP
G
TB
CF
12
HI
MF
IOLF
G
AP Attachment Plug
TB Terminal Block
CB Control Board
RB Relay Board
MF Fan Motor
MC Compressor Motor
CF Capacitor for Fan
CC Capacitor for Compressor
CC
12
0LCL0
MC
1
2
J4
J5
J6
J2
J1
J3
G
J8 (AUX1)
RB CB
OLC Overload Relay of Compressor
DS Full Drain Warning Switch
THS Freeze Protection Thermistor
RTH Room Thermistor
SCP Short Circuit Plate
G Ground
J8 (AUX1) Auxiliary Connector (CPK3)
AUX2 Auxiliary Connector (Not Used)
THS RTH DS
3
2
1
AUX2
Relay Board
DIP Switch
Relay Board Fuse
Terminal Block
Compressor
Capacitor
Fan Motor
Capacitor
Electrical System and Control Box for Classic Plus 14
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 14
Page 15
1. Basic Operation of Classic Plus 14 Electrical Circuit
There are two basic components used to control the operation of the Classic Plus 14 Electrical System:
• Control Panel Assembly
• Control Box
The Control Panel Assembly contains the Control Panel, Control Board (with inputs for the freeze
and room temperature thermistors), drain switch, and a microprocessor.
A. Fan “Only” Mode
Low Fan Mode - When the “Low” Fan Mode button on the control panel is pressed, the microprocessor turns on the button’s LED and activates the Fan “On” Relay (Relay Board), sending line
voltage (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 microprocessor turns on the button’s 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.
ELECTRICAL SYSTEM
B. 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
button’s 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. Pin 1 of the
Compressor Overload Relay is connected (by wire) to the compressor.
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 15
Page 16
ELECTRICAL SYSTEM
2. Control Box
A. Capacitors
DIP Switch
Compressor
Capacitor
Control Box
Temperature Scale Display Switch
Fan Mode Control Switch
STOP OPERATE
DIP Switch
˚C ˚F
S1
CF
STOP OPERATE
Relay Board
Relay Board Fuse
Terminal Block
Fan Motor
Capacitor
The capacitors are used to temporarily
boost the power output available to the
fan motor and the compressor at start-up.
The specifications of each capacitor are
listed below:
CAPACITOR VOLTAGE CAPACITANCE
APPLICATION RATING (µf)
Fan Motor 370 7.5
Compressor 370 45
B. Relay Board
The Relay Board receives signals and
outputs from the control board that
contains a microprocessor. The relay
board contains the compressor, fan on
and fan mode (speed) relays. It also
contains a step-down transformer 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
12(DC) power is sent to the Control Panel
Assembly where it is further reduced to 5
volts for the system logic.
J9
The relay board also contains the DIPSwitch. The DIP-Switch is used to
Relay Board
change the Fan Mode operation from
Stop to Operate and change the Set Point
temperature display from ˚F to ˚C.
NOTE: The relay board must be serviced as a
Relay Board Fuse
complete assembly. It has only
one serviceable
component, the fuse.
(a) Relay Board Fuse
NOTE: 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. It
must be replaced with the exact type of
fuse or an equivalent.
Fuse Specifications: 2/10A 250V
CAUTION: Failure to use the exact type of fuse
DIP Switch
could result in damage to the unit and/or to components. It will also void the warranty of the unit.
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 16
Page 17
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 – 243 watts
Low – 188 watts
UL Listed File Number – E-49807
NOTE: An internal overload relay is used to protect
the fan motor. This relay is built into the fan motor
and will interrupt the flow of current when there is
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. It is contained within the same housing
as the compressor.
Fan Motor
ELECTRICAL SYSTEM
CF1 (White)
CF2 (Brown/White)
Ground
(Green/Yellow)
J5 Low (Red)
J6 High (Black)
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 an overload caused by a high temperature condition in the compressor.
Specifications:
Temperature Variance Trip Time
(seconds)
Contacts Open 284˚F / 140˚C± 41˚F / ± 5˚C
Contacts Closed 165˚F / 74˚C± 48˚F / ± 9˚C
2 – 12
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 17
Page 18
DRAIN W
TER
ELECTRICAL SYSTEM
6. Drain Switch
The Classic Plus 14 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 flashes the "Tank Full"
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 direction of the arrow as shown in the figure below. When the drain tank
base plate is forced down, the top of the drain tank base plate 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 turns the unit off and flashes the "Tank Full" LED.
Operation of Drain Switch
When the drain tank is removed (or the drain tank is emptied), the top of the drain tank base plate returns
to its original position by the tension of the coil spring. Then contacts (1) – (2) of the drain tank switch
close. This provides a ground to the microprocessor through the J103 connector. To re-start the unit,
press one of the fan mode buttons or the “Cool On/Off” button. The unit will return to the previous Temperature Set Point.
To J103
NC
DS2
DS1
C
DRAIN
SWITCH
2
1
SPRING
TOP OF
BASE
PLATE
BASE
PLATEBASE
DRAIN W
EVAPORATOR
DRAIN PAN
DRAIN TUBE
DRAIN TANK
ATER
FULCRUM
7. Condensate Pump Kit (optional)
The Classic Plus 14 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 Classic Plus 14 model.
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 18
Page 19
8. Automatic Restart After Power Interruption
The program within the microprocessor of the Classic Plus 14 contains a feature that will automatically
restart the unit after power is lost and then regained. The unit also has memory in order to return itself
back to the operating mode (including temperature set point) it was in prior to the loss of power.
9. Compressor Protection
There is a Time Delay program within 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 “Cool On/Off” button, temperature set point (thermostatic control), power interruption restart or Condensate Pump (optional)
operation.
Time Delay Program Specifications: 120 ± 10 sec.
10. Temperature Control
The compressor operation (Cool Mode) is controlled by the microprocessor which receives input signals
from the room temperature thermistor (evaporator inlet air) and the setting of the Temperature Set Point.
The Temperature Set Point (desired room temperature) can be adjusted by pressing the ▲ / ▼ buttons on
the Control Panel. The adjustment range of the Temperature Set point is 70˚F to 95˚F (21.1˚C to 35˚C).
11. Fan Mode Control 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:
ELECTRICAL SYSTEM
A. Cool to Stop
When the DIP-Switch is set to the “Down” or “Stop” position, the microprocessor controls the fan
motor using the same room temperature thermistor that it uses to control the compressor. In this
case, both the fan and the compressor stop when the microprocessor receives a sufficiently low
intake air (room temperature) signal from the thermistor (equal to or less than the set point). When
the temperature increases (exceeds the set point) the microprocessor will restart the fan and compressor automatically. However, if the unit has been off for less than 130 sec., the fan will start
before the compressor (time delay feature).
B. Cool to Operate
When the DIP-Switch is set in 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.)
12. Temperature Scale Display Switch
When the DIP Switch is set in the “down” or ˚C position, the Set Point Temperature will be displayed in
degrees Celsius. The LED that indicates ˚C will also be illuminated.
When the DIP Switch is set in the “Up” or ˚F position, the Set Point Temperature will be displayed in
degrees Fahrenheit.. The LED that indicates ˚F will also be illuminated. (This is the “Factory Default”
setting.)
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 19
Page 20
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 the element is dirty, 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. Troubleshooting Chart
Trouble Probable Cause
Trouble Probable Cause
Unit does not operate at all • 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
Unit starts, but stops immediately • Defective Overload Relay
• Defective Fan Motor
• Defective Compressor Motor
• Defective Relay Board
Unit operates, but stops after a • Defective Compressor Motor
few minutes • Defective Overload Relay
• Defective Fan Motor
• Drain Tank Full
• Fan Mode Switch is set to
“Stop” and compressor
cycled off
Water leakage from the unit • Drain Tank not installed
• Drain Tank is defective
(cracked)
• Drain Pan hole is obstructed
Insufficient Cooling (cont’d) • Clogged spine fins
• Set point temperature
exceeds room temperature
• Defective room temperature
thermistor
• Leak in refrigerant system
• Restriction in refrigerant
system
• Compressor not operating
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 Thermistor
• Defective Compressor Motor
• Check wiring connections
• Defective Relay Board
• Defective Control Board
Abnormal noise and/or shaking • 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
Insufficient Air Flow • Clogged spine fins or
Evaporator or Condenser
(running unit without filter(s)
• Fan mode switch on “Low”
• Defective fan motor
Insufficient Cooling • Environmental conditions
exceed design specifications
• Clogged air filter
Fan Motor not operating • 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
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 20
Page 21
TROUBLESHOOTING AND REPAIR
In case of trouble, perform the following inspection
before disassembly.
5. Inspection of Spine Fins
To inspect the spine fins of either the evaporator or condenser you must remove the air
filters. After removal of the air filters, inspect
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.
Spine Fins
7. Inspection of Cooling Capacity
Measure the difference in temperature between
the inlet of the evaporator and the cool air duct.
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.
Operating Environment
Inspection of Cooling Capacity
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 21
Page 22
TROUBLESHOOTING AND REPAIR
8. Disassembly
2
4
3
5
6
7
1
10
4
16
11
12
17
13
Disassembly
8
15
9
14
9
1. Control panel 10. Front panel
2. Upper panel 11. Blower housing (evaporator)
3. Right side panel 12. Drain pan
4. Air filter 13. Left side panel
5. Blower housing (condenser) 14. Drain tank
6. Condenser fan 15. Service panel
7. Rear panel 16. Room thermistor
8. Drain Switch 17. Freeze thermistor
9. Caster
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 22
Page 23
4
TROUBLESHOOTING AND REPAIR
A. Remove Drain Tank.
B. Remove (8) screws from the ducts, then
remove the 2-ducts.
Removal of Drain Tank
C. Remove (4) screws from the Service
Panel.
D. Remove 3 wires, then remove the power
cord.
Removal of Duct Screws and Ducts
Removal of Service Panel Screws
DISCONNECT
DISCONNECT
DISCONNECT
Removal of Power Cord Screws
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 23
Page 24
TROUBLESHOOTING AND REPAIR
E. Remove remaining (13) screws and the
4
3
3
3
Removal of Back Panel Screws
back panel.
4
Removal of Top Panel Screws
2
4 (backside)
F. Remove (14) screws from the Top Panel.
2
G. Top Panel (4).
2
Removal of Top Panel
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 24
Page 25
9. Removal of Electrical Parts
TROUBLESHOOTING AND REPAIR
DIP Switch
Compressor
Capacitor
Removal of Electrical Parts in the Control Box
Relay Board
Relay Board Fuse
Terminal Block
Fan Motor
Capacitor
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 25
Page 26
TROUBLESHOOTING AND REPAIR
Temperature Scale Display Switch
Fan Mode Control Switch
DIP Switch
˚C ˚F
STOP OPERATE
Connections to Relay Board
S1
CF
STOP OPERATE
J9
Main Wiring Harness
Relay Board to Control Panel
J8
Pin #2 Compressor
Overload Relay
To Terminal Block
(T-Terminal)
Jumper or 2-Pin Connector of
(optional) Condensate Pump Kit - CPK-3
J4J1
To Terminal Block
(R-Terminal)
To Fan Motor
(Low Speed)
J5J2
J6J3
F1
To Fan Motor
(High Speed)
Relay Board Ground
(not used)
Relay Board Fuse
Jumper
Drain T ank Switch
NOT USED
Freeze Thermistor
Room Thermistor
Main Wiring Harness
(Control Panel to Relay Board)
Connections to Control Board
J104J103J106J102J101J201
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 26
Page 27
10. Removal of Blower Assembly
TROUBLESHOOTING AND REPAIR
➇
Disassembly of Blower
➀
1. Condenser fan 5. Partition plate
2. Blower housing (condenser) 6. Evaporator fan
3. Fan motor 7. Blower housing (evaporator)
4. Motor bracket 8. Air flow guide
➁
➂
➃
➄
➅
➆
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 27
Page 28
TROUBLESHOOTING AND REPAIR
A. Loosen the set screw using an allen
Removal of Centrifugal Fan
B. Remove the two (2) nuts on the inside of
wrench and then remove the centrifugal
fan.
the housing in the locations shown.
Removal of Blower Housing
A - NUT
C. Remove two nuts and two screws as
depicted.
Then remove the motor bracket together
with the fan motor.
A - NUT
B - SCREW
Removal of Fan Motor Assembly
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 28
Page 29
TROUBLESHOOTING AND REPAIR
D. Remove the centrifugal fan by loosening
the set screw on the shaft. Remove the
fan
motor, by loosening “A” nuts.
Removal of Fan Motor
E. Remove (7) screws from Left Side Panel.
F. Remove (7) screws from Right Side Panel.
3
1
3
Removal of Left Side Panel Screws
3
1
3
Removal of Right Side Panel Screws
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 29
Page 30
TROUBLESHOOTING AND REPAIR
G. Remove (2) screws from Control Panel
Removal of Right Stay Screws
H. Remove (2) screws from Control Panel
Assembly Right Stay.
Assembly Left Stay.
Removal of Left Stay Screws
Removal of Control Panel Assembly
I. 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 Thermistor J101
(2-pin)
(4) Freeze Thermistor J102 (2-pin)
NOTE: Mark each of the 2-pin connectors with a
different color marker to ensure the correct orientation when they are re-connected.
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 30
Page 31
TROUBLESHOOTING AND REPAIR
J. Remove the five (5) screws from the control
board on the control panel assembly. Remove
the control board.
Removal of Control Board
11. Inspection of Capacitor (Fan Motor and Compressor)
Ohmeter Method – Set the ohmeter to the
100K
Ω range. Place the two probes against
the two terminals of the capacitor. At first, the
ohmeter should indicate 0Ω, then the reading
should gradually increase towards infinity (∞).
This indicates that the capacitor is charging. If
the reading indicates infinity right away
(shorted) or the ohmeter fails to move from 0Ω
(open), replace the capacitor.
12. 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 10%
of indicated capacitance, replace the capacitor.
Warning: Properly discharge the capacitor(s)
before testing and after testing has been completed. Failure to do so could cause damage to
test equipment or the unit and/or result in personal
injury (electrical shock) or death.
Inspection of Capacitor
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 31
Page 32
TROUBLESHOOTING AND REPAIR
13. Inspection of Drain Switch
Check for continuity between terminals 1 and
2. Continuity should exist. With switch
depressed, continuity should not exist between terminals 1 and 2. If continuity is not as
specified above, replace the switch.
Measure resistance across the terminals of
the fan motor.
Terminals (at 77˚F (25˚C))
J6 - CF1 Approx. 3.5Ω
J5 - CF1 Approx. 4.7Ω
CF1 - CF2 Approx. 30.4Ω
To J103
Inspection of Drain Switch
NC
DRAIN
SWITCH
DS2
DS1
C
TOP OF
BASE
PLATE
2
1
14. Inspection of Fan Motor
Ground
(Green/Yellow)
Inspection of Fan Motor
Inspection of Compressor Motor
CF1 (White)
CF2 (Brown/White)
J5 Low (Red)
J6 High (Black)
If the measured resistance is not equal to
these standard values, replace the 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.1.1Ω
C – S Approx.2.7Ω
S – R Approx.3.3Ω
If the measured resistance value is not equal
to these standard values, replace the compressor. The compressor uses an external
overload relay. For overload relay specification see chart on page 16.
16. Inspection of Wiring Connection
Refer to the Wiring Diagrams (pg. 40) and check for connection of each wire.
17. Inspection of Thermistor(s)
Using an Ohmeter, check the resistance value across the 2-Pin connector. At normal temperature (77˚F,
25˚C) either thermistor (Room or Freeze) should measure approx. 10,000 or 10k ohms.
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 32
Page 33
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.
B. Inspection of Refrigerant Leak
Carefully check all connections, and each component for leaks whenever the refrigerant system is
installed or repaired. Use an electronic gas leak tester to inspect the system.
C. Insufficient Refrigerant
In case the unit is judged to be deficient in cooling capacity, be sure to perform the inspections in
A. and B. to confirm the cause of trouble. After that, charge the system with refrigerant to the
specified amount.
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.
TROUBLESHOOTING AND REPAIR
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 quite important. As for the shape
of the brazed fitting, it is necessary to
maximize its adhesive area. The clearance
of the brazed fitting must be minimized to
facilitate brazing filler metal to flow into it
by capillary action.
• CLEANING OF BRAZING FILLER METAL
AND PIPE
When the refrigerant system has been
opened up, exposure to heat may have
caused brazing filler metal to stick to the
inside and outside of the pipe. Brazing filler metal may also be compounded with oxygen in the air
to form oxide film. Fats and oils may stick to the pipe from handling. All these factors will reduce
effectiveness of brazing. It is necessary to eliminate excess brazing filler metal using sand paper
and by cleaning thoroughly with a solvent such as Trichlene.
Brazed Fitting and Clearance
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 33
Page 34
TROUBLESHOOTING AND REPAIR
• USE OF DRY NITROGEN GAS
NOTE: Take care not to allow dirt, water, oil, etc. to
enter into the pipe
Vertical Down Joint
• VERTICAL JOINT
During brazing, the inside of the pipe
undergoes an oxidative reaction due to
the brazing flame. Introduce dry nitrogen
gas (1 liters/min.; adjust with the flow
regulator) through the pinch-off tube of
the refrigerant cycle to prevent oxidation.
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.
Vertical Up Joint
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 34
Page 35
TROUBLESHOOTING AND REPAIR
B. Removal of Refrigeration Cycle Components
CAUTION:
1. Before any refrigeration 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 1 liters/min) through the pinchoff tube during any brazing operation.
3. During any component replacement involving brazing, shield nearby parts with a steel plate,
asbestos, etc., to protect them from the flame.
(1) Evaporator
(2) Capillary tube
(3) Condenser
(4) Compressor
NOTE: Hold the compressor body, not the tube, when carrying the compressor.
A
C
Removal of Refrigeration Cycle Components (Refer to 5-2-2.)
Refrigeration Cycle Components
D
F
E
B
PART REPLACED DISCONNECT AT:
Compressor A & B
Condenser A & C
Capillary tube D & E
Evaporator E & F
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 35
Page 36
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.
WARNING:
When handling refrigerant (R-22), the following precautions should always be observed:
• Always wear proper eye protection while handling refrigerant.
• Maintain the temperature of the refrigerant container below 40˚C (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.
• Be careful the liquid refrigerant does not come in contact with the skin.
If liquid refrigerant strikes eye or skin:
• Do not rub the eye or the skin.
• Splash large quantities of cool water on the eye or the skin.
• Apply clean petroleum jelly to the skin.
• Go immediately to a physician or to a hospital for professional treatment.
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
refrigerant cycle with a pipe cutter.
(2) Fit the process tube fitting to the
pinch-off tube on both sides.
Mounting of Process Tube Fitting
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 36
Page 37
TROUBLESHOOTING AND REPAIR
(3) Connect the charging hoses (red -
high pressure side, blue - low pressure side) of the gauge manifold to
the process tube fittings.
NOTE: Connect the hoses using care not to mistake
the high pressure side for the low pressure side and
vice versa.
(4) Connect the charging hose (green) at
the center of the gauge manifold to
the vacuum pump.
B. Evacuation
(1) Open the high pressure valve (HI) and
the low pressure valve (LO) of the
gauge manifold.
Connection of Gauge Manifold
(2) Turn on the vacuum pump to start
evacuation. (Evacuate the system for
approximately 15 minutes.)
(3) When the low pressure gauge indi-
cates 750mmHg (30in.Hg) or larger,
turn off the vacuum pump and close
the high and low pressure valves of
the gauge manifold.
C. Checking Vacuum
(1) Leave the high pressure valve and the
low pressure valve of the gauge
manifold closed for five minutes or
more, and confirm that the gauge
pointer does not return to zero.
(2) If the gauge pointer returns gradually
to zero there is a leak somewhere in
the system (this could also include
gauge manifold). Perform leak check
according to procedure indicated in
D. Once leak has been found and
repaired evacuate the system once
more, and confirm system holds
vacuum.
Evacuation
Checking Vacuum
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 37
Page 38
TROUBLESHOOTING AND REPAIR
D. Checking Gas Leak
Evacuating Air Inside Charging Hose
(1) Remove the charging hose (green)
from the vacuum pump, and connect
the hose to the refrigerant cylinder
(R22).
(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/cm2G.)
After charging is complete, close the
high pressure valve.
Charging with Refrigerant for Gas Leak Check
WARNING: Do not attempt any repair on a
charged system.
WARNING: 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.
(4) Check carefully for gas leaks inside
the refrigerant system using the gas
leak tester.
(5) Repair any leak.
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 B., 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.
CAUTION: Be sure to evacuate the system twice
or more using the repetitive vacuum method.
Evacuation (repeat)
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 38
Evacuate the system an additional time on rainy or
humid days.
Page 39
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.
(3) Securely place the refrigerant cylinder
on a scale with a weighing capacity of
70 lbs (30 kg) that is graduated by 0.2
oz (5 g).
(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.
TROUBLESHOOTING AND REPAIR
Evacuating Air Inside Charging Hose
Standard Amount of Refrigerant:
1.50lbs (0.68kg)
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 lowpressure valve.
(e) Bring the system to a stop.
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.
Charging with Refrigerant
(5) Close the high pressure valve of the
gauge manifold and the valve of the
refrigerant cylinder.
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 39
Page 40
TROUBLESHOOTING AND REPAIR
B. Removal of Gauge Manifold
Removal of Gauge Manifold
Reassemble the unit in the reverse order of removal.
Described below are the parts that require special care
in reassembling the unit. Perform all wiring or rewiring
as referenced in the wiring diagram.
(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.
Compressor Mounting
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 condenser).
Tightening torque:
10.84 ± 2.17 lbf•ft (150 ± 30 kgf•cm)
NOTE: After reassembling, the gap between blower
fan and housing should be 0.06 inches (1.5 mm) or
more.
24. Wiring Notice
Blower Assembly Mounting
25. Perform the inspection of cooling capacity
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 40
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.
and check for abnormal noise or abnormal
vibration.
Page 41
G
AP
G
SCP
TB
T R R1 R2
CC
12
G
1
2
0LCL0
HI
G
CF
12
MC
J4
J5
J6
J2
J1
J3
J8 (AUX1)
RB CB
THS RTH DS
3
2
1
AUX2
MF
IOLF
AP Attachment Plug
TB Terminal Block
CB Control Board
RB Relay Board
MF Fan Motor
MC Compressor Motor
CF Capacitor for Fan
CC Capacitor for Compressor
OLC Overload Relay of Compressor
DS Full Drain Warning Switch
THS Freeze Protection Thermistor
RTH Room Thermistor
SCP Short Circuit Plate
G Ground
J8 (AUX1) Auxiliary Connector (CPK3)
AUX2 Auxiliary Connector (Not Used)
26. Schematic
TROUBLESHOOTING AND REPAIR
MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 41
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