SERVICE M A N U A L CLASSIC PLUS 14 DENSO SALES CALIFORNIA, INC. REGISTERED TO ISO 9002 FILE NO. A5537 (800) 264-9573 www.movincool.com © 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.
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.
CONDENSER (OUTDOOR UNIT) 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.
CONSTRUCTION, SPECIFICATIONS & DATA Cool Air Duct Exhaust Air Duct Centrifugal Fan Capillary Tube Housing for Condenser Fan Condenser Caster with Brake Compressor Drain Switch Control Box Caster Construction of Classic Plus 14 MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 4
CONSTRUCTION, SPECIFICATIONS & DATA Evaporator Fan Control Box Control Panel Cool Air Ducts Upper Panel Fan Motor Side Panel Front Panel Condenser Fan Air Filter(condenser) Evaporator Air Filter (evaporator) Capillary Tube Accumulator Compressor Air Filter (condenser) Drain Tank Condenser Power Cord Casters Base Panel Construction Diagram MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 5
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.
CONSTRUCTION, SPECIFICATIONS & DATA Rating Conditions dry bulb ...................................................................................................95 oF (35 oC) wet bulb .................................................................................................. 83 oF (28.3 oC) humidity .................................................................................................. (60%) Specifications power frequency ...................................................................
CONSTRUCTION, SPECIFICATIONS & DATA 26.5 41.5 3.8 37.7 21.1 16.6 12.5 19.4 2.8 20.6 25.6 2.
CONSTRUCTION, SPECIFICATIONS & DATA @ 115V @ 115V 4.0 (15.9) 14 (25.2) Temperature ˚C (˚F) Cooling Capability (x103 kcal/h (BTU/h)) 3.6 (14.3) 3.2 (12.7) 12 (21.6) 10 (18.0) 8 (14.4) 2.8 (11.1) 6 (10.8) 2.4 (9.5) 40 50 60 70 Relative Humidity of Inlet Air (%) Cool Air Temperature Difference Curve 40 (104) 35 (95) @ 115V 1.7 30 (86) 25 (77) 15 (59) 20 (68) 25 (77) Wet Bulb Temperature ˚C (˚F) Cooling Capability Curve 30 (86) 1.
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.
REFRIGERANT SYSTEM 2. Compressor The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in one casing. A. Compressor Construction The construction of a rotary type compressor is divided into two mechanisms the drive mechanism (compressor motor) and the compression mechanism (compressor). When the rotor shaft of the motor (drive mechanism) turns, the roller of the compressor (compression mechanism) rotates to compress the refrigerant. B.
REFRIGERANT SYSTEM 4. High Temp. / High Press. Liquid Refrigerant 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.
REFRIGERANT SYSTEM Condenser Inlet Pipe Evaporator Inlet Pipe Compressor Discharge Pipe Capillary Tube Evaporator Outlet Pipe Condenser Outlet Pipe Connecting Pipe (evaporator to compressor) Compressor Suction Pipe (insulated) Connecting Tube (condenser to capillary tube) Refrigerant System Piping MOVINCOOL CLASSIC PLUS 14 SERVICE PAGE 13
ELECTRICAL SYSTEM AP THS RTH DS 3 G T R R1 R2 1 SCP 1 CC 2 2 TB MC G G 1 CF 1 2 L0 0LC 2 MF HI J4 IOLF J8 (AUX1) AUX2 J5 G J6 J2 J1 J3 AP TB CB RB MF MC CF CC Attachment Plug Terminal Block Control Board Relay Board Fan Motor Compressor Motor Capacitor for Fan Capacitor for Compressor 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 Aux
ELECTRICAL SYSTEM 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.
ELECTRICAL SYSTEM 2. Control Box A. Capacitors Relay Board Relay Board Fuse DIP Switch Terminal Block 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 APPLICATION Compressor Capacitor Fan Motor Capacitor Fan Motor Compressor VOLTAGE RATING 370 370 CAPACITANCE (µf) 7.5 45 Control Box B.
ELECTRICAL SYSTEM 3. Fan Motor The fan motor is a single phase, induction type two-speed motor. The motor rotates fans on the evaporator side and the condenser side at the same time. Specifications: Rated Voltage: 115 volts 60 Hz Rated Output – High – 243 watts Low – 188 watts UL Listed File Number – E-49807 NOTE: An internal overload relay is used to protect the fan motor.
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.
ELECTRICAL SYSTEM 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.
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.
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.
TROUBLESHOOTING AND REPAIR 8. Disassembly 2 1 4 10 4 3 16 5 11 6 12 17 7 13 8 15 9 14 9 1. 2. 3. 4. 5. 6. 7. 8. 9. Control panel Upper panel Right side panel Air filter Blower housing (condenser) Condenser fan Rear panel Drain Switch Caster 10. 11. 12. 13. 14. 15. 16. 17.
TROUBLESHOOTING AND REPAIR A. Remove Drain Tank. Removal of Drain Tank B. Remove (8) screws from the ducts, then remove the 2-ducts. Removal of Duct Screws and Ducts C. Remove (4) screws from the Service Panel. 4 Removal of Service Panel Screws D. Remove 3 wires, then remove the power cord.
TROUBLESHOOTING AND REPAIR E. Remove remaining (13) screws and the back panel. 4 3 3 3 Removal of Back Panel Screws F. 4 (backside) 4 Remove (14) screws from the Top Panel. 2 Removal of Top Panel Screws 2 G. Top Panel (4).
TROUBLESHOOTING AND REPAIR 9.
TROUBLESHOOTING AND REPAIR To Terminal Block (R-Terminal) Pin #2 Compressor Overload Relay To Fan Motor (Low Speed) J4 J5 J6 J2 J3 S1 C STOP J9 Relay Board Fuse J8 DIP Switch Temperature Scale Display Switch ˚C ˚F Fan Mode Control Switch STOP OPERATE Relay Board Ground (not used) F1 F OPERATE J1 To Terminal Block (T-Terminal) To Fan Motor (High Speed) Main Wiring Harness Relay Board to Control Panel Jumper or 2-Pin Connector of (optional) Condensate Pump Kit - CPK-3 Drain Tank Switch NO
TROUBLESHOOTING AND REPAIR 10. Removal of Blower Assembly ➇ ➀ 1. 2. 3. 4. ➁ ➂ Condenser fan Blower housing (condenser) Fan motor Motor bracket ➄ ➃ 5. 6. 7. 8.
TROUBLESHOOTING AND REPAIR A. Loosen the set screw using an allen wrench and then remove the centrifugal fan. Removal of Centrifugal Fan B. Remove the two (2) nuts on the inside of the housing in the locations shown. A - NUT Removal of Blower Housing C. Remove two nuts and two screws as depicted. Then remove the motor bracket together with the fan motor.
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 3 E. Remove (7) screws from Left Side Panel. 1 3 Removal of Left Side Panel Screws 3 F. Remove (7) screws from Right Side Panel.
TROUBLESHOOTING AND REPAIR G. Remove (2) screws from Control Panel Assembly Right Stay. Removal of Right Stay Screws H. Remove (2) screws from Control Panel Assembly Left Stay. Removal of Left Stay Screws I.
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.
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. 14. Inspection of Fan Motor Measure resistance across the terminals of the fan motor. TOP OF BASE PLATE DRAIN SWITCH To J103 NC DS2 2 1 DS1 C Inspection of Drain Switch Terminals (at 77˚F (25˚C)) J6 - CF1 Approx. 3.
TROUBLESHOOTING AND REPAIR 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.
TROUBLESHOOTING AND REPAIR • 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 liters/min.; adjust with the flow regulator) through the pinch-off tube of the refrigerant cycle to prevent oxidation. NOTE: Take care not to allow dirt, water, oil, etc. to enter into the pipe Vertical Down Joint • VERTICAL JOINT Heat the whole brazed fitting to a proper brazing temperature.
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.
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.
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. Connection of Gauge Manifold B. Evacuation (1) Open the high pressure valve (HI) and the low pressure valve (LO) of the gauge manifold.
TROUBLESHOOTING AND REPAIR D. Checking Gas Leak (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). Evacuating Air Inside Charging Hose (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.
TROUBLESHOOTING AND REPAIR 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).
TROUBLESHOOTING AND REPAIR B. Removal of Gauge Manifold (1) Crimp the pinch-off tube with a pinchoff 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. 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.
G G SCP 1 CF R1 2 R2 MOVINCOOL CLASSIC PLUS 14 SERVICE G HI 0LC 2 J3 J1 J2 J6 J5 J4 2 1 Attachment Plug Terminal Block Control Board Relay Board Fan Motor Compressor Motor Capacitor for Fan Capacitor for Compressor IOLF MF L0 AP TB CB RB MF MC CF CC TB 1 CC MC RTH 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 Us
