© 1992 NIPPONESE CO.LTD. All Rights Reserved. This book, parts thereof, may not be reproduced or copied in any form without ihe written permission of the publisher.
1. GENERAL DESCRIPTION 1) 2) 3) Generally speaking conventional air conditioners cool the entire enclosed environment. They act as “heat exchange, requiring an indoor unit (evaporator) o supply cool air to the indoor, and an outdoor unit {condenser) to exhaust exchanged heat to the outdoor. Unlike conventional air conditioners, the SPOT COOL is a cooling system which directs cool air to specific areas or objects.
2. CONSTRUCTION AND SPECIFICATION 2-1.
1N 2) Basic Construction The interior of SPOT COOL is divided into two sections. The front section houses the evaporator and control box, and the rear section the condenser and the compressor. Air Flow 1. Air flow for the condenser Condenser cooling air is drawn through the sides and rear of the unit, and discharged through the exhaust hot air outlet located on the top of the unit. 2.
2-2. Specifications nem mode! SHUSH [Rating Condition] (inlet air) 35°C 60%RH {WB 28.2°C [Features] Power frequency {Hz) 80 Line Voltage {Volt) Three phase 460 Power consumption (Kw} 7.
3. REFRIGERANT SYSTEM The component parts of the refrigerant system include the following: » Compressor « Evaporator « Condenser + Modulating tank « Capillary tube « High pressure switch These parts are all connected by copper piping, with brazed connections.
3-1. Compressor The compressor used in the SPOT COOL is of a reciprocating hermetic type, incorporating a drive motor and compression mechanism in an enclosed vessel. 3-1-1. Construction The reciprocating type compressor consists of a drive section (motor), and a compression mechanism as shown below. When the rote shaft of the motor rotates, the crank shaft causes the piston to reciprocate in the cylinder and absorb and compress the refrigerant.
3-1-2. Operation 1) Suction When the piston is on a downward stroke, pressure inside the cylinder is reduced. When this pressure becomes lower than the suction side (low pressure side) pressure, the suction valve at the top of the cylinder opens and the refrigerant Snoop enters the cylinder. 2) Compression As the piston commences Hs upward stroke the .refrigerant is compressed, causing a gradual increase in pressure, within the cylinder.
3-2. Condenser The condenser, which serves as a heat exchange, has thin aluminum projections, called spine fins, fastened to a copper tube. Heat is exchanged by forcing cooling air across the condenser fins. 3.3. Capillary Tube The following table shows the specifications of the capillary tube. Mode! Qty Purpose of Use L D. {mm) Length (mm) 2 1000 SHUSH For cooling 3 525 3-4. Evaporator The evaporator is a heat exchange using platens and fuses.
3-6. 3-7. High Pressure Switch The high pressure switch prevents the condenser and compressor from being damaged by an excessively high pressure in the high pressure end of the refrigerating cycle, ie., the refrigerant condensing pressure. The switch is normally closed. The diaphragm detects variations in pressure and, as the pressure increases, the snap disk snaps back to push the pin down, causing the internal contacts to open. This generates a signal 1o open the auxiliary relay. (Refer to P.12) .
4. ELECTRICAL SYSTEM The component parts of the electrical system include the following; « Control box « Control switch « Fan motor « Compressor motor « Over current relays * Relays Lamps etc. ™1 : Terminal block for power CFO TB2 : Terminal bock for control T MF1 : Fan motor for evaporator RL MF2 : Fan motor for condenser HRS MC : Motor for compressor 10L1 MCF : Relay for fan motor 0Lz MCC : Relay for compressor motor FOLIO RX 1 Auxiliary relay THS OCC . Over current relay for MC cs CFO{ .
4-1. Control Box ) The interior of the control box is shown in the figure below. OVER CURRENT TERMINAL BLOCK RELAY FOR MF1 FOR CONTROL RELAY FOR FAN MOTOR ANTI.FREEZING THERMOSTAT RELAY FOR COMPRESSOR MOTOR CONTROL SWITCH TRANSFORMER GROUNDING POWER INDICATOR LAMP TERMINAL BLOCK WARNING INDICATOR LAMP FOR POWER OVER CURRENT RELAY FOR MC Control Box Transformer This transformer is designed 1o coven 460V to 240V and supply power to the contort circuit.
4-1-2. Auxiliary Relay When the power is supplied fo the unit, this relay is energized across terminals 7 and 8 and closed across terminals 5 and 3 and across 6 and 4. These conditions remain unchanged in all operator modes (FAN or COOL). !f one of the errors mentioned below occurs, the auxiliary relay is dine; sized across terminals 7 and 8, and opened across terminals § and 3 and across 6 and 4. This shuts off power to the fan motor relay and compressor motor relay bringing the unit to a stop.
4-1-3. Compressor Relay This compressor relay is closed when the unit is operating in FOOL mode, with power supplied to the compressor. In the following cases, the relay opens 1o cut off power to the compressor. *When the auxiliary relay is opened by the high pressure switch OFF, over current relay OFF compressor overload relay OFF, or internal overload protector of fan motor OFF. *When the evaporator is frozen.
4-1-5. Over current Relay For the three-phase blower motor and compressor motor, an over current relay is usually used as a safety device. This prevents the motor coil from booming i an over current situation has occurred due to abnormal load on the blower motor, compressor motor, extraordinary change in supply voltage, ¢ loss of current in one phase.
4-2. Control Switch The control switch is employed to start or stop operation. This switch is of a 250V, 20A rating rotary type (3-positions). The switching positions are OFF-FAN-COOL. Each contact is switched by a cam mechanism.
4-3. Fan Motor The fan motors are three phase, induction type. The following table shows the specifications of the fan motors. When the control switch is set to FAN, the evaporator fan motor rotates. When it is set to COOL, both the evaporator and condenser tan motors rotate. The fan motor is equipped with an internal protector which cuts in at 120°C. i an unusual temperature rise occurs in the motor coll, the protector isolates the power supply via an auxiliary relay to prevent the motor coil from numbing.
4-5. Anti-Freezing Thermostat When the evaporator has frozen, the contact of the thermostat opens to stop the compressor and the ventilating operation is automatically activated. When the evaporator has defrosted, the contact closes to restart the compressor. The heat sensing tube of the thermostat is mounted at the evaporator outlet tube and is insulated trim surrounding air by heat insulating material.
4-6. Wiring Proper connections are indicated at all the wire ends. GRADING ON COPPER TUBE CONTROL BOX { MILLINERY TB1 : Terminal bock for power CFO : Undercurrent relay for MF2 TB2 : Terminal block for control! TL .
5-2. Cooling Capability Characteristics 1) Cooling Capability Curve tush) FE/min) 1500 1300 1100 900 e 1o 100 90 80 CFPEBS 170 WET BULB TEMP. —20 — keelhaul) -1 17 -1 186 2700 -1 2400 -4 2100 -11800 1500 COOLING CAPABILITY TOTAL AIR VOLUME DRY BULB TEMP.
2) Cool Air Temperature Difference Curve TEMPERATURE DIFFERENCE BETWEEN CRH /fi// 432 444 LAz X10 (P mind RELATIVE HUMIDITY INLET AIR 3I0X10{wm) TOTAL AIR VOLUME 0148 If the air of 104°F or higher is drawn) the temperature of outlet air increase by about 3°F.
3) Extension static pressure and air volume curve of cool air.
1. TROUBLE SHOOTING Before trouble shooting this system the following inspection should be performed. a) Inspection of power source voltage and phase sequence. Check the voltage of the power source. ’ Model 50HU : Three phase, 460 volts, 60 Hz. Check the condition of the fuse or circuit breaker in the power source. Check the rotating direction of blower. if the blower rotates in the opposite direction, phase sequence of the power source is reverse.
TROUBLE SYMPTOM POSSIBLE CAUSE REMEDY 1) Defective drain pan Repair Water leakage {Crack or hole) from the unit 2) Detective drain hose Repair ot replace (Clogged or loose connection) 1) Loose compressor mounting nut | Tighten 2} Loose or deformed condenser Tighten or replace Abnormal 8 fan or evaporator fan mmg or 3) Interference of fan and scroll Readjust shaking 4) Interference with other materials | Remove and inspect to the tan 1) Defective evaporator fan motor | Refer to 4-4 2) Detective evaporator fa
2. INSPECTION OF UNIT in case of trouble, perform the following inspection before disassembly. 2-1. Inspection of Clogging at Heat Exchange of Evaporator and Condenser. Check the heat exchange of the evaporator and condenser for dit and clogging. ¥ they are dirty or clogged, remove and wash each pan, 2-2. Examination of Operating Environment Check the Environment Around the Unit.
3. DISASSEMBLY (Refer to P.2) 3-1. Removal of Outer Panels 1) Remove the following parts 1. Sifters 2. Exhaust hot air outlet 3. Front panel 4. Evaporator panel 6. Condenser panel . Right side pane! 7. Rear panel PANEL mares FILTERS evaporator PANEL Removal of Outer Panels 2) Remove the three screws from the control box and open the control box cover. 3) Remove the four lead wires of the power wire from the terminal block. Loosen the iwe screws fixing the conduit and disconnect the power wire.
3-2. Removal of Electrical Pan 1) Remove the electrical wiring according to the wiring diagram as shown below. GRADING &N COPPER TUBE TB1 : Terminal block for power TB2 : Terminal block for control MF1 : Fan motor for evaporator MF2 : Fan motor for condenser MC : Motor for compressor MCF : Relay for tan motor MCC : Relay for compressor motor RX : Auxiliary relay CCC : Overture relay for MC QC : Over current relay for MF1 TF : Transformer CFO RL HRS 10L1 0oL2 THS cs CONTROL BOX .
2) Remove the electrical pans, in the control box. (Refer to P11) 3) Remove the control switch, power indicator lamp and waning indicator damp as shown. Pl POWER INDICATOR Lamp == CONTROL SWITCH WARING INDICATOR LAMP | | moi Removal of Control Switch 3-3. Removal of Bower Assembly (for evaporator) 1. Frame 4. Ring 2. Fan motor 5. Fan 3. Motor mounting bracket 6.
1} Remove the ring by loosening the four S Crews. 2) Remove the fan moor with bracket by loosening the four nuts. 3) Remove the centrifugal fan by loosening the set bolt and nut (left handed screw) using a hexagonal key wrench and wrench.
3-4. Removal of Blower Assembly (for condenser) 1. Fan 2. Motor 3. Bracket, motor 20118 1) Remove the fan by loosening the nut (feel 2) handed screw). Note: Tightening torque for nut. 400~500 kg-cm (30~35 lob-ft) Remove the blower motor from brace! by loosening the three nuts.
4. INSPECTION AND REPAIR OF ELECTRICAL SYSTEM 4-1. Inspection of Transformer Measure resistance between the terminals (460V-01, 240V-02) of the transformer. Resistance : 460V-01 (Primary coil) : 75Q (at 20°C) 240V-02 (Secondary coil) : 240 (at 20°C) Note: Primary rated voltage AC 480 volts Secondary rated voltage AC 240 volts Inspection of Transformer If the resistance is not comparable o the above standard values, replace the transformer.
4-2. Inspection of Control Switch At each position of the control switch, there should be continuity across the following terminals. Switch Position | Conducting Terminals OFF 2-85 FAN 1-5 cool #f there is no switch continuity, replace the control switch, 4-3. Inspection of Warning Indicator Lamp and Power Indicator Lamp. Make a test circuit as shown in the figure. if the lamp fails to light up, replace it. 4-4. Inspection of Fan Motor © Measure the resistance between each terminal of the fan motor.
4.5, Inspection of Anti-freezing Thermostat At normal temperature, (18°C or higher) there should be continuity across the iwo terminals. If not, replace the thermostat. Inspection of Anti-freezing Thermostat 4-6. Inspection of High Pressure Switch At normal pressure when the unit is off, there should be continuity across the two terminals. If not, replace the high pressure switch. Note: Cult off pressure 27.5 kg/onvG (381 PSI) Reset pressure 205 gloom (291 PSI) M 4-7.
48, 4-9. inspection of Compressor Relay & Fan Motor Relay Check for continuity across the terminals when the test button is depressed racy again when released. Depressed: All terminal pairs are conducing. Released: All terminal pairs are not conducting. Measure the resistance across terminals A and B. Standard resistance: 650~8000 It the resistance is out ot this range, replace the relay. inspection of Over Current Relays Check for continuity across the terminals 12, 34 and 5-6.
4-10. Inspection of Auxiliary Relay Check for continuity between the relevant terminals as follows. Terminals 7 8 Dappling no | O voltage O O Dappling voltage O O ; 240V (AC) o Note * O——O : CONTINUITY inspection of Auxin Re Measure the resistance across terminals 7 fray Ray and 8. Standard resistance: 14~16kQ. i the resistance is out of this range, and/or continuity is not as per the above table, replace the auxiliary relay. 4-11.
5. INSPECTION AND REPAIR OF REFRIGERANT SYSTEM 5-1. Inspection When something is wrong with the refrigerant system, # fails 1o cool effectively. Possible causes are clogging. leakage or insufficient refrigerant. In such a case, carry out the following inspection procedure, Inspection of Refrigerant Clogging Check for clogging in the component parts of the refrigerant system and the pipes connecting them.
The gas detector shout be used in the following way: 1} Check the amount of propane liquid in the container. 2} install the propane container to the gas detector body by muting it fully clockwise. 3) When fighting the detector, insert the match into the igniting hole and tum the adjusting handier slowly counterclockwise. This will ignite the gas detector. ) 4) The reactor (copper ring) must be red hol, bul the flame must be kept as small as possible. The smaller the flame, the more sensitive the detector.
Correct Fitting, Correct Clearance In general, the strength of brazing filler metal is lower than that of the base metal. LEA ¢ 5. So, the shape and clearance of the brazed fighting is very important. E As for the shape of the brazed fitting. # is necessary to maximize its bonding area. The clearance of the brazed fitting must be mswfcmzarmlm minimized in order to draw in the brazing filler metal by capillary action.
5-2-2. Removal of Refrigerant Cycle Relatives 1. When removing a brazed portion, protect the other pans from the flame with a steel plate, asbestos, etc. 2. Before removing the brazed portion from the refrigerant cycle, be sure to cut off the end of the pinch-off tube and bleed the cycle of gas. 3. In this case, also breed the refrigerant cycle of N, gas though the open pinch-off tube in order to prevent oxidization.
§-3. Charging the System with R.22 Be sure to purge and same the system with refrigerant 1o the specified amount in the following way: CAUTION: 1} When handing refrigerant the following precautions should be observed. A) Ways wear eye protection while handing refrigerant. B) Keep the refrigerant container below 40°C (104°F). C) Do not handle refrigerant in an enclosed room. D) Do not handle refrigerant near an open flame (especially while smoking a cigarette).
§-3. Charging the System with R.22 Be sure to purge and same the system with refrigerant 1o the specified amount in the following way: CAUTION: 1} When handing refrigerant the following precautions should be observed. A) Ways wear eye protection while handing refrigerant. B) Keep the refrigerant container below 40°C (104°F). C) Do not handle refrigerant in an enclosed room. D) Do not handle refrigerant near an open flame (especially while smoking a cigarette).
3) Connect the charging hoses {red one on high pressure side, and blue one on low pressure side) of the gauge manifold to the process tube fittings. Note: Connect the hoses using care not fo 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. 5-3-2. Purging 1) Open the high pressure naive (Hf} and the iow pressure naive (LO) of the gauge manifold. 2) Tum on the vacuum pump to start purging.
5-3-4. Checking Gas Leak 1} Remove the charging hose (green) iron the vacuum pump, and connect the hose to the refrigerant cylinder (R22). Note: Before this step, it the mouthpiece for refrigerant cylinder (service tool : No. 945502050), 1o the outlet of the refrigerant cylinder. Purging Alr inside Charging Hose 2) Loosen the nut on the gauge manifold side of the charging hose {(green). Open the naive of the refrigerant cylinder to purge air from inside the charging hose.
5-3-5. Purging (Repeat) 1) Close the valve of the refrigerate Cylinder. Then remove the charging hose {green) from the refrigerant cylinder, and connect it to the vacuum pump. Note: Keep the high pressure valve and the low pressure vale of the gauge manifold closed. 2} In the procedure of above purge the system until the low pressure gauge indicates 750mmHg or more. (For 15 minutes or more) 3) After purging is complete, close the high pressure valve and the iow pressure naive of the gauge manioc.
3) Place the refrigerant cylinder on a scale. (weighting capacity: 70 lbs;. graduated in 0.2 0z.) 4) Open the high pressure valve of the gauge manifold and the valve of the Charge the system with refrigerant 1o the specified amount, looking at the graduations of the scale.
5-4-2. Removal of Gauge Manifold 1) Pinch off the pinch-off wbe with a pinch-off tool. 2) Remove the gauge manifold charging hose and the process tube fitting. Crush the end of the pinch-off tube, with the pinch off tool still in position 3) Braze the end of the pinch-off tube. 4) Remove the pinch off tool and make sure that gas leakage is not observed at the pinched off portion and the brazed end. 6. REASSEMBLY Reassemble the unit in the reverse order of removal.
7. SERVICE PARTS LIST The service parts of the SPOT COOL are supplied as shown below. The standard parts of the unit, which are standardized by ISO (International Standardization Organization), are bolts, nuts and screws. The specifications of these standard parts are included in this pans list over page.
SERVICE PARTS iLL. NO. NOMENCLATURE PART NO. aTy. REMARKS Unit says, SHUSH 4841001040 1 1 Frame, base 484300-0870 1 include 2, 21~24 2 Leg 484921-0040 4 3 Panel, rear 484410-0391 1 4 Panel, condenser, upper 484420-0091 1 5 Panel, condenser, fight 484410-0371 1 6 Panel, condenser, left 484410-0381 1 7 Filter, condenser 484401-0140 3 8 Frame, condenser filter 484300-0210 3 9 Panel, right 484410-2870 1 .
SERVICE PARTS itl. NO. NOMENCLATURE PART NO. QTy. REMARKS 1 Compressor says 484650-0930 1 2 Pressure regulator 484782-0050 1 3 Core says, condenser 484600-0560 1 4 Core says, evaporator 484600-0650 1 include & 5 Pipe says, capillary 484640-0150 1 6 High pressure switch 484660-0270 1 7 Bracket 484321-0400 2 *8 Pipe, charging 4848000440 1 8 Cushion 484804-0170 4 10 Co liar 484915-0230 4 11 Nut, hex. 949056-2500 4 M8, Hex.
SERVICE PARTS ILL. NO. | NOMENCLATURE PART NO. Qry. REMARKS 1 Frame 484300-0880 1 2 Casing, fan 484260-0011 1 3 Bracket, motor 484330-0400 1 4 Motor 484211-0850 1 5 Ring 484381-0200 1 6 Fan 4842210151 1 include set bolt 7 Nut, special 481216-0020 1 Hex. size 18 8 Clip,short 480841-0010 1 Length 100 9 Nut, tangle 82150-08081 12 Hex, size 12, M8 10 Washer, toothed 949016-0320 8 M8 11 Bok, hex. 80120-08251 4 MB, £25, Hex. size 12 12 Washer, Spring 948017-1270 1 T1.
213 SERVICE PARTS ILL. NO. NOMENCLATURE PART NO. Qry. REMARKS 1 Bracket, motor 484330-0390 1 2 Motor 484211-0840 1 3 Fan 484221-0080 1 4 Nut, special 481216-0020 1 Hex. size 19 5 Clip, shewn 480841-0010 1 Length 100 6 Clip, middies 481951-0020 3 Length 150 7 Screw, w/Washer 91370-06147 8 M8, 214 8 Washer, toothed 948016-0120 8 Mé 9 Nut, flange 92150-08081 3 M8, Hex.
SERVICE PARTS iLL. RO, NOMENCLATURE PART NO. QTy.