Movincool CM 25 Service Manual
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Movincool CM 25 Service Manual

Movincool CM 25 Service Manual

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SERVICE MANUAL

CM 25
Unit Serial Number Range: 1009XXXXC25 to Present
(From October 2009 to Present)

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Summary of Contents for Movincool CM 25

  • Page 1: Service Manual

    SERVICE MANUAL CM 25 Unit Serial Number Range: 1009XXXXC25 to Present (From October 2009 to Present)

  • Page 2: Serial Number Location And Identification

    All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher. DENSO PRODUCTS AND SERVICES AMERICAS, INC. reserves the right to make changes without prior notice. MovinCool®, Office Pro®, and SpotCool® are registered trademarks of DENSO Corporation.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Operation Section 1. PRECAUTIONS FOR SAFETY Foreword............... 6 Definition of Terms .
  • Page 4 Table of Contents 5.12 Condenser Fan Motor Operation ........... 36 5.13 Internal Drain Pump Operation .
  • Page 5 Table of Contents Repair Section 6. TROUBLESHOOTING Troubleshooting ..............43 Self-Diagnostic Codes .

  • Page 6: Precautions For Safety

    Operation Section 1. PRECAUTIONS FOR SAFETY 1.1 Foreword • This manual has been published to service the MovinCool CM 25. Use this manual only when servicing the CM 25. 1.2 Definition of Terms Describes precautions that should be observed in order to prevent injury to WARNING the user during installation or unit operation.

  • Page 7: Specifications

    Operation Section 2. SPECIFICATIONS 2.1 Exterior Dimension Diagram 17.8 DIA. 13.8 DIA. 12 4 x DIA. 0.6 29.8 10.7 31.5 UNIT: inch ILL00663-00...

  • Page 8: Technical Specifications

    Operation Section 2.2 Technical Specifications Wall Mounted Controller (WMC) with LCD Operation display Electronic Features Control Electronic with Inverter Circuit Voltage Requirement Single-Phase 208/230 V 60 Hz Electronic Characteristics Min.- Max. Voltage Min. 198 V, Max. 253 V Recommended Fuse Size 20 A Cooling Capacity and Power Consumption Total Cooling Capacity...
  • Page 9 Operation Section • Dry contact type (recommended) Fire Alarm Input • No-voltage contact input/Contact Signal Connection resistance less than 100 ohm Warning Signal Output 2 A at 30 V DC/AC max. with resistive load W x D x H (without flange) 53 x 32 x 20 in (1346 x 813 x 508 mm) Dimension W x D x H (with flange)

  • Page 10: Characteristics

    Operation Section 2.3 Characteristics • Value range for each outdoor temperature shown in the graphs is based on the compressor speed. (1) How to read the characteristics < Example > Condition: Cooling Capacity: Evaporator Inlet Air Dry Bulb : 77 °F (25 °C) Max: 24000 Btu/h Evaporator Inlet Air Wet Bulb : 59 °F (15 °C)
  • Page 11 Operation Section (2) Cooling capacity curve Condenser Inlet Air Temperature 50°F (10°C) Condenser Inlet Air Temperature 95°F (35°C) Condenser Inlet Air Temperature 115°F (46°C) 95 (35) 86 (30) 77 (25) 68 (20) 59 (15) (10) (15) (20) (25) Evaporator Inlet Air Wet Bulb Temp. °F (°C) IILL00676-00 <...
  • Page 12 Operation Section (3) Power consumption curve Condenser Inlet Air Temperature 115°F (46°C) Condenser Inlet Air Temperature 95°F (35°C) Condenser Inlet Air Temperature 50°F (10°C) 95(35) 86(30) 77(25) 68(20) 59(15) (35) (10) (15) (20) (25) (30) Evaporator Inlet Air Wet Bulb Temp.°F (°C) ILL00677-00 <...
  • Page 13 Operation Section (4) Current consumption curve Condenser Inlet Air Temperature 115°F (46°C) Condenser Inlet Air Temperature 95°F (35°C) Condenser Inlet Air Temperature 50°F (10°C) 95(35) 86(30) 77(25) 68(20) 59(15) (35) (20) (25) (30) (10) (15) Evaporator Inlet Air Wet Bulb Temp.°F (°C) ILL00678-00 <...
  • Page 14 Operation Section (5) Cool air temperature difference curve 28.8(16) 25.2(14) Condenser Inlet Air Temperature 21.6(12) 50°F (10°C) 18.0(10) Condenser Inlet Air Temperature 14.4 (8) 95°F (35°C) 10.8 (6) Condenser Inlet Air Temperature 7.2 (4) 115°F (46°C) 3.6 (2) 95(35) 86(30) 77(25) 68(20) 59(15)

  • Page 15: Construction

    Operation Section 3. CONSTRUCTION 3.1 Exterior Components Cool Air Exhaust (12.0 in.Dia.Flange) Condenser (Hot) Air Exhaust Connection For Optional Condensate Pump Evaporator (Room) Air Intake (12.0 in.Dia.Flange) Fixing Position For Optional Drain Pipe For Pump Condensate Pump Mounting Holes Condensate Pan Drain For Gravitational Drain/Maintenance Service Panel Stop Switch Wall Mounted Controller/...

  • Page 16: Internal Structure

    Operation Section 3.2 Internal Structure High-Pressure Switch Electronic Expansion Valve Compressor Overload Relay Evaporator Accumulator Condenser Evaporator Fan Evaporator Fan Motor Compressor Control Box Condenser Fan Condenser Fan Motor I003141...

  • Page 17: Basic Construction

    Operation Section 3.3 Basic Construction • The MovinCool CM 25 is compact in Condenser Control Box Evaporator construction due to the condenser and evaporator being enclosed in one unit. The interior of the unit is divided into two sections. One section contains the evaporator which cools room interior air.

  • Page 18: Refrigeration System Construction

    Operation Section 4. REFRIGERATION SYSTEM 4.1 Refrigeration System Construction The component parts of the refrigeration system include the following: • Compressor, Evaporator, Condenser, Accumulator, Electronic expansion valve These parts are all connected by copper tubing. All the connections are brazed. Evaporator Inlet Pipe Condenser Outlet Pipe...
  • Page 19 Operation Section Flow of Refrigerant CTS1 (Condenser Thermistor) OLC (Compressor Overload Relay) CTS3 (Evaporator Pipe Outlet Thermistor) Accumulator (Condenser Fan Motor) Condenser Evaporator Compressor (Evaporator Fan Motor) RTS2 (Evaporator Inlet Air Thermistor) HPRS (High-Pressure Switch) (Electronic Expansion Valve) CTS2 (Evaporator Pipe (Condenser Inlet Air Thermistor) Inlet Thermistor) Wall Mounted Controller (WMC)

  • Page 20: Compressor

    Operation Section 4.2 Compressor • The CM 25 is equipped with a variable speed compressor, which is driven by state of the art inverter technology. • A variable speed compressor automatically adjusts its speed as the heat load in the room changes.
  • Page 21 Operation Section (3) Operation 1) Start of compression Discharge 1) The cylinder is filled with low pressure gas. Valve 2) Since pressure in the discharge chamber is higher than in the cylinder, the discharge valve is kept closed. Piston Cylinder I003185 2) Suction and compression Discharge...

  • Page 22: Condenser

    Operation Section (4) Compressor lubrication • The lubrication system is comprised of a hollow shaft, an oil scraper mounted at the bottom end of a shaft journal (shaft bearing), Rotor and the lubrication groove for the shaft journal. The lubrication groove is wider than the oil Hollow Shaft orifice.

  • Page 23: Electronic Expansion Valve

    Operation Section 4.4 Electronic Expansion Valve • The electronic expansion valve causes rapid Valve Spring Spring refrigerant expansion by injecting "high- Magnet Valve Holder temperature, high-pressure liquid refrigerant" Stopper Delivery Screw from the condenser through a small orifice. The Valve resultant "low-temperature, low-pressure mist refrigerant"...

  • Page 24: Accumulator

    Operation Section 4.6 Accumulator • The accumulator is mounted on the suction from Evaporator 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.

  • Page 25: Electrical System

    Operation Section 5. ELECTRICAL SYSTEM 5.1 Circuit Diagram CONTROL CIRCUIT RTS2 CTS3 CTS2 CTS1 RTS1 HPRS FLTS Fire Output Millivolt Alarm Signal Thermostat Input C4 G4 CN17 CN20 CN19 CN10 CN11 CN14 CN13 CN12 DIP SWITCH CN18 Power Supply Circuit Module AC 208/230 V 1-PHASE, 60 Hz...

  • Page 26: Control Box

    Operation Section 5.2 Control Box RB: Relay Board IND: Inductor Coil TB1: Terminal Block 1 NF: Noise Filter TB2: Terminal Block 2 I003190...

  • Page 27: Power Supply Requirements

    Operation Section 5.3 Power Supply Requirements • The unit requires a single-phase 208/230 V, 60 Hz power supply to operate. • The power supply should be a dedicated single outlet circuit with a UL approved short-circuit and ground fault protective breaker with a fuse size of 20 A maximum. •...

  • Page 28: Wall Mounted Controller (Wmc)

    Operation Section 5.4 Wall Mounted Controller (WMC) • The WMC for this unit should be mounted within the room close to the return air grill to provide convenient system control. LCD Display Control Panel 4.8 in (120 mm) 4.8 in (120 mm) 0.6 in (15 mm) I003163 ON/OFF button...

  • Page 29: Lcd Display

    Operation Section LCD Display I003164 COOL or FAN ONLY Illuminates to indicate COOL on or FAN ONLY on. RUN or AUTO Illuminates to indicate fan mode set to RUN or AUTO. HI or LO Illuminates to indicate fan speed set to High or Low. Room temperature Illuminates temperature in either Fahrenheit (°F) or Celsius (°C) (See Note).
  • Page 30 Operation Section • WMC connection Connection Table Unit Terminal Wall Mounted Unit Controller Terminal No. Wire No. (Color) P (Red) C4 (White) G4 (Black) Shield Conductor Ground Screw (Green) (Ground Screw) Wall Mounted Controller (WMC) I003165 < NOTE > If the wiring needs to be extended, a maximum extension wire can be extended up to 316 feet. Shield wire 16-22 AWG is recommended for use as an extension wire to reduce noise interference.
  • Page 31 Operation Section For WMC supplied with the CM 25 serial number from 0113XXXXC25 to present • If the reading of the room temperature value is not accurate, adjustment can be done by setting the DIP switch located inside the WMC using the table shown below as reference.

  • Page 32: Field-Supplied Millivolt Wall Thermostat (Mwt) Connection

    Operation Section 5.5 Field-Supplied Millivolt Wall Thermostat (MWT) Connection • The CM 25 is equipped with terminals for connection to the MWT. The MWT can be installed for convenient access in any room. - Use with a single- and multi-stage system wall thermostat.

  • Page 33: Warning Signal Connection (Output Signal Terminal L+ And L-)

    Operation Section 5.6 Warning Signal Connection (Output Signal Terminal L+ and L-) • The unit is equipped with a warning signal output relay type (Form-C, normal open dry contact) that can be used to monitor the failure condition. • The relay contactor is closed when the following conditions have occurred: - Condensation overflows - Temperature sensor fails - Cooling function fails...

  • Page 34: Fire Alarm Control Panel Connection (Input Signal Terminal E+ And E-)

    Operation Section 5.7 Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-) • The unit is equipped with a normal open input signal that can be connected directly from the fire alarm control panel. When receiving the signal from the fire alarm control panel, the unit turns off and does not turn back on until the power source is reset, or the MWT turns off and on.

  • Page 35: Basic Operation

    Operation Section 5.8 Basic Operation • The following components are controlled based on settings and signals from the WMC or MWT in accordance with signals from various sensors: compressor, evaporator fan motor, condenser fan motor, electronic expansion valve, internal drain pump. 5.9 Compressor Operation (1) Startup speed control •...

  • Page 36: Evaporator Fan Motor Operation

    Operation Section 5.11 Evaporator Fan Motor Operation • The evaporator fan motor is controlled by signals from the WMC or MWT. (1) When the WMC is connected • ON/OFF control and fan speed are determined by the WMC settings. Fan motor settings - AUTO: The fan motor turns ON when the compressor is ON, and OFF when the compressor is OFF.

  • Page 37: Internal Drain Pump Operation

    5.16 Automatic Restart After Power Interruption (Automatic Recovery Function) • The program within the CM 25 microprocessor 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 (either manual or preset program) it was in prior to the loss of power.

  • Page 38: Relay Board

    Operation Section 5.17 Relay Board • The relay board controls components such as the compressor and fan motor based on both signals received from the WMC or MWT, as well as signals from various sensors. The relay board is equipped with a compressor control device called the “STI module”. The relay board also contains fuses and a DIP switch.
  • Page 39 Operation Section (2) DIP switch configuration and setting • The controller of the unit is equipped with DIP switches that default in the OFF position. The DIP switch can be set to configure the following functions. DSW1 DSW2 DSW3 DSW4 I003192 Switch Switch...

  • Page 40: Compressor

    Operation Section 5.18 Compressor (1) Compressor motor • The CM 25 uses an inverter-controlled DC compressor. compressor motor operated by three-phase voltage outputted from the STI module on the relay board. Specifications: - Rated Voltage: DC 220 V - Rated Output: 1380 W...

  • Page 41: Fan Motor

    Operation Section 5.19 Fan Motor (1) Evaporator fan motor • The CM 25 uses an inverter-controlled DC evaporator fan motor. • The evaporator fan motor is operated by DC motor actuation voltage outputted by the relay board. Evaporator motor speed controlled by a relay board built into the fan motor.

  • Page 42: Temperature Thermistor

    Operation Section 5.20 Temperature Thermistor • The temperature thermistor detects temperature as a resistance value. I001695 Specification Symbol Denomination Characteristic Detect “SHORT” Detect “OPEN” RTS1 WMC room thermistor 8 k ohm at 77°F (25°C) 181°F (83°C) or higher -29°F (-34°C) or less Evaporator inlet air RTS2 5 k ohm at 77°F (25°C)

  • Page 43: Troubleshooting

    Repair Section 6. TROUBLESHOOTING WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltages may remain in the unit immediately after the power is disconnected. 6.1 Troubleshooting • Before troubleshooting the system, the following inspection should be performed. (1) Inspection of power source voltage •...

  • Page 44: Self-Diagnostic Codes

    Repair Section 6.2 Self-Diagnostic Codes • Self-diagnostic codes are displayed on the WMC and indicate by LED on the relay board under the following conditions. • LED on the relay board indicates self-diagnostic codes for the MWT under the following conditions.
  • Page 45 Repair Section Self-Diagnostic Relay Board Warning Code LED (Red) Alarm Cause Signal Detection Contents Pattern User Service Output Mode Mode Evaporator fan motor When a fan motor speed of  locked 50 rpm or less is detected four times within 10 seconds Condenser fan motor ...
  • Page 46 Repair Section Relay Board Warning Self-Diagnostic Alarm LED (Red) Cause Signal Detection Contents Pattern Code Output When the evaporator pipe inlet thermistor temperature at or below 26.5°F (-3°C) is detected during compressor Freezing abnormality   operation. However, detection is not possible for 5 minutes after the compressor starts.
  • Page 47 Repair Section Alarm (buzzer) patterns Pattern 1 Pattern 2 Pattern 3 Pattern 4 0.5 sec 1 sec 4 sec I003173...
  • Page 48 Repair Section Alarm clear method • Self-diagnostic codes are not displayed for the MWT. To identify the cause, check the LED on the relay board and refer to the charts on page 44 to 46. Self-Diagnostic Alarm Clear Method Code Cause User Service...
  • Page 49 Repair Section Self-Diagnostic Alarm Clear Method Code Cause User Service Wall Mounted Controller (WMC) Millivolt Wall Thermostat (MWT) Mode Mode Input overcurrent Power device temperature abnormality Reset the power from the circuit DC voltage abnormality Press RESET button. breaker. Power device damage abnormality Circuit malfunction Alarm Clear Method...

  • Page 50: Troubleshooting Chart

    • If conditions persist after the above actions have been taken, turn the unit off, disconnect the power and contact your MovinCool reseller or a qualified technician. • Self-diagnostic codes are not displayed for the MWT. To identify the cause, check the LED on...
  • Page 51 Repair Section Condition Check Area Self-Diagnostic Codes Unit does Possible Cause Remedy Buzzer (WMC) Pattern operate. User Service Mode Mode Signal is input from the Check the fire alarm system and confirm fire alarm. there is no signal input to the unit, then RESET the controller Drain hose clogged Remove any blockage or excessive kinks...
  • Page 52 Repair Section Condition Check Area Self-Diagnostic Codes Unit does Possible Cause Remedy Buzzer (WMC) Pattern operate. User Service Mode Mode Operating outside of the Check environmental condition. Do not operating temperature operate the unit outside the operating range. condition range. (See page 9.) RESET the controller Insufficient air volume.
  • Page 53 Repair Section Condition Check Area Self-Diagnostic Codes Unit does Possible Cause Remedy Buzzer (WMC) Pattern operate. User Service Mode Mode Loose CTS2 thermistor Reconnect the CTS2 thermistor and check connection. the connection. RESET the controller Defective CTS2 Replace CTS2 thermistor. thermistor (short or RESET the controller open).
  • Page 54 Repair Section Condition Check Area Self-Diagnostic Codes Unit does Possible Cause Remedy Buzzer (WMC) Pattern operate. User Service Mode Mode Excessive current from RESET the controller twice or three times. If the STI module to the the error still occurs, replace the compressor. compressor.
  • Page 55 Repair Section Condition Check Area Possible Cause Remedy Insufficient Cooling Air is not Compressor start delay (120 Compressor starts after 120 seconds cool. seconds) is activated. automatically. Freeze protection is Compressor starts automatically when activated. evaporator outlet pipe temperature (CTS3) rises more than 43°F (6°C) while compressor stops.

  • Page 56: Self-Diagnostic Code Display Operation And Control

    Repair Section 6.4 Self-Diagnostic Code Display Operation and Control (1) WMC • When an abnormality occurs in a unit, a self- diagnostic code and “CHECK” will display on the WMC. Switching the self-diagnostic code display mode • The self-diagnostic code display can be switched between user mode and service Self-Diagnostic mode.

  • Page 57: Self-Diagnostic Code Records Display Operation (Only When Connected With Wmc)

    • The unit power on time, compressor operation time, and self-diagnostic codes can be displayed on the WMC when it is connected to CM 25. The unit power on time and compressor operating time can be stored up to 65535 hours (automatically cleared to 0 hour and start counting). The self-diagnostic codes can be stored up to 4 different codes.
  • Page 58 Repair Section (2) Exiting the self-diagnostic code records display • To exit the self-diagnostic code records display, press the "RESET" button, or do not operate the system for 1 minute. Display No. Display code Function Total unit power on time (unit: h) Compressor operating time (unit: h) Self-diagnostic code display Self-diagnostic code record 1...

  • Page 59: Operational Status Display Control (Only When Connected With Wmc)

    6.6 Operational Status Display Control (Only When Connected With WMC) • The operational status of each functional part can be displayed while the CM 25 is running. (1) Display method • Press and hold the “”, “”, and “FAN MODE” buttons simultaneously for 3 seconds.
  • Page 60 Repair Section Displayed Display Display Item Display Example Code Units Compressor speed 90 (90 rps) Electronic expansion valve position pulse 3 50 (350 pulse) Evaporator fan motor speed 8 80 (880 rpm) Condenser fan motor speed 8 65 (865 rpm) Compressor operating current 15 (15 A) Evaporator inlet air thermistor (RTS2)

  • Page 61: Initialize Fan Motor

    Repair Section 6.7 Initialize Fan Motor • Initialize the motor to correct the motor speed when any of the following components are replaced: evaporator fan motor, condenser fan motor, relay board. (1) Operation method 1) With the power supply OFF, turn DIP switch 2-1 ON. 2) Turn the power supply ON.
  • Page 62 Repair Section Initialize Fan Motor TEST Mode DSW1 DSW2 DSW3 DSW4 I003178...

  • Page 63: Test Mode

    • Test operation can be performed using the test mode. (1) Operation method • Set the CM 25 to standby mode, turn DIP switch 3-1 ON, then turn on the unit. The unit will automatically operate at the following conditions.

  • Page 64: Basic Inspection

    Repair Section 6.9 Basic Inspection • Perform the following inspection before disassembly. (1) Inspection of plate fins • To inspect the plate fins of either the evaporator or 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.

  • Page 65: Inspection Of Compressor

    Repair Section 6.10 Inspection of Compressor (1) Compressor motor • Measure resistance across the terminals of the compressor motor. (All terminals must be disconnected from the unit.) • Between terminals {at 68°F (20°C)} - U-V Approx. 0.64 ohm - V-W Approx. 0.64 ohm - W-U Approx.

  • Page 66: Inspection Of Electronic Expansion Valve Control Coil

    Repair Section 6.11 Inspection of Electronic Expansion Valve Control Coil • Measure resistance across the connector pins of the electronic expansion valve control coil. • Between connector pins {at 68 °F (20 °C)} - Blue-Red Approx. 46 ohm - Amber-Red Approx. 46 ohm - Yellow-Red Approx.

  • Page 67: Inspection Of Refrigeration System

    Repair Section 6.14 Inspection of Refrigeration System • In most cases, the probable cause for insufficient cooling is a clog in the system, leakage or an incorrect amount of refrigerant. In such cases, inspect the system according to the following procedure.

  • Page 68: Parts Construction

    Repair Section 7. 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. 7.1 Parts Construction Rear Panel Right Panel Evaporator Inlet Air Top Panel Thermistor (RTS2) Evaporator Pipe...

  • Page 69: Disassembly

    Repair Section 7.2 Disassembly 1) Loosen the bottom screw. Service Panel 2) Take out the nine (9) screws, and then remove the service panel. Screws (9) Bottom Screw (1) I003120 3) Disconnect the two (2) power supply lines from the terminal, and disconnect the ground line. Terminal CAUTION •...
  • Page 70 Repair Section 5) Take out the thirteen (13) screws, and then remove the front right panel. Screws (9) Front Right Panel Screws (4) I003123 6) Take out the eleven (11) screws, and then remove the front left panel. Screws (4) Screws (7) Front Left Panel I003124...

  • Page 71: Removal Of Evaporator Fan Assembly

    Repair Section 7.3 Removal of Evaporator Fan Assembly Frame Ring Fan Motor Set Screw Frame I003127 < NOTE > Initialization is required after replacing the evaporator fan motor. (See page 61) 1) Take out the screw, and the four (4) nuts. Screw (1) Nuts (4) Evaporator Fan...
  • Page 72 Repair Section 3) Take out the six (6) screws, and then remove the Set Screw ring. Loosen the set screw with an Allen wrench Ring Set Screw and remove the fan. Screws (6) I003130 4) When assembling the fan, ensure that the screws 0.12 in (3 mm) 0.12 in (3 mm) align with the motor axis positioning holes.

  • Page 73: Removal Of Condenser Fan Assembly

    Repair Section 7.4 Removal of Condenser Fan Assembly Frame Ring Ring Set Screw Motor Frame I003134 < NOTE > Initialization is required after replacing the condenser fan motor. (See page 61) 1) Take off the six (6) nuts. Nuts (2) Nuts (2) Nuts (2) Condenser Fan...
  • Page 74 Repair Section 3) Take out the six (6) screws, and then remove the Set Screw Set Screw ring. Loosen the set screw with an Allen wrench and remove the fan. Ring Screws (6) I003137 4) When assembling the fan, ensure that the screws 0.12 in (3 mm) 0.12 in (3 mm) or more...

  • Page 75: Removal Of Electrical Components

    Repair Section 7.5 Removal of Electrical Components Relay Board and Bracket Assembly Ground Bolt Stop Switch Terminal Block 1 Inductor Coil Noise Filter Ground Bolt Terminal Block 2 Stay I003202...
  • Page 76 Repair Section (1) Relay board to Wall Mounted to Compressor to Millivolt Controller Overlord Relay Thermostat to Evaporator Pipe Inlet Thermistor and to High-Pressure to Float Evaporator Outlet Switch Switch to Electronic to Stop to Evaporator Thermistor Expansion Valve Switch Inlet Air Thermistor DIP Switch...
  • Page 77 Repair Section Replacement of Relay Board 1) Attach the relay board with the six (6) screws. Always tighten the ground line for the relay board together with the bottom right screw. Make sure that the DIP switches on the new relay board are all set to the off position.

  • Page 78: Refrigeration System Repair

    Repair Section 8. REFRIGERATION SYSTEM REPAIR WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltages may remain in the unit immediately after the power is disconnected. 8.1 Repair of Refrigeration System • In case there is a leak, obstruction, or trouble in the refrigeration system, replace or repair the part in question.
  • Page 79 Repair Section (3) Cleaning brazing filler metal and pipe • When the refrigeration 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.

  • Page 80: Removal Of Refrigeration System Components

    Repair Section 8.2 Removal of Refrigeration System Components WARNING • Before replacing any refrigeration cycle component, recover the refrigerant using standard recovery procedures and equipment. • 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 the figure below.

  • Page 81: Charging The System With R-410A Refrigerant

    Repair Section 8.3 Charging the System with R-410A Refrigerant • Always ensure that the refrigeration system has been properly evacuated before charging with the specified amount of R-410A. • Equipment is only for R-410A. • Liquid charge (no gas charge). •...
  • Page 82 Repair Section (1) Connection of gauge manifold 1) Properly remove the crushed end of the pinch-off tube at the high-pressure side and the low Charging Hose Side pressure side of the refrigerant cycle with a pipe Refrigerant cutter. Cycle Side 2) Fit the process tube fitting to the pinch-off tube on both sides.
  • Page 83 Repair Section (3) Checking vacuum 1) Leave the high-pressure valve and the low- Valve Setting Leave valves closed for 5 pressure valve of the gauge manifold closed for 5 minutes or more. Pointer of Closed Closed pressure gauge returning to minutes or more, and confirm that the gauge zero indicates there is a leak.
  • Page 84 Repair Section (4) Checking for gas leaks 1) Remove the charging hose (green) from the Valve Setting vacuum pump, and connect the hose to the Closed Closed Air Purging refrigerant cylinder (R-410A). Open The Valve 2) Loosen the nut on the gauge manifold side of the of Refrigerant Cylinder charging hose (green).
  • Page 85 Repair Section (5) Evacuation (repeat) 1) Close the valve of the refrigerant cylinder. Then Valve Setting remove the charging hose (green) from the Gauge Closed Open Closed Closed 30 inHg (100 k Pa) or larger refrigerant cylinder, and connect it to the Low-Pressure refrigerant recovery machine.

  • Page 86: Refrigerant Charging Work

    Repair Section 8.4 Refrigerant Charging Work (1) Refrigerant charging 1) Remove the charging hose (green) from the Valve Setting vacuum pump, and connect it to the refrigerant Closed Closed Air Purging cylinder (R-410A). Open The Valve 2) Loosen the nut on the gauge manifold side of the of Refrigerant Cylinder charging hose (green).
  • Page 87 Repair Section (2) Removal of gauge manifold 1) Crimp the pinch-off tube with a pinch-off tool. Pinch-Off Tool 2) Remove the gauge manifold and the process to Gauge Manifold Side tube fitting. Crush the end of the pinch-off tube. Pinch-Off Tube 3) Braze the end of the pinch-off tube.

  • Page 88: Reassembly

    Repair Section 9. REASSEMBLY 9.1 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. 9.2 Compressor Mounting •...
  • Page 89 P/N: SV0075-02 Third Issue: December 2016...

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