Movincool 15SF Service Manual
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Movincool 15SF Service Manual

Movincool 15SF Service Manual

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SERVICE MANUAL
15SF
DocID: 00G00092E

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Summary of Contents for Movincool 15SF

  • Page 1 SERVICE MANUAL 15SF DocID: 00G00092E...
  • Page 2 All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher. DENSO AUTOMOTIVE SYSTEMS AUSTRALIA PTY. LTD. reserves the right to make changes without prior notice. MovinCool® is a registered trademark of DENSO Corporation.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Operation Section 1. PRECAUTIONS FOR SAFETY Foreword............... 5 Definition of Terms .
  • Page 4 Table of Contents Repair Section 7. TROUBLESHOOTING Troubleshooting ..............32 Self-Diagnostic Codes .

  • Page 5: Precautions For Safety

    Please use this service manual only when servicing the 15SF. • Please forward these instructions to subsequent owners of your MovinCool 15SF. • Refer to the 15SF spare parts catalogue for spare parts ordering information. 1.2 Definition of Terms Describes precautions that should be observed in order to prevent injury to WARNING the user during installation or unit operation.

  • Page 6: General Precautions

    • All electrical work should only be performed by qualified electrical personnel. Repair to electrical components by non-certified technicians may result in personal injury and/or damage to the unit. All electrical components replaced must be genuine MovinCool parts, purchased from an authorized reseller.

  • Page 7: Specifications

    Operation Section 2. SPECIFICATIONS 2.1 Exterior Dimension Diagram 2100 Minimum clearance 500 mm OBSTACLE 95 175 Minimum clearance 500 mm Minimum clearance 500 mm Unit: mm ILL00698-00...

  • Page 8: Technical Specifications

    Operation Section 2.2 Technical Specifications ITEM SPECIFICATIONS Electronic Features Operation Digital Electronic Electrical Characteristics Voltage Requirement 1 Phase, 230 V, 50 Hz Operating Voltage Max. 254.4 V Range Min. 196.6 V Starting Current 25 A Recommended Breaker Size 10 A Cooling Capacity and Power Consumption Evaporator: 35 °C, 60 %RH Cooling Capacity...
  • Page 9 Operation Section ITEM SPECIFICATIONS Safety Devices Compressor Overload Relay Included Fan Motor Overload Relay Included Freeze Protection Thermistor Included Drain Warning Switch Included Automatic Restart (Power Interruption) Included Compressor Time Delay 120 sec Control Devices Temperature Control Included • Specifications are subject to change without notice. <...

  • Page 10: Characteristics

    Operation Section 2.3 Characteristics (1) Cooling capacity curve Wet Bulb Temp. °C ILL00720-00 (2) Power consumption curve Wet Bulb Temp. °C ILL00721-00...
  • Page 11 Operation Section (3) Cool air temperature difference curve Relative Humidity. % ILL00722-00...

  • Page 12: Construction

    Operation Section 3. CONSTRUCTION 3.1 Internal Structure Control Panel Evaporator Inlet Air Thermistor (RTS) Condenser Air Outlet Cooling Air Duct Housing for Housing for Condenser Fan Evaporator Fan Condenser Fan Evaporator and Motor Freeze Protection Thermistor (CTS) Condenser Capillary Tube Compressor and Drain Tank Accumulator...

  • Page 13: Refrigeration System

    Operation Section 4. REFRIGERATION SYSTEM 4.1 Refrigeration System Construction The component parts of the refrigeration system include the following: • Compressor, Evaporator, Condenser, Accumulator, Capillary tube The parts above are all connected by copper piping with brazed connections. Evaporator Outlet Pipe Condenser Evaporator Evaporator Inlet Pipe...

  • Page 14: Compressor

    Operation Section 4.2 Compressor • The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in one casing. (1) Compressor construction • The construction of a rotary type compressor is divided into two mechanisms; the drive mechanism (compressor motor), and the compression mechanism (compressor).
  • Page 15 Operation Section (2) Basic compressor operation • The roller (compression mechanism) is set Discharge eccentrically with a certain distance given from Hole Spring Discharge the axis of the center of the cylinder. A spring Suction Valve Hole loaded blade is mounted on the cylinder. The Blade roller turns to compress the refrigerant in the space between the cylinder and eccentrically...
  • Page 16 Operation Section (3) Operation 1) Start of compression 1) The cylinder is filled with low pressure gas. Discharge Blade 2) Since pressure in the discharge chamber is higher Valve than in the cylinder, the discharge valve is kept closed. Roller I001676 2) Suction and compression 1) The pressure in the cylinder increases gradually.

  • Page 17: Condenser

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

  • Page 18: Capillary Tube

    Operation Section 4.4 Capillary Tube • The capillary tube is a long thin tube that High Temp./High Pressure utilizes line flow resistance as an expansion Liquid Refrigerant valve. The length and the inner diameter of the capillary tube are determined according to the capacity of the refrigeration system, operating conditions, and the amount of refrigerant.

  • Page 19: Electrical System

    Operation Section 5. ELECTRICAL SYSTEM 5.1 Circuit Diagram IOLF AC230V 1Φ 50Hz CN21 CN01 CN25 52CM Jumper CN03 Line CN17 52CM CN13 CN12 CN11 CN16 Jumper Line t’ t’ Attachment Plug Capacitor for Fan Motor Terminal Block Auxiliary Relay Relay Board Drain Switch Control Board Room Thermistor...

  • Page 20: Control Box

    Operation Section 5.2 Control Box RB: Relay Board CN15 CN16 CN14 CN02 CN03 CN04 CN11 CN12 CN13 CN17 52CM CN25 CN01 CN24 TB: Terminal Block RX: Auxiliary Relay CC: Capacitor for Compressor CF: Capacitor for Fan Motor ILL00726-00 (1) Capacitor •...
  • Page 21 Operation Section (2) Auxiliary relay • The auxiliary relay is normally closed when the unit is in operation (fan or cool), and supplies power to the fan motor. • When current flows across A1 and A2, terminals 13 and 14, 23 and 24, 33 and 34, 43/41 and 44/42 conduct.
  • Page 22 Operation Section (3) Relay board • The relay board contains the dip switch, compressor and fan relays, and a step-down transformer that reduces the line voltage from 230 VAC to approximately 12.7 VAC. This voltage is then rectified from 12.7 VAC to 12 VDC and used for relay coil activation. The 12 VDC voltage is sent to the control panel assembly, further being reduced to 5 V for the system logic.
  • Page 23 Operation Section 3) Dip switch setting • The controller is equipped with a four position dip switch that defaults in the OFF position. The dip switch can be set to configure the following functions: Symbol Item Function On --- Disable “onboard buzzer” DSW4 Buzzer Off --- Enable “onboard buzzer”...

  • Page 24: Control Specifications

    • When the FAN button is pressed, the 52ID (fan motor on/off) relay on the relay board turns on, operating the fan. • For the 15SF, the 52ID relay turns the auxiliary relay on to operate the fan. Specifications: - 52ID (Fan motor On-Off) relay output: 5 A at AC 250 V (2) Compressor start control •...
  • Page 25 Operation Section (4) Compressor time delay control (compressor protection) • Compressor protection consists of a time delay program within the microprocessor. This program prevents a heavy load from being applied to the compressor motor when restarting the unit (cool mode) after a very short period of time. This “delay” is in effect any time the compressor is turned on by either the COOL ON/OFF button, or power interruption restart (automatic recovery.) Specifications:...
  • Page 26 Operation Section (6) Temperature control • During cool mode, temperature control changes the 52CM (compressor on/off) relay status according to RTS temperature in the available range (-20 °C to 60 °C). 52CM (Compressor Relay) Set Temp. -1.7 °C Set Temp Inlet Air Temperature When compressor operation continues within this range for more than 5 minutes, the 52CM relay stops.

  • Page 27: Compressor

    Operation Section 5.4 Compressor (1) Compressor motor • The compressor motor is a single-phase motor and is contained within the same housing as the compressor. Specifications: Rated Voltage 230 V Rated Power Output 0.94 kW I002355 (2) Compressor overload relay •...

  • Page 28: Fan Motor

    Operation Section 5.5 Fan Motor • The fan motor is a single phase, induction type. The motor rotates the fan on both the evaporator side and the condenser side at the same time. Specifications: Rated Voltage 230 V Rated Power Output 0.35 kW I001692 <...

  • Page 29: Drain Tank Switch

    Operation Section 5.7 Drain Tank Switch • The drain switch activates and stops the operation of compressor motor and fan motor when approximately 16 L of drain water accumulates in the drain tank. At the same time, control panel display "FL", and compressor and fan operations stop. This system uses a 250 V, 0.1 A rating micro switch for this function.

  • Page 30: Operation

    Operation Section 6. OPERATION 6.1 Operation of Control Panel (1) Control panel • Before operating the unit, it is important to be familiar with the basic operation of the control panel. Activates/deactivates the cool mode; turns the unit off. COOL ON/OFF Button FAN Button Activates/deactivates the fan only mode;...
  • Page 31 Operation Section (2) Fan only mode • When the FAN button on the control panel is pressed, the FAN “ON” LED illuminates, and the fan operates. At this time, the compressor is off, and only the fan is in operation. When the FAN button is pressed again, the fan stops.

  • Page 32: Troubleshooting 7.1 Troubleshooting

    Repair Section 7. TROUBLESHOOTING 7.1 Troubleshooting • Before troubleshooting the system, the following inspection should be performed. WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. (1) Inspection of power supply •...

  • Page 33: Self-Diagnostic Codes

    Repair Section 7.2 Self-Diagnostic Codes • Self-diagnostic codes are displayed on the control panel under the following conditions. Refer to the troubleshooting chart on page 35 and 36 for the remedies. Indication Condition Buzzer When the drain tank switch is activated, the LED displays “FL” and the unit turns off automatically.

  • Page 34: Troubleshooting Chart

    Repair Section 7.3 Troubleshooting Chart • To accurately troubleshoot the problem, it is important to carefully confirm the nature of the problem. Common problems are: - Insufficient cooling. - Unit does not operate. - Overflow of drain water. - Abnormal noise or vibrations. - Others.
  • Page 35 Repair Section Condition Possible Cause Remedy Insufficient Cooling Check Area Cause 1. Coil resistance of fan motor. Short or open circuit. Replace fan motor. (0 ohm or  ohm) 2. Fan motor on-off relay (52ID) Open circuit or insufficient Replace relay board. on the relay board.
  • Page 36 Repair Section Condition Possible Cause Remedy Unit stops operation. Check Area Cause 2. Display code “E1”. Loose evaporator inlet air Reconnect the thermistor. evaporator inlet air thermistor and check the connection. RESET the controller Control Control Defective evaporator inlet air Replace the evaporator panel panel LED...
  • Page 37 2. Compressor fixing nuts. Loose nuts. Tighten nuts further. vibration. 3. Piping. Pipe interference. Repair interfering section. 4. Panel fixing screws. Loose screws. Tighten screws further. (5) Others • For any other problems, please contact your MovinCool service representative or DENSO.

  • Page 38: Basic Inspection

    Repair Section 7.4 Basic Inspection • Perform the following inspections before disassembly. (1) Inspection of plate fins • To inspect the plate fins of the condenser, the air filter must be removed. After removal of the air filters, inspect the plate fins for any dirt, dust, lint, or debris that may have caused insufficient cooling performance of the unit.

  • Page 39: Compressor Inspection

    Repair Section 7.5 Compressor Inspection (1) Compressor motor inspection • Measure resistance across the terminals of the compressor motor. Resistance at 25 °C Approx. 3.48 ohm Approx. 4.09 ohm • If the measured resistance is not equal to the I002356 standard values listed above, replace the compressor.

  • Page 40: Capacitor Inspection (For Fan Motor And Compressor)

    Repair Section 7.7 Capacitor Inspection (For Fan Motor and Compressor) (1) Ohmmeter method • Set the ohmmeter to the 10 M ohm range. Place the two probes against the two terminals of the capacitor. At first, the ohmmeter indicates small value, then the reading should gradually increase towards infinity (), indicating that the capacitor is charging.

  • Page 41: Auxiliary Relay Inspection

    Repair Section 7.8 Auxiliary Relay Inspection • Check the continuity across the terminals 13 and 14, when the test button is depressed as well as when released. Terminals State of Reset Switch Continuity Depressed Continuity 13-14 Released No continuity (Reference) Depressed Continuity 23-24...

  • Page 42: Wiring Connection Inspection

    Repair Section 7.11 Wiring Connection Inspection • Refer to the wiring diagram on page 19, and check the connection of each wire. CAUTION Secure the wires using clamps to prevent contact with the edges of the structure, etc. Secure the wires in the same position as prior to removal.

  • Page 43: Parts Construction

    Repair Section 8. DISASSEMBLY WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. 8.1 Parts Construction Evaporator Inlet Upper Panel Cooling Air Duct Air Thermistor Control Panel Right Side Panel...

  • Page 44: Disassembly

    Repair Section 8.2 Disassembly 1) Remove the drain tank. Cooling Air Duct Screws (8) 2) Unfasten the two clips and the lower-side hook, and then remove the front panel. 3) Take out the eight (8) screws, and then remove the two cooling air ducts. Front Panel Drain Tank I002611...
  • Page 45 Repair Section 6) Take out the thirteen (13) screws, and then remove the rear panel. Screws (13) Rear Panel ILL00733-00 7) Take out the fourteen (14) screws, and then Upper Panel Screws (2) remove the upper panel. Screws (4) CAUTION The two screws (2*) used on the front side of the upper panel differ from the rest.
  • Page 46 Repair Section 10) Unfasten the two connectors (11-pin, 5-pin) from Connectors the control panel. Board Clamp Upper Panel 11) Remove the wiring harnesses from the clamp Control Panel and board clamp. Clamp I001749 12) Take out the seven (7) screws, and then remove the left-side panel.

  • Page 47: Fan Motor Removal

    Repair Section 8.3 Fan Motor Removal Housing for Evaporator Fan Condenser Fan Evaporator Fan Partition Plate Motor Bracket Fan Motor Housing for Condenser Fan ILL00734-00...
  • Page 48 Repair Section 1) Loosen the set screw with a hex key, and then Condenser Fan remove the condenser fan. CAUTION • Set Screw Torque Value (for Installation) - 14.7 ± 3.0 N•m Set Screw I002571 2) Take off the two (2) nuts, and then remove the Housing for condenser fan housing.
  • Page 49 Repair Section 5) Take off the four (4) nuts, and then remove the fan motor. Nuts (4) Fan Motor I002616...

  • Page 50: Removal Of Electrical Components

    Repair Section 8.4 Removal of Electrical Components WARNING • Disconnect power supply from the unit before performing any service. Beware that some residual voltage may remain in the unit immediately after the power is disconnected. (1) Removal of control panel 1) Take out the eight (8) screws, and then remove the control panel.
  • Page 51 Repair Section (2) Removal of wire-harness in control box • Disconnect all the wires from the electrical parts in control box. 2-P (Red) 3-P (Black) 2-P (Black) 52CM4 (White) 52CM3 (White) CN15 CN16 CN14 CN02 CN03 CN04 CN11 CN12 CN13 5-P (Black) CN17 52CM...
  • Page 52 Repair Section (3) Removal of control box 1) Take off the three (3) nuts, and then remove the Control Box control box. Nuts (3) I002606...
  • Page 53 Repair Section (4) Removal of electrical parts • Terminal block (power connection): Remove the two (2) screws from the control box. • Auxiliary relay: Remove the relay from the holder. • Capacitor for compressor: Remove the two (2) screws from the control box. •...

  • Page 54: Full Drain Switch Removal

    Repair Section 8.5 Full Drain Switch Removal 1) Take out the two (2) screws, and then remove the full drain switch cover. Full Drain Switch Cover Screws (2) I002609 2) Unfasten the wiring harness connector. Harness Connector 3) Take out the two (2) screws, and then remove the full drain switch.

  • Page 55: Refrigeration System Repair

    Repair Section 9. REFRIGERATION SYSTEM REPAIR WARNING • This air conditioner uses R-410A refrigerant under high pressure. It is both dangerous and illegal to tamper with the sealed refrigerant system without appropriate licensing and training. Deliberate release of refrigerant is illegal in Australia, New Zealand and other regions.
  • Page 56 Repair Section (3) Cleaning brazing filler metal and piping • When the refrigeration system has been opened up, exposure to the heat may have caused brazing filler metal to stick to the inside and outside of the pipe. Brazing filler metal may also be compounded with oxygen in the air to form the oxide film.

  • Page 57: Removal Of Refrigeration System Components

    Repair Section 9.2 Removal of Refrigeration System Components WARNING • Before replacing any refrigeration component, recover the refrigerant using standard recovery procedures. • When recovering the refrigerant, use the pinch-off tubes at the low pressure side (tube 1) and high pressure side (tube 2) as shown in figure below. CAUTION •...

  • Page 58: Preparing The System For Charging With R-410A Refrigerant

    Repair Section 9.3 Preparing the System for Charging with R-410A Refrigerant • Always ensure that the refrigeration system has been properly evacuated before charging with the specified amount of R-410A. • Equipments is for R-410A only. • Liquid charge (no gas charge). •...
  • Page 59 Repair Section (1) Inspection of the unit before refrigerant recovery • Inspect the refrigerant system and test for leaks using standard test methods in accordance with local regulations. (2) Connection of gauge manifold 1) Properly remove the crushed end of the pinch-off tube at the high pressure side of the refrigerant Charging Hose Side...

  • Page 60: Refrigerant Charging Work

    Repair Section (4) Checking vacuum 1) Leave the high pressure valve of the gauge Valve Setting manifold closed for at least 60 minutes. Closed Closed 2) If the gauge pointer indicates a rise of more than Pressure Gauge 13 Pa, there may be a leak or moisture somewhere in the system (this could also include Return gauge manifold).
  • Page 61 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 62: Reassembly

    Repair Section 10. REASSEMBLY 10.1 Reassembly of Unit • Reassemble the unit in the reverse order of removal. Described below are the parts that require special care in reassembling the unit. Perform all wiring or rewiring as referenced in the wiring diagram.

  • Page 63: Fan Assembly

    Repair Section 10.3 Fan Assembly 1) Install the evaporator fan and condenser fan. Allow a clearance of 1.5 mm or more between the evaporator fan and the fan casing. CAUTION • Tightening torque: 1.5 mm 1.5 mm or more or more - 14.7 ±...
  • Page 64 P/N: SV0080-00 First Issue: February 2014...

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