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Table of Contents

Repair Section

7. TROUBLESHOOTING

7.1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

7.2

Self-Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7.3

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.4

Basic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.5

Compressor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.6

Fan Motor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.7

Capacitor Inspection (For Fan Motor and Compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.8

Auxiliary Relay Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.9

Full Drain Switch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.10 Thermistor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.11 Wiring Connection Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.12 Inspection of Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8. DISASSEMBLY

8.1

Parts Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8.2

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8.3

Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8.4

Removal of Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.5

Full Drain Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

9. REFRIGERATION SYSTEM REPAIR

9.1

Repair of Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

9.2

Removal of Refrigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

9.3

Preparing the System for Charging with R-410A Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

9.4

Refrigerant Charging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

10. REASSEMBLY

10.1 Reassembly of Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

10.2 Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

10.3 Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10.4 Wiring Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10.5 Perform an Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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Содержание 15SF

Страница 1: ...SERVICE MANUAL 15SF DocID 00G00092E...

Страница 2: ...d 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 pr...

Страница 3: ...eristics 10 3 CONSTRUCTION 3 1 Internal Structure 12 4 REFRIGERATION SYSTEM 4 1 Refrigeration System Construction 13 4 2 Compressor 14 4 3 Condenser 17 4 4 Capillary Tube 18 4 5 Evaporator 18 4 6 Accu...

Страница 4: ...nnection Inspection 42 7 12 Inspection of Refrigeration System 42 8 DISASSEMBLY 8 1 Parts Construction 43 8 2 Disassembly 44 8 3 Fan Motor Removal 47 8 4 Removal of Electrical Components 50 8 5 Full D...

Страница 5: ...s catalogue for spare parts ordering information 1 2 Definition of Terms Describes precautions that should be observed in order to prevent injury to the user during installation or unit operation Desc...

Страница 6: ...recovery and charging equipment must be specifically rated for use with R 410A Observe Refrigerant Handling Code of Practice and all other applicable regulatory requirements Before replacing any refri...

Страница 7: ...FICATIONS 2 1 Exterior Dimension Diagram ILL00698 00 OBSTACLE OBSTACLE 95 175 326 420 491 525 2100 45 672 1050 284 503 163 100 Unit mm DIA 350 OBSTACLE Minimum clearance 500 mm Minimum clearance 500 m...

Страница 8: ...Current Consumption 6 7 A COP 2 9 Power Factor 97 Compressor Type Hermetic Rotary Output 0 94 kW Evaporator Type of Evaporator Spine Fin Type of Fan Centrifugal Fan Air Flow 800 m3 h Motor Output 1 0...

Страница 9: ...2 Measured at 1 0 m from surface of the unit Safety Devices Compressor Overload Relay Included Fan Motor Overload Relay Included Freeze Protection Thermistor Included Drain Warning Switch Included Au...

Страница 10: ...e 2 Power consumption curve ILL00720 00 20 15 25 30 25 30 35 40 3 0 3 5 4 0 4 5 5 0 5 5 Cooling Capacity kW Dry Bulb Temp C Wet Bulb Temp C ILL00721 00 25 30 35 20 25 30 35 40 1 0 1 2 1 4 1 6 1 1 1 3...

Страница 11: ...Operation Section 11 3 Cool air temperature difference curve ILL00722 00 Delta T C Relative Humidity 40 50 60 70 Temperature Difference Between Inlet and Outlet 15 14 13 12 11 10 9 8 7...

Страница 12: ...umulator Condenser Fan and Motor Housing for Condenser Fan Housing for Evaporator Fan Control Box Relay Board Capacitor Auxiliary Relay Condenser Air Outlet Cooling Air Duct Freeze Protection Thermist...

Страница 13: ...connected by copper piping with brazed connections ILL00724 00 Condenser Flow of Refrigerant Capillary Tube Compressor Fan Motor Evaporator Condenser Condenser Inlet Pipe Condenser Outlet Pipe Connec...

Страница 14: ...f 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 roll...

Страница 15: ...blade is in contact with the roller by means of spring force The blade partitions the space between the suction side and the discharge side to keep compressed refrigerant from returning to the suctio...

Страница 16: ...closed 3 Discharge 1 The pressure in the cylinder exceeds that in the discharge chamber and the discharge valve opens 2 On the suction side refrigerant suction continues 4 Completion of compression 1...

Страница 17: ...ating the bearing In this lubrication system oil enters into each bearing separately and returns to the oil reservoir This system effectively prevents bearing temperature increases and offers high rel...

Страница 18: ...is removed from the air being pulled across the evaporator by the centrifugal fan The resulting cool air is expelled through the cooling air ducts 4 6 Accumulator The accumulator is mounted on the suc...

Страница 19: ...ze Protection Thermistor Room Thermistor OLC Overload Relay For Compressor IOLF Internal Overload Relay For Fan Motor OLC MC MF IOLF AC230V 1 50Hz AP Jumper Line Jumper Line CTS RTS DS RB F CB CC Capa...

Страница 20: ...each capacitor is shown below Specifications Capacitor Rated Voltage Capacitance For Fan Motor 400 V 10 F For Compressor 400 V 35 F ILL00726 00 RB Relay Board CF Capacitor for Fan Motor TB Terminal B...

Страница 21: ...ally 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 Specificat...

Страница 22: ...nts This unit requires a 1 phase 230 V 50 Hz power supply 2 Relay board fuse The relay board fuse is the only serviceable component on the relay board assembly This fuse provides protection against da...

Страница 23: ...hat defaults in the OFF position The dip switch can be set to configure the following functions I002623 Symbol DSW4 DSW3 DSW2 DSW1 Item Function On Disable onboard buzzer Off Enable onboard buzzer On...

Страница 24: ...ard turns on operating the compressor Specifications 52CM Compressor On Off relay output 20 A at AC 250 V 3 Anti freeze control Anti freeze controls turns the compressor on and off by turning the 52CM...

Страница 25: ...atus of memory during power interruption When the input power is off the status items below are saved in the memory Running status on or off Operating mode Cool mode or fan only mode Set temperature T...

Страница 26: ...he 52CM compressor on off relay status according to RTS temperature in the available range 20 C to 60 C ILL00727 00 ON OFF 52CM Compressor Relay Set Temp 1 7 C Set Temp Inlet Air Temperature When comp...

Страница 27: ...sor motor This relay is mounted within the connector housing that attaches to the top of the compressor The relay interrupts the flow of current when there is an overload condition such as high curren...

Страница 28: ...up in the fan motor 5 6 Temperature Thermistor The evaporator inlet air thermistor RTS is installed upstream of the evaporator and detects evaporator inlet temperature as a resistance value The freeze...

Страница 29: ...rating micro switch for this function When approximately 16 L of drain water accumulates in the drain tank the drain tank base plate which is supported at fulcrum a is pushed down in the direction of...

Страница 30: ...rature set point during cool mode Shows a blinking set point temperature for 5 seconds then continuously indicates room temperature Room Temperature Set Point Display Illuminates to indicate the curre...

Страница 31: ...ops and only the fan continues to operate Fan operate mode Initial setting NOTE The fan only mode will not operate after the cool mode has been activated Once the cool mode is activated the unit canno...

Страница 32: ...ircuit breaker and residual current device RCD before connecting the unit and then at least once a month during operation 2 Inspection of air filters Remove the air filters and check the filter elemen...

Страница 33: ...1 Buzzer is located on the relay board Indication Condition Buzzer 1 No 1 When the drain tank switch is activated the LED displays FL and the unit turns off automatically No No 2 When evaporator inle...

Страница 34: ...the installation place 2 Dirt in condenser or evaporator Insufficient heat exchange Clean fins 3 Frost in refrigeration cycle Clogging at the frost section Replace clogged section 4 No temperature di...

Страница 35: ...nection state Improper connection Repair duct connection 4 Fan motor Insufficient rotation Replace motor Condition Possible Cause Remedy Unit does not operate Check Area Cause Control panel LED displa...

Страница 36: ...Fan Motor insulation resistance Insulation failure on fan motor Replace fan motor 3 Compressor insulation resistance Insulation failure on compressor Replace compressor Unit stops after running for a...

Страница 37: ...Cracks in drain pan Check and replace 2 Water level in drain pan Clogged drain hose Check and repair 3 Drain hole Reversed air flow from drain hole Insert a trap on the discharge drain hose 4 Clogged...

Страница 38: ...or debris that may cause poor cooling performance If spine fin cleaning is necessary it is recommended that this service be performed by a qualified service technician 3 Examination of operating envi...

Страница 39: ...ad relay inspection Check for continuity across two terminals of the overload relay At normal temperature there should be continuity across the terminals If there is no continuity across the terminals...

Страница 40: ...ly open or the ohmmeter fails to move from 0 ohm shorted replace the capacitor 2 Capacitance tester method Use a capacitance tester to check the capacitor for the values indicated below If the value t...

Страница 41: ...istor Inspection Use an ohmmeter to check the resistance across the 2 pin connector at normal temperature 25 C Terminals State of Reset Switch Continuity 13 14 Depressed Continuity Released No continu...

Страница 42: ...ure 1 Clogged refrigeration system Check the component parts of the refrigeration system including piping that could be clogged with refrigerant If clogged with refrigerant only the clogged part is pa...

Страница 43: ...the power is disconnected 8 1 Parts Construction ILL00730 00 Upper Panel Right Side Panel Air Filter Air Filter Rear Panel Service Panel Caster Cooling Air Duct Front Panel Drain Pan Drain Tank Left S...

Страница 44: ...t 8 screws and then remove the two cooling air ducts 4 Take out the six 6 screws and then remove the service panel 5 Remove the two 2 power supply lines from the terminal block and remove the ground w...

Страница 45: ...iffer from the rest Ensure that the correct screws are used when attaching the upper panel 8 Unfasten the connector on the evaporator inlet air thermistor wiring harness 9 Remove the wiring harness fr...

Страница 46: ...screw is used when attaching the left side panel 13 Remove the two air filters from the right side panel 14 Take out the thirteen 13 screws and then remove the right side panel CAUTION The screw 1 on...

Страница 47: ...Repair Section 47 8 3 Fan Motor Removal ILL00734 00 Evaporator Fan Fan Motor Motor Bracket Partition Plate Condenser Fan Housing for Evaporator Fan Housing for Condenser Fan...

Страница 48: ...he two 2 nuts and then remove the condenser fan housing 3 Take off the four 4 nuts and then remove the fan motor together with the motor bracket 4 Loosen the set screw with a hex key and then remove t...

Страница 49: ...Repair Section 49 5 Take off the four 4 nuts and then remove the fan motor Fan Motor Nuts 4 I002616...

Страница 50: ...er 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 eig...

Страница 51: ...electrical parts in control box ILL00735 00 CN13 CN12 CN11 CN04 CN03 CN02 CN14 CN16 CN15 CN01 CN24 4 52CM CN17 CN25 3 CF1 Black TBT Black TBR White 52CM3 White 52CM4 White 11 P 5 P Black RX13 Black R...

Страница 52: ...Repair Section 52 3 Removal of control box 1 Take off the three 3 nuts and then remove the control box I002606 Control Box Nuts 3...

Страница 53: ...ay from the holder Capacitor for compressor Remove the two 2 screws from the control box Capacitor for fan motor Remove the two 2 screws from the control box Relay board Remove the six 6 supports from...

Страница 54: ...he two 2 screws and then remove the full drain switch cover 2 Unfasten the wiring harness connector 3 Take out the two 2 screws and then remove the full drain switch I002609 Screws 2 Full Drain Switch...

Страница 55: ...able to use a slightly reduced 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 necess...

Страница 56: ...e of the pipe undergoes an oxidative reaction due to the brazing flame Introduce dry nitrogen gas 1 L min adjust with the flow regulator through the pinch off tube of the refrigerant NOTE Take care no...

Страница 57: ...e 1 and high pressure side tube 2 as shown in figure below CAUTION To prevent oxidation dry nitrogen should be conducted flow rate 1 L min through the pinch off tube during any brazing operation Durin...

Страница 58: ...ecially when handling refrigerant Take caution so that 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 lar...

Страница 59: ...versa 4 Connect the outlet hose at the center of the gauge manifold to the vacuum pump 3 Evacuation 1 Open the high pressure valve Hl of the gauge manifold 2 Turn on the vacuum pump to start evacuati...

Страница 60: ...efrigerant cylinder Charge the system with refrigerant to the specified amount Standard Amount of Refrigerant 0 75 0 02 kg CAUTION The amount of refrigerant charged has a great effect on the cooling c...

Страница 61: ...he 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 3 Inspection of the unit after refrigerant char...

Страница 62: ...tion 1 Install three 3 cushions and three 3 collars to the bolts and mount the supplied compressor to the unit NOTE Cushions and collars are packaged in the supplied compressor assembly 2 Insert three...

Страница 63: ...ning torque 14 7 3 0 N m 10 4 Wiring Notice 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 t...

Страница 64: ...P N SV0080 00 First Issue February 2014...

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