Movincool | Office Pro 60 | Service manual | Movincool Office Pro 60 Service manual

Movincool Office Pro 60 Service manual
SERVICE MANUAL
OFFICE PRO 60
© 2001 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.
SERVICE MANUAL
O F F I C E P R O 60
FOREWORD
This manual has been published to service the MovinCool Office Pro 60. Please use this
service manual only when servicing the Office Pro 60.
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.
NOTE: Provides additional information that facilitates installation or unit operation.
GENERAL PRECAUTIONS
WARNINGS:
• All electrical work if necessary, 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, purchased from an authorized reseller.
• When handling refrigerant, always wear proper eye protection and do not allow the
refrigerant to come in contact with your skin.
• Do not expose refrigerant to an open flame.
• The proper electrical outlet for MovinCool units must be equipped with a “UL” approved ground-fault breaker to prevent electrical shock from the unit.
• When brazing any tubing, always wear eye protection and work only in a well ventilated area.
• Disconnect power before servicing unit.
• Be careful of any sharp edges when working on unit.
i
ii
TABLE OF CONTENTS
FOREWORD ............................................................................................................................... i
DEFINITION OF TERMS ............................................................................................................ i
GENERAL PRECAUTIONS ........................................................................................................ i
TABLE OF CONTENTS .............................................................................................................iii
GENERAL DESCRIPTION ........................................................................................................ 1
CONSTRUCTION, SPECIFICATIONS, & DATA ....................................................................... 3
REFRIGERANT SYSTEM .......................................................................................................... 9
ELECTRICAL SYSTEM ........................................................................................................... 15
TROUBLESHOOTING & REPAIR ........................................................................................... 21
iii
iv
GENERAL DESCRIPTION
CONDENSER
(OUTDOOR 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.
MovinCool Spot Cooling Systems have the following
features:
EVAPORATOR
(INDOOR UNIT)
Conventional Air Conditioner
1. Compact Design
The innovative design of MovinCool has resulted
in one compact unit, replacing the need for two
separate units.
2. Easy Transportation and Installation
With the whole cooling system built into one
compact unit, MovinCool requires no piping and
can be easily transported and installed.
3. Energy Conservation
MovinCool is economical because it cools only
the area or objects which need to be cooled.
Office Pro 60
1
GENERAL DESCRIPTION
2
CONSTRUCTION, SPECIFICATIONS, and DATA
EVAPORATOR FAN
EXHAUST AIR OUTLET
EVAPORATOR MOTOR
EVAPORATOR
CONDENSER FAN
CONDENSER MOTOR
COOL AIR VENT
CAPILLARY TUBE
DRAIN PAN
DRAIN SWITCH
(BEHIND CONTROL BOX)
CONDENSER
CONDENSATE PUMP
COMPRESSOR
CONTROL BOX
Construction of Office Pro 60
3
CONSTRUCTION, SPECIFICATIONS, and DATA
POWER
CORD
EVAPORATOR
FAN MOTOR
EVAPORATOR FAN
TOP PANEL
EXHAUST AIR OUTLET
COOL AIR VENT
SIDE PANEL
BACK HANDLE
CONTROL PANEL
CONDENSER FAN MOTOR
FRONT HANDLE
CONDENSER FAN
CONDENSER
FRONT PANEL
CAPILLARY TUBES
EVAPORATOR
COMPRESSOR
DRAIN PUMP
POWER CORD
CASTER
Construction Diagram
4
CONSTRUCTION, SPECIFICATIONS, and 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 (optional).
The rear section contains the condenser, the
compressor and the control box.
2. Air Flow
Air drawn from the right side face passes through
the condenser which extracts the heat. This hot
air is blown out through the upper exhaust air
duct. Air taken in from the front face is cooled by
the evaporator and then blown through the cool
air vent. All the air inlets are equipped with filters,
while the exhaust air outlet is protected by wire
mesh.
EXHAUST
AIR OUT
COOL
AIR OUT
COOL
AIR OUT
CONDENSER
AIR IN
EVAPORATOR
AIR IN
Air Flow
3. Compressor and Fans
The compressor is hermetically sealed. A twospeed fan motor is used with two centrifugal fans
to draw air across the evaporator and condenser.
4. Drain Tank (Optional)
The capacity of the drain tank is 5.0 gallons (19
liters). The unit is equipped with a “Tank Full” LED
and a device to automatically stop the operation
of the unit when the drain tank reaches a level of
approximately 4.0 gallons (15 liters).
5. Condensate Pump
The condensate pump will pump water from the
pump’s main tank to a nearby sink or floor drain.
The pump will lift the water a vertical distance of
18 feet. A plastic hose is supplied with the pump.
The condensate pump is included with the Office
Pro 60. It is important that the drain line from the
pump is not kinked or bent.
5
CONSTRUCTION, SPECIFICATIONS, and DATA
Rating Conditions
dry bulb ...................................................................................... 95˚ F (35˚ C)
wet bulb ..................................................................................... 83˚ F (28.2˚ C)
humidity ..................................................................................... (60%)
Specifications
power frequency ........................................................................ 60Hz
line voltage ................................................................................. single phase 208/230V
power consumption .................................................................... 7.1 Kw
current consumption .................................................................. 33 Amps
power factor ............................................................................... 94%
starting current ........................................................................... 140A
power wiring ............................................................................... 6 (3-core) AWG
Power Requirements
transformer size ......................................................................... 20 KVA
Cooling Unit
cooling capability ....................................................................... 15,100 Kcal/hr
60,000 BTU/hr
cooling system ........................................................................... direct expansion
Blower
type of fan .................................................................................. centrifugal fan
air volume:
Evaporator (High speed) ........................ 1940 ft 3/min (3296 m3/h)
Evaporator (Lo speed) ............................ 1770 ft 3/min (3007 m3/h)
Condenser (High speed) ........................ 2830 ft 3/min (4804 m3/h)
Condenser (Lo speed) ........................... 2650 ft 3/min (4502 m3/h)
motor output:
Condenser (High) ................................... 1.12 Kw
Condenser (Low) ................................... 0.93 Kw
Evaporator (High) ................................... 0.50 Kw
Evaporator (Low) .................................... 0.33 Kw
Compressor
type ............................................................................................ Hermetic scroll
output ......................................................................................... 4.7 Kw
refrigerant type ........................................................................... R-22
refrigerant capacity .................................................................... 6.83 lbs (3.1 kg)
Safety Devices
compressor overload protector .................................................. included
fan motor protector .................................................................... included
anti-freezing thermistor .............................................................. included
full drain tank switch .................................................................. included
automatic restart (power interruption) ........................................ included
compressor time delay program ................................................ included
Dimensions & Weight
W x D x H (in) ............................................................................. 30" x 52" x 64.4"
W x D x H (mm) ......................................................................... 760 x 1320 x 1635
weight (lbs/kg) ............................................................................ 625 / 283
Operating Conditions
inlet air (relative humidity) .......................................................... 106˚ F (41˚ C)
65˚ F (18.3˚ C), (50%)
Control Devices
temperature control .................................................................... included
programmable timer ................................................................... included
two speed fan ............................................................................ included
Specifications
Specifications are subject to change without notice.
6
30.3
CONSTRUCTION, SPECIFICATIONS, and DATA
27.10
22.80
10.2
40.80
24.20
51.70
30.31
Exterior Dimensions (units: inches)
7
4.16
6.75
9.90
64.40
18.70
2.80
16 ø
DATA
@ 230V
@230V
273 (65)
252 (60)
Temperature ˚C (˚F)
Cooling Capability
(x103 KCAL/h (BTU/h))
14 (25.2)
231 (55)
12 (21.6)
10 (18.0)
8 (14.4)
210 (50)
6 (10.8)
189 (45)
1
2
3
4
5
40
6
50
60
70
Relative Humidity of Inlet Air (%)
@230V
8
33 (91.4)
28 (82.4)
Power Consumption (kW)
7.5
23 (73.4)
18 (64.4)
12
(53.6)
17
(62.6)
22
(71.6)
27
(80.6)
Wet Bulb Temperature ˚C (˚F)
Cooling Capability Curve
7
6.5
6
5.5
5
1
Dry Bulb Temperature ˚C (˚F)
Dry Bulb Temperature ˚C (˚F)
Cool Air Temperature Difference Curve
38 (100.4)
2
3
4
5
38 (100.4)
33 (91.4)
28 (82.4)
23 (73.4)
18 (64.4)
12
(53.6)
17
(62.6)
22
(71.6)
27
32
(80.6) (89.6)
Wet Bulb Temperature ˚C (˚F)
Power Consumption Curve
8
6
REFRIGERANT SYSTEM
1. The component parts of the refrigerant system include the following:
• Compressor
• Evaporator
• Condenser
• Modulating tank
• Capillary tube
These parts are all connected by copper tubing. All the connections have been brazed.
EVAPORATOR
MODULATING
TANK
CONDENSER
CAPILLARY
TUBE
COMPRESSOR
FLOW OF
REFRIGERANT
CONDENSER
CONDENSER
FAN
CAPILLARY
TUBES
EVAPORATOR
FAN
MODULATING
TANK
COMPRESSOR
EVAPORATOR
Refrigerant System
9
REFRIGERANT SYSTEM
1. Compressor
The compressor used for the unit is hermetically sealed. The compressor and the compressor motor are in
one casing.
A. Compressor Theory of Operation
The scroll utilizes an involute spiral which, when matched with a mating scroll form, generates a series
of crescent-shaped gas pockets between the two members. During compression, one scroll remains
stationary (fixed scroll) while the other form (orbiting scroll) is allowed to orbit (but not rotate) around the
first form. As this motion occurs, the pockets between the two forms are slowly pushed to the center of
the two scrolls while simultaneously being reduced in volume. When the pocket reaches the center of
the scroll form, the gas, which is now at a high pressure, is discharged out of a port located at the
center. During compression, several pockets are being compressed simultaneously, resulting in a very
smooth process. Both the suction process (outer portion of the scroll members) and the discharge
process (inner portion) are continuous.
B. Compressor Operation
1) Compression in the scroll is created by the
interaction of an orbiting spiral and a
stationary spiral. Gas enters the outer
openings as one of the spirals orbits.
2) The open passages are sealed off as gas
is drawn into the spiral.
3) As the spiral continues to orbit, the gas is
compressed into two increasingly smaller
pockets.
10
REFRIGERANT SYSTEM
4) By the time the gas arrives at the center
port, discharge pressure has been
reached.
5) Actually, during operation, all six gas
passages are in various stages of compression at all times, resulting in nearly
continuous suction and discharge.
NOTE: Upon compressor shut-off, the compressor
may run backward for a moment or two until
internal pressures equalize. This has no effect on
compressor durability but may cause an unexpected sound after the compressor is turned off
and should not be diagnosed as a malfunction.
2. Condenser
The condenser is a heat exchanger utilizing plate
fins. Heat is given off and absorbed by air being
pulled across the condenser fins by the centrifugal fan and then expelled through the exhaust air
outlet.
11
REFRIGERANT SYSTEM
3. Capillary Tubes
The capillary tubes are long thin tubes utilizing
line flow resistance to serve as an expansion
valve. The length and the inner diameter of the
capillary tubes are determined by the capacity of
the refrigeration system, specified operating
conditions, and the amount of refrigerant.
HIGH TEMP. / HIGH PRESS.
LIQUID REFRIGERANT
The capillary tubes cause the high pressure, high
temperature liquid refrigerant sent from the
condenser to expand rapidly as the refrigerant is
sprayed out through the fixed orifice in the
capillary tubes. As a result, the temperature and
state of the refrigerant become low and mist-like
respecitively, causing it to evaporate easily.
LOW TEMP. / LOW PRESS.
GAS AND LIQUID MIXTURE
Capillary Tube
4. Evaporator
The evaporator, like the condenser, is a heat
exchanger utilizing plate fins. Heat is removed
from the air being pulled across the evaporator
by the centrifugal fan and the resulting cool air is
expelled through the cool air vent.
5. Modulating Tank
The modulating tank consists of a copper pipe
and tank sections, each being separated from the
other. The pipe connects to the evaporator outlet
at one end and to the compressor at the other;
the tank connects to the evaporator inlet. The
modulating tank is covered with insulation to
reduce thermal effects of ambient temperature. It
varies the quantity of refrigerant in the refrigerating cycle for optimum operating condition; it
stores part of refrigerant under light load and
delivers additional refrigerant to the cycle under
heavy load.
FROM EVAPORATOR
MODULATING
TANK
TO EVAPORATOR
INLET
TO COMPRESSOR
Modulating Tank
12
REFRIGERANT SYSTEM
6. High Pressure Switch
The high pressure switch prevents the condenser
and compressor from being damaged by excessively high pressure in the high pressure line of
the refrigeration cycle. The switch is normally
closed. The snap disk responds to variations in
pressure and, if pressure is abnormally high, the
snap disk moves down to push the pin down,
causing the internal contacts to open. This
interrupts the ground signal at the Control Board
(J104) connector) which turns the compressor off.
Possible causes of this trouble include:
A. The condenser air filter is dirty, restricting air
flow.
B. The condenser blower is defective.
High Pressure Switch
13
REFRIGERANT SYSTEM
CONDENSER
INLET PIPE
CAPILLARY
TUBE
COMPRESSOR
DISCHARGE PIPE
HIGH PRESSURE
SWITCH PIPE
(CONDENSER TO
CAPILLARY TUBE)
EVAPORATOR
INLET PIPE
COMPRESSOR
SUCTION PIPE
(EVAPORATOR
TO COMPRESSOR,
INSULATED)
CONDENSER
OUTLET PIPE
Refrigerant System Piping
14
ELECTRICAL SYSTEM
AP
G T1 T
DS
230V 1 PHASE 60Hz
RTH
CC
HPRS
THS
R R1
MCC
TB
MC
1
IOLC
C
J8
J7
J6
J5
J4
J3
J2
J1
G
G
CF1
HI
LO
MF1
IOLF
CF2
G
HI
1
J201 J202 J203 J204
RB
J9
J201
CB
10
J10
10
ODS
MF2
LO
FDS
IOLF
CONDENSATE PUMP
MDP
G
G
AP
TB
CB
RB
MF1
MF2
MC
CF1
CF2
CC
IOLF
Attachment Plug
Terminal Block
Control Board
Relay Board
Condenser Fan Motor
Evaporator Fan Motor
Compressor Motor
Capacitor for Condenser Fan Motor
Capacitor for Evaporator Fan Motor
Capacitor for Compressor
Inner Overlaod Relay of Fan Motor
IOLC
DS
THS
RTH
G
HPRS
MCC
MDP
FDS
ODS
J10
Inner Overload Relay of Compressor
Full Drain Tank Warning Switch
Freeze Protection Thermistor
Room Thermistor
Ground
High Pressure Switch
Relay for Compressor and Condenser Motor
Condensate Pump Motor
Drain Float Switch
Drain Overflow Switch
Connector for Condensate Pump
COMPRESSOR
CAPACITOR
RELAY BOARD
EVAPORATOR FAN
CAPACITOR
RELAY BOARD
FUSE
COMPRESSOR
RELAY
L1
L3
T1
T3
TERMINAL
BLOCK
CONDENSER FAN
CAPACITOR
Electrical System and Control Box
15
ELECTRICAL SYSTEM
1. Basic Operation of Office Pro 60 Electrical Circuit
There are two basic components used to control the operation of the Office Pro 60 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. Fan “Only” Mode (Evaporator)
Low Fan Mode - When the “Low” Fan Mode button on the control panel is pressed, the microprocessor
turns on the button’s LED and activates the Fan “On” Relay (Relay Board), sending line voltage (208/
230 VAC) to the N.C. (Normally Closed) contacts of the fan “mode” relay. This output is connected to
the J7 terminal (relay board) where the LOW SPEED wire of the fan motor is connected.
Note: Low fan mode does not operate in Fan “Only” mode.
High Fan Mode – When the “High” Fan Mode button on the control panel is pressed, the microprocessor turns on the button’s LED and activates both the Fan “On” Relay and Fan “Mode” Relay. This sends
line voltage (208/230 VAC) from the Fan “On” Relay to the N.O. (Normally Open) contacts of the Fan
“Mode” Relay. This output is connected to the J8 terminal (relay board) where the HIGH SPEED wire of
the Fan Motor is connected.
B. Cool Mode - In Addition to Fan “Only” Mode (as described above)
When the Cool On/Off button on the control panel is pressed, the microprocessor turns on the button’s
LED and if the Temperature Set Point is less than the current room temperature, this activates the
Compressor Relay (Relay Board) after a ninty second delay. This sends line voltage (208/230 VAC) to
16
ELECTRICAL SYSTEM
the J4 terminal (Relay Board) where the wire
from the Compressor wire harness is connected.
COMPRESSOR
CAPACITOR
RELAY BOARD
2. Control Box
A. Capacitors
EVAPORATOR FAN
CAPACITOR
The capacitors are used to temporarily boost
the power output available to the fan motor
and the compressor at start-up.
RELAY BOARD
FUSE
COMPRESSOR
RELAY
L1
L3
T1
T3
TERMINAL
BLOCK
The specifications of each capacitor are
listed below:
CONDENSER FAN
CAPACITOR
CAPACITOR
APPLICATION
VOLTAGE CAPACITANCE
RATING
(µf)
Evaporator Fan Motor
Compressor
Condenser Fan Motor
Control Box
440
370
370
15
70
25
B. Relay Board
The relay board receives signals and outputs
from the control board that contains a microprocessor. The relay board contains the
compressor, fan on and fan mode (speed)
relays. It also contains a step-down transformer that converts the line voltage (230
VAC) to 12 volts. This is then converted from
AC to DC and used for relay coil activation.
The 12V (DC) power is sent to the Control
Panel Assembly where it is further regulated
to 5 volts for the system logic.
The relay board also contains the DIP-Switch.
The DIP-Switch is used to change the Fan
Mode operation from Stop to Operate and
change the Set Point temperature display
from ˚F to ˚C.
DIP Switch
S1
C
C2
J9
F
C1
K1
D1
NOTE: The relay board must be serviced as a
complete assembly. It has only one serviceable
component, the fuse.
C3
K2
D2
C4
(a) Relay Board Fuse
NOTE: The relay board fuse is the only serviceable
component on the relay board assembly.
J10
K3
D3
C5
R2
This fuse provides protection against damage
to the step-down transformer. It must be
replaced with the exact type of fuse or an
equivalent.
R3
FT1
D4
D7
K4
Q1
T1
VR6
RELAY
BOARD
FUSE
R1
F1
J4
J8
J3
J7
J2
J6
J1
J5
Fuse Specifications: 2/10A 250V
CAUTION: Failure to use the exact type of fuse
2/10A 250V
F1
Relay Board
17
ELECTRICAL SYSTEM
could result in damage to the unit and/or to
components. It will also void the warranty of the
unit.
3. Fan Motor (Evaporator)
The fan motor is a single phase, induction type
two-speed motor.
EVAPORATOR FAN MOTOR
Specifications: Rated Voltage: 230 Volts 60 Hz
Rated Output: (low) 326 watts
(high) 500 watts
GROUND (GREEN/YELLOW)
J7 (RED)
CF22 (BROWN/WHITE)
CF21 (ORANGE)
J8 (BLACK)
4. Fan Motor (Condenser)
The condenser fan motor is a single phase
induction type two-speed motor.
Evaporator Fan Motor
Specifications: Rated Voltage: 932 Volts 60Hz
Rated Output: (low) 932 watts
(high) 1195 watts
CONDENSER FAN MOTOR
5. Compressor Motor
The compressor motor is a single phase motor. It
is contained within the same housing as the
compressor.
Specifications: Rated Voltage: 230 volts
Rated Output: 4700 Watts
GROUND (GREEN/YELLOW)
J5 (RED)
CF12 (BROWN)
CF11 (ORANGE)
J6 (BLACK)
NOTE: An internal overload relay is used to protect the compressor motor and fan motor(s). This
relay is built into the compressor motor and fan
motor(s) and will interrupt the flow of current
when there is an overcurrent situation or if abnormally high temperature builds up in the compressor motor or fan motor(s).
Condenser Fan Motor
6. Condensate Pump
The Office Pro 60 model comes standard with a
CONDENSATE PUMP
Condenser Fan Motor
18
ELECTRICAL SYSTEM
condensate pump, which collects the water that
forms on the evaporator during normal cooling
operation and eliminates the need for a drain tank.
When the water collects to level (A) in the pump
reservoir, the drain pump begins to operate and
discharges the water.
When the water level drops below level (B), the
drain pump will stop.
A
B
NOTE:
•
•
If for any reason the water level exceeds that of
level (A) in the pump reservoir, an overflow
Drain Switch will stop the compressor operation.
Condensate Pump (Drain Pump)
If the Fan Mode Control DIP Switch (see pg.17) has been set from the COOL to the STOP position,
the Fan will also turn off while the drain
pump is discharging water.
7. Drain Switch (If drain tank is equipped)
The Office Pro 60 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 0.1 AMP, 250 VAC micro-switch for this function. When drain water accumulates
approximately 4.0 gallons (15 liters) in the drain tank, the drain tank base plate, which is supported at its
fulcrum, is pushed down in the arrow direction as shown in the figure below. When the drain tank base
plate is forced down, the top of the drain tank base plate turns off the contacts (1) – (2) of the micro switch.
TOP OF
BASE
PLATE
EVAPORATOR
DRAIN
SWITCH
To J103
DRAIN PAN
NC
DS2
2
1
DRAIN TUBE
DS1
C
DRAIN TANK
DRAIN WATER
SPRING
FULCRUM
BASE
PLATE
BASE
Operation of Drain Switch
19
ELECTRICAL SYSTEM
This causes the ground signal at the J103 connector of the control panel assembly to close. When the
microprocessor detects this event, it shuts the unit off and flashes the “Tank Full” LED.
When the drain tank is removed (or the drain tank is emptied), the top of the drain tank base plate returns to
its original position from the tension of the coil spring. Then contacts (1) – (2) of the drain tank switch open.
This provides a ground to the microprocessor through the J103 connector.
8. How to re-start the unit
If the program “Run” LED is flashing, press the “Cool On/Off” button to continue running the program. If the
program “Run” LED is illuminated continuously (program activated), no further steps are necessary. If no
program exists or the program was “deactivated”, press one of the fan mode buttons or the “Cool On/Off”
button. The unit will return to the previous Temperature Set Point.
9. Automatic Restart after Power Interruption
The program within the microprocessor of the Office Pro 60 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. Any “Preset”
Program will also be retained in the memory in the event power loss occurs.
10. Compressor Protection
There is a Time Delay program within the microprocessor. This prevents a heavy load from being applied on
the Compressor Motor when restarting the unit (Cool Mode) after a very short period of time. This “delay” is
in effect any time when the compressor is turned on by either the “Cool On/Off” button, temperature set
point (thermostatic control), power interruption restart or Condensate Pump operation.
Time Delay Program Specifications: 120 ± 10 sec.
11. Temperature Control
The compressor operation (Cool Mode) is controlled by the microprocessor which receives input signals
from the room temperature thermistor (evaporator inlet air) and the setting of the Temperature Set Point.
The Temperature Set Point (desired room temperature) can be adjusted by pressing the ▲ / ▼ buttons on
the Control Panel. The adjustment range of the Temperature Set point is 65˚F to 105˚F (18˚C to 40˚C).
12. Fan Mode Control Switch
The fan motor operation is controlled by relays on the relay board through a microprocessor in the control
panel assembly. The fan program in the microprocessor can be changed by a DIP-Switch on the upper right
side of the Relay Board located in the Control Box. There are two settings:
A. Cool to Stop
When the DIP-Switch is set to the left or “Stop” position, the microprocessor controls the fan motor
using the same room temperature thermistor that it uses to control the compressor. In this case, both
the fan and the compressor stop when the microprocessor receives a sufficiently low intake air (room
temperature) signal from the thermistor (equal to or less than the set point). When the temperature
increases (exceeds the set point) the microprocessor will restart the fans and the compressor automatically. However, if the unit has been off for less than 75 sec., the evaporator fan will start at the same
time as the compressor (time delay program).
B. Cool to Operate
When the DIP-Switch is set in the right or “Operate” position, the microprocessor controls the fan
operation using control panel inputs only. The fan will operate continuously during Fan Only and Cool
Modes. (This is the “Factory Default” setting.)
13. Temperature Scale Display Switch
When the DIP Switch is set in the left or ˚C position, the Set Point and Room Temperature will be displayed
in degrees Celcius (˚C). The LED that indicates ˚C will also be illuminated.
When the DIP Switch is set in the right or ˚F position, the Set Point and Room Temperature will be displayed
in degrees Farenheit (˚F). The LED that indicates ˚F will also be illuminated (this is the “factory default”
setting).
20
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 230 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. Inspection of Drain Tank (If equipped)
Be sure tank is fully drained.
The following chart is provided as a guide for categorized problem remedies. Detailed information is contained in the OPERATION MANUAL supplied with the unit.
4. Self-Diagnostic Codes
Self-Diagnostic codes will be displayed on the control
board under the following conditions:
TANK
dF
When the evaporator anti-freeze thermistor
disengages the compressor.
When the drain tank switch shuts off the unit
(full tank LED flashes).
AS
When unit disengages the compressor while
the condensate pump is discharging water.
HP
When the high pressure switch disengages
the compressor.
AM
C
PM
FULL
SET POINT
FL
F
SET TEMP
ROOM TEMP
CLOCK/TIMER
HRS
MIN
FAN ON/OFF
START TIME
END TIME
SET CLOCK
SET
COOL ON/OFF
RUN
PROGRAM
Office Pro 60
OP60 Control Panel
21
TROUBLESHOOTING AND REPAIR
5. Pump Maintenance
WARNING: When performing any maintenance and/or
troubleshooting, make sure that all electrical power is
off. This means before service, unplug the unit from
the electrical outlet or if permanently wired, make sure
the circuit breaker is in the off position.
1) Remove any dirt or debris which may collect
in the bottom of the reservoir tank.
2) On a monthly basis, check the condensate
drain hose for kinks, blockage or any other
damage that may obstruct condensate pump
from draining properly.
3) Always replace the fan motor cover to keep
electrical parts free of dust, dirt and any other
foreign material.
22
TROUBLESHOOTING AND REPAIR
6. Hose Installation
Note: The OP60 is equipped with a 20 foot (6 m)
hose.
DRAIN OUTLET SPOUT
Feed the 20 foot (6m) hose through the grommet on
the right side of the unit and connect to the drain
outlet spout.
GROMMET
Note: Do not use more than 18 feet (5.5 m) of
drain hose vertically. This is the maximum head
(lift) of the Condensate Pump.
DRAIN HOSE
When securing the drain hose to the highest vertical
position (no more than 18 feet (5.5m)) and running the
hose to the drain, run the drain hose on a downward
slope at a minimum of 1/4 inch (6.25 mm) per foot for
proper drainage.
18' (5.5 m) MAX
1/4" (6.25 mm)
TAPER PER FOOT
CONDENSATE
PUMP
GROMMET
23
TROUBLESHOOTING AND REPAIR
7. Troubleshooting Chart
Trouble
Unit does not operate at all
Probable Cause
• Check for Power at
Receptacle
• Fan mode DIP switch is set to
“Stop” and current Set Point
Temperature exceeds Room
Temperature
• Fan mode DIP switch is set to
“Stop” and unit has
Condensate Pump that is
defective
• Check for Power at Terminal
Block
• Check for Power at Relay
Board
• Check all wire connections
• Defective Drain Tank Switch
• Check Relay Board Fuse
• Defective or Incorrect Relay
Trouble
Insufficient Air Flow
Probable Cause
• Clogged fins on Evaporator or
Condenser (running unit
without filter(s))
• Fan on “Low” setting
• Defective fan motor
• Static pressure exceeds
design specifications
Insufficient Cooling
• Environmental conditions
exceed design specifications
• Clogged air filter
• Clogged fins
• Set point temperature
exceeds room temperature
• Defective room temperature
thermistor
• Exhaust outlet not properly
ducted
• Leak in refrigerant system
• Restriction in refrigerant
system
Display not working
• Compressor not operating
Compressor not operating
• Set point temperature
exceeds room temperature
• Unit is operating in Fan Only
Mode (Cool Mode not
activated)
• Defective Condensate Pump
• Defective Compressor
Capacitor
• Defective Thermistor
• Defective Compressor Motor
• Check wiring connections
• Defective Relay Board
• Defective Control Board
Evaporator or Condenser Fan
Motor(s) not operating
• Fan mode DIP switch is set to
“Stop” and current Set Point
Temperature exceeds Room
Temperature
• Fan mode DIP switch is set to
“Stop” and unit has
Condensate Pump that is
defective
• Check wire connections
• Defective fan motor capacitor
• Defective fan motor
• Defective Relay Board
• Defective Control Board
Board
• Defective Control Board
Unit starts, but stops immediately
• Room temperature and antifreeze thermistor connectors
are reversed on control board
• Defective Fan Motor
• Defective Compressor Motor
• Defective Relay Board
Unit operates, but stops after a
few minutes
• Drain Tank Switch activated
• Fan Mode Switch is set to
“Stop” and unit reached “set
point” temperature so
compressor cycled off
• Defective Compressor Motor
• Defective Fan Motor
• Fan Mode Switch is set to
“Stop” and compressor
cycled off
Water leakage from the unit
• Condensate pump not
working
• Drain Tank not installed
• Drain Tank (if available) is
defective (cracked)
• Drain Pan hole is obstructed
• Drain hose kinked
Abnormal noise and/or shaking
• Loose Compressor mounting
nut
• Deformed or worn rubber
grommet on the compressor
mounting bolt
• Internal interference with
other components
• Damaged or out of balance
fan
24
TROUBLESHOOTING AND REPAIR
In case of trouble, perform the following inspection
before disassembly.
8. Inspection of Plate Fins
To inspect the plate fins of either the evaporator
or condenser you must remove the air filters.
After removal of the air filters, inspect the plate
fins for any dirt, dust, lint, or debris that may have
caused poor cooling performance of the unit. If
cleaning of the fins is necessary, it is recommended that this service be performed by a
qualified service technician.
Plate Fins
9. Examination of Operating Environment
Operating environments will vary depending on
location, climate and surrounding conditions.
Installation location also can cause operational
problems. Consult your reseller concerning
operational environment requirements.
Operating Environment
10. Inspection of Cooling Capacity
Measure the difference in temperature between the
inlet of the evaporator and the cool air vent. If the
difference is out of the range given in the graphs on
page 8, proceed with the possible causes
suggested in the troubleshooting chart on page 24.
THERMOMETER
THERMOMETER
COOL
AIR OUT
COOL
AIR OUT
THERMOMETER
EVAPORATOR
AIR INLET
Cooling Capacity
25
TROUBLESHOOTING AND REPAIR
11. Disassembly
UPPER PANEL
TOP FRONT PANEL
CONTROL PANEL
FRONT RIGHT
PANEL
AIR OUTLET GRILLE
BLOWER HOUSING
CONDENSER FAN
ROOM THERMISTOR
UPPER BACK
PANEL
FREEZE
THERMISTOR
FILTER ELEMENT
FRONT PANEL FILTER ASSEMBLY
LEFT FRONT PANEL
EVAPORATOR FAN
CONDENSATE PUMP
SIDE PANEL
FILTER DOOR
DRAIN PAN ASSEMBLY
DRAIN TANK
(OPTIONAL)
DRAIN TANK
PANEL
ASSEMBLY
REAR PANEL
MIDDLE
FRAME
SUB-ASSEMBLY
TO
POWER
CORD
BACK LEFT PANEL
SERVICE PANEL
PIVOTING
CASTOR
CASTOR
PIVOTING
WITH
BRAKE
Disassembly
26
TROUBLESHOOTING AND REPAIR
A. Remove drain tank (if equipped).
Removal of Drain Tank (if equipped)
B. Remove twelve (12) screws from upper front
panel.
4
3
3
2
Removal of Upper Front Panel Screws
C. Slide upper front panel forward and remove.
Removal of Upper Front Panel
27
TROUBLESHOOTING AND REPAIR
D. Louver can be removed from upper front
panel by unsnapping the lock tab and removing the louver from its pivots.
Removal of Air Outlet Louver
E. Remove thirteen (13) screws from left rear
panel. Then remove four (4) screws from the
service panel.
2
4
4
4
3
Removal of Service Panel and rear panel
F.
8
Removal of upper rear panel
28
Remove eight (8) screws from right upper rear
panel.
TROUBLESHOOTING AND REPAIR
G. Remove fourteen (14) screws from right front
panel.
10
4
Removal of right front panel
H. Remove fourteen (14) screws from upper
panel.
8
3
3
Removal of upper panel screws
I.
Remove nine (9) screws from rear panel.
4
5
Removal of back panel screws
29
TROUBLESHOOTING AND REPAIR
J. Remove twelve (12) screws from left front
panel.
12
Removal of left front panel
12. Removal of Electrical Parts
AP
G T1 T
DS
230V 1 PHASE 60Hz
RTH
CC
HPRS
THS
R R1
MCC
TB
MC
1
IOLC
C
G
G
CF1
HI
MF1
LO
IOLF
G
HI
CF2
J8
J7
J6
J5
J4
J3
J2
J1
1
J201 J202 J203 J204
RB
J9
J201
J10
10
10
CB
ODS
MF2
LO
FDS
IOLF
CONDENSATE PUMP
MDP
G
G
AP
TB
CB
RB
MF1
MF2
MC
CF1
CF2
CC
IOLF
Attachment Plug
Terminal Block
Control Board
Relay Board
Condenser Fan Motor
Evaporator Fan Motor
Compressor Motor
Capacitor for Condenser Fan Motor
Capacitor for Evaporator Fan Motor
Capacitor for Compressor
Inner Overlaod Relay of Fan Motor
IOLC
DS
THS
RTH
G
HPRS
MCC
MDP
FDS
ODS
J10
COMPRESSOR
CAPACITOR
Inner Overload Relay of Compressor
Full Drain Tank Warning Switch
Freeze Protection Thermistor
Room Thermistor
Ground
High Pressure Switch
Relay for Compressor and Condenser Motor
Condensate Pump Motor
Drain Float Switch
Drain Overflow Switch
Connector for Condensate Pump
RELAY BOARD
EVAPORATOR FAN
CAPACITOR
RELAY BOARD
FUSE
COMPRESSOR
RELAY
L1
L3
T1
T3
TERMINAL
BLOCK
CONDENSER FAN
CAPACITOR
Removal of Electrical Parts in the Control Box
30
TROUBLESHOOTING AND REPAIR
TEMPERATURE SCALE
DISPLAY SWITCH
˚C
˚F
DIP SWITCH
31
C
C2
J9
F
C1
K1
D1
FAN MODE CONTROL SWITCH
STOP
OPERATE
C3
K2
D2
C4
2 PIN CONNECTOR
OF CONDENSATE PUMP
J10
K3
D3
C5
R2
R3
FT1
D4
D7
K4
Q1
TO COMPRESSOR
(DRIVER RELAY)
T1
TO COMPRESSOR
RELAY
VR6
R1
J4
J8
J3
J7
J2
J6
J1
J5
F1 2/10A 250V
NEUTRAL
WIRE FOR UNIT
POWER (TO BOARD)
!"# # #$ %&'
Connections to Relay Board
TO EVAPORATOR
FAN MOTOR (LOW SPEED)
TO CONDENSER
FAN MOTOR (HIGH SPEED)
TO CONDENSER
FAN MOTOR (LOW SPEED)
F1
RELAY BOARD FUSE
TO EVAPORATOR
FAN MOTOR (HIGH SPEED)
Connections to Control Board
31
TROUBLESHOOTING AND REPAIR
13. Removal of Blower Assembly
SET SCREW
CONTROL PANEL STAY
CONDENSER
HOUSING BOX
EVAPORATOR FAN CASING
EVAPORATOR
FAN MOTOR
RING
SUB-ASSEMBLY
SET SCREW
EVAPORATOR FAN
MOTOR
RING SUB-ASSEMBLY
CONDENSER
FAN MOTOR
CONDENSER FAN
MIDDLE FRAME
SUB-ASSEMBLY
CONDENSER
FAN HOUSING
Disassembly of Blower
14. Removal of Condenser Fan Motor
A. Loosen the set screw using a 5/16” open
ended wrench.
SET SCREW
Removal of Centrifugal Fan
32
TROUBLESHOOTING AND REPAIR
B. Remove the six (6) nuts on the inside of the
housing in the locations shown.
3
3
Removal of Blower Housing
C. Remove motor wires from the three (3) motor
wiring ties.
3
Removal of Fan Motor Assembly
D. Lift fan motor up then pull rear motor forward
and remove. Centrifical fan will drop into
condenser fan housing.
Removal of Fan Motor (Condenser)
Removal of Condenser Fan
A. Rest the fan motor backwards and place on
mounting bracket. Secure motor with two (2)
nuts.
2
Removal of Fan Motor
33
TROUBLESHOOTING AND REPAIR
B. Remove the ring sub-assembly by removing
the six (6) screws.
3
3
Removal of Ring Sub-Assy
C. Loosen the four (4) nuts securing the fan
casing. Lift the enclosure off its mounting.
Slide the condenser fan out through opening.
2
2
Removal of Fan Casing Nuts
Removal of Evaporator Fan Motor
A. Loosen the set screw using a 5/16” open
ended wrench.
SET SCREW
Loosening of Set Screw
B. Remove four (4) nuts from housing while
holding fan securely with one hand. Remove
motor wires from the two (2) front motor
wiring ties.
2
4
Removal of Fan Housing Nuts
34
TROUBLESHOOTING AND REPAIR
C. Pull evaporator motor forward and remove.
Removal of Fan Motor (Evaporator)
Removal of Control Board
A. Remove two (2) screws from the control panel
stay.
2
Removal of Control Panel Screws
B. Remove three (3) screws from the control
panel stay.
3
Removal of Control Panel Screws
C. Slowly slide control panel assembly out of
box.
Removal of Control Board
35
TROUBLESHOOTING AND REPAIR
D. Disconnect the following connectors from the
control board:
(A) Wire Harness, Relay Board to Control
Board J201 (10-pin)
A
B C
(B) Room Thermistor J101 (2-pin)
(C) Freeze Thermistor J102 (2-pin with black
tape)
(D) Drain Tank Switch J103 (2-pin)
(E) High Pressure Switch Sub-Harness
NOTE: Mark each of the 2-pin connectors with a
different color marker to ensure the correct orientation when they are re-connected.
Removal of Connectors from Control Panel
E. Remove the five (5) screws from the control
board on the control panel assembly. Remove
the control board.
Removal of Control Board
15. Inspection of Capacitor (for Fan Motors and
Compressor)
Ohmeter Method – Set the ohmeter to the 100KΩ
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. If the
reading indicates infinity right away (shorted) or
the ohmeter fails to move from 0Ω (open), replace
the capacitor.
16. Capacitance Tester Method
Using a capacitance tester and the chart on page
17, test the capacitor for the value indicated. If
the value tested is not within 10% of indicated
capacitance, replace the capacitor.
Inspection of Capacitor
TOP OF
BASE
PLATE
WARNING: Properly discharge the capacitor(s)
before testing and after testing has been completed. Failure to do so could cause damage to
test equipment or the unit and/or result in personal injury (electrical shock) or death.
DRAIN
SWITCH
To J103
18. Inspection of Drain Switch
Check for continuity between terminals 1 and 2.
Continuity should exist. With switch depressed,
no continuity should exist between terminals 1
and 2. If continuity is not as specified above,
replace the switch.
NC
DS2
2
1
DS1
C
Inspection of Drain Switch
36
D E
TROUBLESHOOTING AND REPAIR
17. Inspection of Condenser Fan Motor
Measure resistance across the terminals of the
fan motor.
CONDENSER FAN MOTOR
Terminals (at 77˚F (25˚C))
J6-CF12 Approx. 21.2Ω
J5-CF11 Approx. 32.4Ω
J5-J6
Approx. 0.592Ω
If the measured resistance does not approximately equal these standard values ±10%,
replace the fan motor.
GROUND (GREEN/YELLOW)
J5 (RED)
CF12 (BROWN)
CF11 (ORANGE)
J6 (BLACK)
Inspection of Condenser Fan Motor
18. Inspection of Evaporator Fan Motor
Measure resistance across the terminals of the
fan motor.
Terminals (at 77˚F (25˚C))
CF21-J8 Approx. 1.55Ω
CF22-J8 Approx. 70.2 Ω
J7-J8
Approx 89.7 Ω
EVAPORATOR FAN MOTOR
If the measured resistance does not approximately equal these standard values ±10%,
replace the fan motor.
GROUND (GREEN/YELLOW)
J7 (RED)
CF22 (BROWN/WHITE)
CF21 (ORANGE)
J8 (BLACK)
Inspection of Evaporator Fan Motor
19. Inspection of Compressor Motor
Measure resistance across the terminals of the
compressor motor.
Terminals (at 77˚F (25˚C))
R-C
Approx. 2.0Ω
C-S
Approx. 2.2Ω
S-R
Approx. 3.8Ω
If the measured resistance does not approximately equal these standard values ±10%,
replace the fan motor.
Inspection Of Compressor Motor
37
TROUBLESHOOTING AND REPAIR
20. Inspection of Wiring Connection
Refer to the Wiring Diagrams on page 46 and check for connection of each wire.
21. Inspection of Thermistor
Using an Ohmeter, check the resistance value across the 2-pin connector. At normal temperature (77˚F
(25˚C)) either thermistor (room or freeze) should measure approximately 10,000 or 10K ohms.
22. Inspection
In most cases, the probable cause for insufficient cooling is a clogged system, too much static pressure
refrigerant 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. Inspection of Refrigerant Leak
Carefully check all connections, and each component for leaks whenever the refrigerant system is
installed or repaired. Use an electronic gas leak tester to inspect the system.
C. Insufficient Refrigerant
In case the unit is judged to be deficient in cooling capacity, be sure to perform the inspections in
24A and 24B to confirm the cause of trouble. After that, charge the system with refrigerant to the
specified amount.
23. Repair of Refrigerant System
In case there is a leak, obstruction, or trouble in the refrigerant system of the Spot Cooling System, replace
or repair the part in question. After replacing any component all connections must be brazed.
A. Proper Brazing Techniques
It is desirable to use a slightly reducing 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
necessary to preheat the base metal properly depending on the shape, size or thermal conductivity of
the brazed fitting.
The most important point in flame brazing is to bring the whole brazed fitting to a proper brazing
temperature. Care should be taken to not cause overflow of brazing filler metal, oxidization of brazing
filler metal, or deterioration due to the overheating of flux.
38
TROUBLESHOOTING AND REPAIR
•
In general, the strength of brazing filler metal
is lower than that of the base metal. So, the
shape and clearance of the brazed fitting are
quite important. As for the shape of the
brazed fitting, it is necessary to maximize its
adhesive area. The clearance of the brazed
fitting must be minimized to facilitate brazing
filler metal to flow into it by capillary action.
CLEARANCE
0.025 ~ 0.075 mm
•
FORM THE PIPE FITTING WITH A TUBING TOOL
BRAZING FILLER METAL
45º
BURNER
•
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 (1l/min.;
adjust with the flow regulator) through the
pinch-off tube of the refrigerant cycle to
prevent oxidation.
VERTICAL DOWN JOINT
Veritcal Down Joint
TUBE
CLEANING OF BRAZING FILLER METAL
AND PIPE
When the refrigerant 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. Fats and oils may
stick to the pipe from handling. All these
factors will reduce effectiveness of brazing. It
is necessary to eliminate excess brazing filler
metal using sand paper and by cleaning
thoroughly with a solvent such as Trichlene.
Form the Pipe Fitting
TUBE
BRAZED FITTING AND ITS CLEARANCE
NOTE: Take care not to allow dirt, water, oil, etc. to
enter into the pipe
VERTICAL UP JOINT
•
VERTICAL JOINT
Heat the whole brazed fitting to a proper
brazing temperature. Bring the brazing filler
metal into contact with the fitting so that the
brazing filler metal starts flowing by itself.
Stop heating the fitting as soon as the
brazing filler metal has flown into the clearance. Since the brazing filler metal flows
easily into the portion heated to a proper
temperature, it is essential to keep the whole
fitting at a proper brazing temperature.
BURNER
45º
BRAZING FILLER METAL
Vertical Up Joint
39
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 1l/min) through the pinch-off tube
during any brazing operation.
3. During any component replacement involving brazing, shield nearby parts with a steel plate, asbestos, etc., to protect them from the flame.
(1)
(2)
(3)
(4)
Evaporator
Capillary tubes
Condenser
Compressor
NOTE: Hold the compressor body, not the tube, when carrying the compressor.
B
G
E
F
A
C
PART TO REPLACE
DISCONNECT AT
COMPRESSOR ASSY
A&D
CONDENSER
A&C
HIGH PRESSURE SWITCH TUBE
B
EVAPORATOR ASSY
E, F & G
D
Refrigeration Cycle Components
40
TROUBLESHOOTING AND REPAIR
24. 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. (Never in an enclosed environment.)
• Do not expose refrigerant to an open flame.
• Never smoke while performing repairs, especially when handling refrigerant.
• Be careful 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 large quantities of cool water on the eye or the skin.
• Apply clean petroleum jelly to the skin.
• Go immediately to a physician or to a hospital for professional treatment.
STEP 1. CONNECT MANIFOLD GAUGE
STEP 2. EVACUATE THE SYSTEM
750 mmHg (29.55 inHg)
OR MORE OF VACUUM
15 MINUTES OR MORE
WHEN LEAK IS FOUND, REPAIR
THE CONNECTION OR COMPONENTS
STOP EVACUATING THE SYSTEM
LEAVE FOR FIVE MINUTES
CHECK THE VACUUM
STEP 3. CONNECT TO REFRIGERANT SOURCE
STEP 4. TEST THE SYSTEM FOR LEAKS
STEP 5. CHARGE THE SYSTEM WITH R-22*
* SEE SPECIFICATIONS ON PAGE 6
STEP 6. REMOVE MANIFOLD GAUGE
A. Connection of Gauge Manifold
(1) Properly remove the crushed end of the
pinch-off tube at the high pressure side
and the low pressure side of the refrigerant cycle with a pipe cutter.
CHARGING
HOSE SIDE
REFRIGERANT
CYCLE SIDE
(2) Fit the process tube fitting to the pinchoff tube on both sides.
SEAL
PINCH-OFF TUBE
Connection of Gauge Manifold
41
TROUBLESHOOTING AND REPAIR
NOTE: Connect the hoses using care not to mistake
the high pressure side for the low pressure side and
vice versa.
LOW PRESSURE
VALVE (CLOSED)
(3) Connect the charging hoses (red - high
pressure side, blue - low pressure side) of
the gauge manifold to the process tube
fittings.
HIGH PRESSURE VALVE
(CLOSED)
RED HOSE
GREEN HOSE
PROCESS TUBE FITTING
HIGH PRESSURE
SIDE TUBE
(4) Connect the charging hose (green) at the
center of the gauge manifold to the
vacuum pump.
BLUE HOSE
LOW PRESSURE
SIDE TUBE
VACUUM PUMP
(AT A STOP)
Hose Connection
B. Evacuation
VALVE SETTING
LOW PRESSURE GAUGE
(1) Open the high pressure valve (HI) and the
low pressure valve (LO) of the gauge
manifold.
LO
HI
LO
OPEN OPEN
HI
CLOSED CLOSED
750 mmHg OR LARGER
GAUGE
HIGH PRESSURE GAUGE
LOW PRESSURE
VALVE (CLOSED)
(2) Turn on the vacuum pump to start
evacuation. (Evacuate the system for
approximately 15 minutes.)
(3) When the low pressure gauge indicates
750mmHg (29.55 in.Hg) or larger, turn off
the vacuum pump and close the high and
low pressure valves of the gauge manifold.
HIGH PRESSURE VALVE
(CLOSED)
HIGH PRESSURE
SIDE TUBE
LOW PRESSURE
SIDE TUBE
VACUUM PUMP
(IN OPERATION)
Evacuation
C. Checking Vacuum
VALVE SETTING
(1) Leave the high pressure valve and the
low pressure valve of the gauge manifold
closed for five minutes or more, and
confirm that the gauge pointer does not
return to zero.
LO
HI
CLOSED CLOSED
LEAVE VALVES CLOSED FOR 5 MINUTES
OR MORE. POINTER OF LOW PRESSURE
GAUGE RETURNING TO ZERO INDICATES
THERE IS A LEAK.
LOW PRESSURE GAUGE
(2) If the gauge pointer returns gradually to
zero there is a leak somewhere in the
system (this could also include gauge
manifold). Perform leak check according
to procedure indicated in 24D. Once leak
has been found and repaired evacuate
the system once more, and confirm
system holds vacuum.
RETURN
BRAZING OF PIPING
Checking Vacuum
42
TROUBLESHOOTING AND REPAIR
D. Checking Gas Leak
VALVE SETTING
LO
(1) Remove the charging hose (green) from
the vacuum pump, and connect the hose
to the refrigerant cylinder (R-22).
HI
AIR PURGING
BLUE
OPEN THE VALVE
OF REFRIGERANT
CYLINDER
CHARGING HOSE (GREEN)
RED
REFRIGERANT
CYLINDER R-22
CLOSED CLOSED
TO PROCESS TUBE FITTING
Checking Gas leak
(2) Loosen the nut on the gauge manifold
side of the charging hose (green).
VALVE SETTING
LO
LOW PRESSURE
HI
LO
HI
(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.
OPEN OPEN GAUGE READING CLOSED CLOSED
4 kg/cm2G
LOW PRESSURE GAUGE
(57 psiG)
4 kg/cm2G (57 psiG)
LOW PRESSURE VALVE
(CLOSED)
OPEN HIGH PRESSURE VALVE
REFRIGERANT
CYLINDER R-22
PROCESS TUBE FITTING
VALVE OF
REFRIGERANT
CYLINDER
(OPEN)
(4) Check carefully for gas leaks inside the
refrigerant system using the gas leak
tester.
HIGH PRESSURE
SIDE TUBE
LOW PRESSURE
SIDE TUBE
(5) Repair any leak.
Still Checking Gas Leak
WARNING: Do not attempt any repair on a
charged system.
WARNING: Before checking for gas leaks, fully
confirm that there is nothing flammable in the
area to cause an explosion or fire. Contact of
refrigerant with an open fire generates toxic gas.
E. Evacuation (Repeat)
VALVE SETTING
LOW PRESSURE GAUGE
LO
HI
LO
OPEN OPEN
(1) Close the valve of the refrigerant cylinder.
Then remove the charging hose (green)
from the refrigerant cylinder, and connect
it to the refrigerant recovery machine.
HI
CLOSED CLOSED
750 mmHg OR LARGER
GAUGE
LOW PRESSURE
VALVE
HIGH PRESSURE GAUGE
NOTE: Keep the high pressure valve and the low
pressure valve of the gauge manifold closed.
HIGH PRESSURE VALVE
(2) Using procedure 24B., evacuate the
system until the low pressure gauge
indicates 750mmHg (30in.HG) or greater.
(For 15 minutes or more.)
HIGH PRESSURE
SIDE TUBE
LOW PRESSURE
SIDE TUBE
VACUUM PUMP
(IN OPERATION)
(3) After evacuation is complete, close the
high and the low pressure valves of the
gauge manifold.
Evacuation
CAUTION: Be sure to evacuate the system twice
or more using the repetitive vacuum method.
Evacuate the system an additional time on rainy
or humid days.
43
TROUBLESHOOTING AND REPAIR
25. Refrigerant Charging Work
VALVE SETTING
A. Refrigerant Charging
LO
(1) Remove the charging hose (green) from
the vacuum pump, and connect it to the
refrigerant cylinder (R-22).
HI
AIR PURGING
(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.
BLUE
(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).
OPEN THE VALVE
OF REFRIGERANT
CYLINDER
CHARGING HOSE (GREEN)
RED
REFRIGERANT
CYLINDER R-22
CLOSED CLOSED
TO PROCESS TUBE FITTING
Refrigerant Charging Work
(4) Open the high pressure valve of the
gauge manifold and the valve of the
refrigerant cylinder. Charge the system
with refrigerant to the specified amount.
VALVE SETTING
LO
HI
OPEN OPEN
SPECIFIED AMOUNT
OR REFRIGERANT
LO
HI
CLOSED CLOSED
4 kg/cm2G
(57 psiG)
Standard Amount of Refrigerant:
6.83 lbs / 3.1 kg
LOW PRESSURE VALVE
HIGH PRESSURE VALVE
VALVE OF
REFRIGERANT
CYLINDER
(a) Close the high-pressure valve of
manifold.
REFRIGERANT
CYLINDER R-22
PROCESS TUBE FITTING
If the system cannot be charged with the
specified amount of refrigerant under this
condition, follow the steps below:
HIGH PRESSURE
SIDE TUBE
LOW PRESSURE
SIDE TUBE
WEIGHT
(b) Operate the refrigerant system.
Refrigerant Charging Work
(c) Slowly open the low-pressure valve
while observing the scale reading.
(d) When the scale reads the specified
amount, immediately close the lowpressure valve.
(e) Bring the system to a stop.
CAUTION: The amount of refrigerant charged
has a great effect on the cooling capacity of the
unit. Charge to the specified amount, always
observing the scale graduations while charging.
(5) Close the high pressure valve of the
gauge manifold and the valve of the
refrigerant cylinder.
PINCH-OFF TOOL
B. Removal of Gauge Manifold
TO GAUGE
MANIFOLD SIDE
(1) Crimp the pinch-off tube with a pinch-off
tool.
PINCH-OFF TUBE
(2) Remove the gauge manifold and the
process tube fitting. Crush the end of the
pinch-off tube.
CHARGING HOSE
TO REFRIGERANT
CYCLE SIDE
(3) Braze the end of the pinch-off tube.
PROCESS TUBE FITTING
(4) Ensure that a gas leak is not present at
the pinched off portion and the brazed
end.
Removal of Gauge Manifold
44
TROUBLESHOOTING AND REPAIR
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.
26. Compressor Mounting
Mount the compressor on the frame, using
cushions, steel collars, spring washers, plate
washers and nuts.
COMPRESSOR
NUT
SPRING
WASHER
PLATE
WASHER
CUSHION
STEEL
COLLAR
Compresor Mounting
27. Blower Assembly
a. Install blower fan (for evaporator). Allow a
clearance of 3mm (minimum) on each
side of the evaporator fan.
b. Install blower fan (for condenser). Allow a
clearance of 3mm (minimum) on each
side of the condenser fan.
Tightening torque:
10.84 ± 2.17 lbf•ft (150 ± 30 kgf•cm)
Evaporator Blower Assembly
28. 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 they were before removal.
29. Perform the inspection of cooling capacity
and check for abnormal noise or abnormal
vibration.
Condenser Blower Assembly
30. Caster Maintenance
a. Lubricate bearings in caster as needed
with standard bearing grease using the
zerk fitting.
NOTE: Casters should roll and swivel freely.
Check for dirt or dust build up. Remove dust or
dirt build up.
45
G
G T1 T
AP
AP
TB
CB
RB
MF1
MF2
MC
CF1
CF2
CC
IOLF
R R1
Wiring Diagram
46
C
MCC
CF2
CF1
CC
IOLF
G
LO
LO
MF2
HI
IOLF
MF1
HI
IOLC
MC
Attachment Plug
Terminal Block
Control Board
Relay Board
Condenser Fan Motor
Evaporator Fan Motor
Compressor Motor
Capacitor for Condenser Fan Motor
Capacitor for Evaporator Fan Motor
Capacitor for Compressor
Inner Overlaod Relay of Fan Motor
TB
230V 1 PHASE 60Hz
G
IOLC
DS
THS
RTH
G
HPRS
MCC
MDP
FDS
ODS
J10
G
MDP
FDS
ODS
J10
RB
G
10
DS
HPRS
CB
J201 J202 J203 J204
J201
1
CONDENSATE PUMP
10
J9
1
THS
Inner Overload Relay of Compressor
Full Drain Tank Warning Switch
Freeze Protection Thermistor
Room Thermistor
Ground
High Pressure Switch
Relay for Compressor and Condenser Motor
Condensate Pump Motor
Drain Float Switch
Drain Overflow Switch
Connector for Condensate Pump
J8
J7
J6
J5
J4
J3
J2
J1
RTH
TROUBLESHOOTING AND REPAIR
31. Schematic
DENSO SALES CALIFORNIA, INC.
TECHNICAL SERVICE DEPARTMENT
First Issue: January 2002
DSCA P/N: LA990009-0842
Printed in U.S.A.
(800) 264-9573
www.movincool.com
DSCA P/N: LA990009-0842
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