MovinCool OFFICEPRO63 Service Manual

SERVICE MANUAL
OFFICE PRO 63
SERIAL NUMBER FROM JANUARY 2008 (0108) TO PRESENT
DocID: 00G00017E
© 2008 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 registered trademark of DENSO
Corporation.
Table of Contents
Table of Contents
Operation Section
1. PRECAUTIONS FOR SAFETY
1.1
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. GENERAL DESCRIPTION
2.1
Spot Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2
Compact Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3
Easy Transportation and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4
Energy Conservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. CONSTRUCTION
3.1
Exterior Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2
Exterior Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3
Internal Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4
Basic Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5
Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7
Compressor and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.8
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.9
Condensate Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.10 Drain Tanks (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. SPECIFICATIONS
4.1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2
Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5. REFRIGERANT SYSTEM
5.1
Refrigerant System Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.4
Capillary Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.5
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.6
High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table of Contents
6. ELECTRICAL SYSTEM
6.1
Circuit Diagram and Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2
Basic Operation of The Office Pro 63 Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.5
Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.6
Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.7
Condensate Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.8
Drain Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.9
Automatic Restart after Power Interruption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.10 Compressor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.11 Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.12 Fan Mode Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.13 Temperature Scale Display Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.14 Warning Signal Connection (Output Signal Terminal L+ and L-) . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.15 Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-) . . . . . . . . . . . . . . . . . . . . . 32
Table of Contents
Repair Section
7. TROUBLESHOOTING
7.1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.2
Self-Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4
Basic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8. DISASSEMBLY
8.1
Parts Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.3
Removal of Electrical Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.4
Removal of Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.5
Removal of Condensate Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.6
Removal of Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.7
Inspection of Capacitor (for Fan Motor and Compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.8
Inspection of Drain Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.9
Inspection of Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.10 Inspection of Compressor Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.11 Inspection of Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.12 Inspection of Wiring Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.13 Inspection of Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9. REFRIGERANT SYSTEM REPAIR
9.1
Repair of Refrigerant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.2
Removal of Refrigeration Cycle Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.3
Charging the System with R-410A Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.4
Refrigerant Charging Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10. REASSEMBLY
10.1 Removal of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10.2 Compressor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10.3 Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10.4 Wiring Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10.5 Perform the Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10.6 Caster Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10.7 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6
Operation Section
1. PRECAUTIONS FOR SAFETY
1.1 Foreword
• This manual has been published to service the MovinCool Office Pro 63. Please use this service
manual only when servicing the Office Pro 63.
1.2 Definition of Terms
WARNING
CAUTION
NOTE
Describes precautions that should be observed in order to prevent injury to
the user during installation or unit operation.
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.
Provides additional information that facilitates installation or unit operation.
1.3 General Precautions
WARNING
• 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 parts, 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.
Operation Section
7
2. GENERAL DESCRIPTION
2.1 Spot Cooler
• In general, 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
Condenser
(Outdoor Unit)
Evaporator
(Indoor Unit)
exchanged heat to the outdoors.
• Unlike
conventional
air
conditioners,
the
MovinCool Office Pro 63 is a spot cooler which
I000501
directs cool air to particular areas or objects.
MovinCool Office Pro 63 has the following features:
2.2 Compact Design
• The innovative design of MovinCool Office Pro
63 has resulted in one compact unit, replacing
the need for two separate units.
2.3 Easy Transportation and
Installation
• With the whole cooling system built into one
compact unit, MovinCool Office Pro 63
requires
no
piping
and
can
be
easily
transported and installed.
2.4 Energy Conservation
• MovinCool Office Pro 63 is economical
because it cools only the area or objects which
need to be cooled.
I001905
Operation Section
8
3. CONSTRUCTION
3.1 Exterior Dimensions
(30.2)
(55.0)
(65.0)
(6.1)
(10.0)
(27.6)
(62.2)
(18.7)
(DIA. 15.7)
(2.6)
(3.6)
(2.6)
(3.6)
(29.9)
(Unit: inch)
(8.5)
(40.8)
(51.6)
(2.4)
I001906
Operation Section
9
3.2 Exterior Components
Operation Panel
Cold Air Outlet Grill
Caster
Evaporator Air Inlet Grill
Condenser Air Outlet Duct
Condenser Air Inlet Panel
Power Cord
Service Panel
I001907
10
Operation Section
3.3 Internal Structure
Fan Motor
(Evaporator)
Fan
(Condenser)
Fan Motor
(Condenser)
(Behind Fan)
Fan
(Evaporator)
Evaporator
High Pressure
Switch
Capillary Tube
Drain Pan
Condensate Pump
Transformer
Compressor
Condenser
Drain Switch
Control Box
I001950
3.4 Basic Construction
• The MovinCool Office Pro 63 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, and the lower front face contains the condensate pump
and optional drain tanks. The rear section contains the condenser, the compressor, the
transformer and the control box.
Operation Section
11
3.5 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, and the exhaust air duct is protected by metal grill.
Exhaust Air Out
Cool Air Out
Evaporator Air In
Condenser Air In
I001909
3.6 Electrical System
• The MovinCool Office Pro 63 is equipped with a compressor operated at 460 V, 3 phase and a
dry-type distribution transformer operated 460 V, single phase at primary side and 230 V single
phase at secondary side which supply power source for fan motors, relay board, and
condensate pump.
3.7 Compressor and Fans
• The compressor is hermetically sealed. Two sets of a two-speed fan motor with a centrifugal fan
are used to draw air across the evaporator and condenser.
3.8 Transformer
• The transformer is a dry-type distribution transformer rated 5 KVA at 460 V primary side and
230 V secondary side.
12
Operation Section
3.9 Condensate Pump
• The condensate pump and a 20 ft (6 m) drain hose are included with the Office Pro 63 to provide
continuous operation without the need of the drain tanks. The condensate pump has a maximum
head lift of 17 ft (5.2 m) at system operated voltage of 460 VAC.
3.10 Drain Tanks (optional)
• A set of two 5.0 gal (19 L) drain tanks are supplied as optional accessory for Office Pro 63. When
drain tanks are used instead of condensate pump, the condensate (water) is collected into both
tanks. The drain switch activates and stops the operation when tanks reach the level of
approximately 8.0 gal (30 L).
Operation Section
13
4. SPECIFICATIONS
4.1 Technical Specifications
ITEM
Electronic Features
Cooling
Capacity*1
Refrigerant Circuit
SPECIFICATIONS
Control Panel
Electronic
Thermostat Control
Electronic
Capacity
Compressor
60000 Btu/h (17585 W)
Compression Type
Motor Rated Output at 460 V
Plate Fin
Condenser
Plate Fin
Refrigerant/Enclosed quantity
Fan Type
Evaporator
Max. Air Flow-high/low
Motor Rated Output-high/low at 230 V
Max. External Static Pressure
Ventilation Equipment For
Fan Type
Condenser
Max. Air Flow - high/low
Motor Rated Output-high/low at 230 V
Centrifugal
1940/1770 CFM (3300/3000 m3/h)
0.60/0.33 kW
0.9 IWG (224 Pa)
Centrifugal
2830/2650 CFM (4810/4500 m3/h)
1.2/0.92 kW
Max. External Static Pressure
0.85 IWG (212 Pa)
Power Requirement
460 V, 3 PH, 60 Hz
MIN. MAX. Voltage
MIN 414 V, MAX 506 V
Current Consumption*1
Total Power Consumption*1
Power
Factor*1
Starting Current
Recommended Fuse size
9.5 A
6.6 kW
87 %
65 A
20 A
NEMA Plug Configuration
Gage x Length
Signal Connection
Capillary Tube
R-410 A/4.41 lb (2.00 kg)
Ventilation Equipment For
Power Cord
3.89 kW
Evaporator
Refrigerant Control
Electronic Characteristics
Hermetic Scroll
Fire Alarm Input
L16-20
12 AWG (4-core) x 6 ft
• Dry contact type (recommended)
• No-Voltage Contact Input/Contact
resistance Less than 100 ohm
Warning Signal Output
2 A at 30 V (DC/AC) or less
(resistive load)
Net weight
705 lb (320 kg)
14
Operation Section
ITEM
Operating Condition
Sound Level*2 *3
SPECIFICATIONS
Inlet air: Maximum
105 °F (41 °C), 50 %RH
Inlet air: Minimum
65 °F (18.3 °C), 50 %RH
With Condenser Duct-high/low
69/67 dB(A)
Without Condenser Duct-high/low
71/69 dB(A)
Max. Duct Equivalent Length-Per Cold Duct Hose/Hot Duct Hose
Condensate Pump
40/100 ft (12.1/30.5 m)
1/30 HP, 230 V, 0.5 A, 75 W,
Discharge: 3/8 in (9.53 mm)
OD barbed
• Specifications are subject to change without notice.
< NOTE >
*1 : Rating Condition: 95 °F (35 °C), 60 %RH
*2 : Measured at 3.28 ft (1 m) from surface of unit.
*3 : Internal dry-type distribution transformer may produce a humming noise up to 31 dB(A) at maximum operated voltage (506 V) during stand-by state.
Operation Section
15
4.2 Characteristics
<Cool Air Temperature Difference Curve>
65
23.4(13)
60
21.6(12)
55
19.8(11)
50
18.0(10)
Delta-T °F (°C)
Cooling Capacity (x103 Btu/h)
<Cooling Capacity Curve>
45
Dry Bulb Temp. °F (°C)
40
95(35)
16.2(9)
14.4(8)
12.6(7)
86(30)
10.8(6)
77(25)
9.0(5)
68(20)
7.2(4)
30
50
(10)
<Power Consumption Curve>
70
80
12
Current Consumption (A)
7.0
6.0
5.0
10
8
6
4.0
4
95(35)
95(35)
86(30)
77(25)
68(20)
68
(20)
77
(25)
86
(30)
Wet Bulb Temp. °F (°C)
95
(35)
Dry Bulb Temp. °F (°C)
Power Consumption (kW)
50
60
Relative Humidity (%)
<Current Consumption Curve>
8.0
Dry Bulb Temp. °F (°C)
40
59
68
77
(15)
(20)
(25)
Wet Bulb Temp. °F (°C)
86(30)
77(25)
68(20)
68
(20)
77
(25)
86
(30)
95
(35)
Wet Bulb Temp. °F (°C)
I001951
16
Operation Section
5. REFRIGERANT SYSTEM
5.1 Refrigerant System Construction
The component parts of the refrigerant system include the following:
• Compressor, Evaporator, Condenser, Capillary tube, High Pressure Switch
These parts are all connected by copper tubing. All the connections have been brazed.
Evaporator
Condenser
Evaporator Pipe
Capillary Tube
Compressor
Discharge Pipe
Evaporator Outlet Pipe
Condenser Inlet Pipe
Compressor
Compressor Suction Pipe
Condenser Outlet Pipe
Flow of Refrigerant
Condenser
Capillary
Tubes
Condenser
Fan
Evaporator
Fan
Compressor
Evaporator
I001952
Operation Section
17
5.2 Compressor
• The compressor used for the unit is hermetically sealed. The compressor and the compressor
motor are in one casing.
(1) Compressor theory of operation
• The scroll utilizes an involuted 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.
(2) Compressor operation
1㧕
2㧕
3㧕
4㧕
5㧕
I001767
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.
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 >
When the compressor shuts off, the compressor motor may run backward for a moment or two
until internal pressures is equalized. 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.
18
Operation Section
5.3 Condenser
• The condenser is a heat exchanger with copper tubes that are covered with thin aluminum
projections called 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 duct.
5.4 Capillary Tube
• The capillary tube is a long thin tube utilizing
High Temp./High Pressure
Liquid Refrigerant
line flow resistance to serve as an expansion
valve. The length and the inner diameter of the
capillary tube are determined by the capacity of
the refrigeration system, specified operating
conditions, and the amount of refrigerant. The
capillary tube causes the high pressure, high
Low Temp./Low Pressure
Gas and Liquid Mixture
temperature liquid refrigerant sent from the
I001887
condenser to expand rapidly as the refrigerant
is sprayed out through the fixed orifice in the capillary tube. As a result, the temperature and
state of the refrigerant becomes low and mist-like respectively, causing it to evaporate easily.
5.5 Evaporator
• The evaporator, like the condenser, is a heat exchanger covered with 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.
5.6 High Pressure Switch
• The
high
condenser
pressure
and
switch
compressor
prevents
from
the
Pressure of Refrigerant
being
damaged by excessively high pressure in the
Snap Disk
Movable Point
high pressure line of the refrigeration cycle.
The switch is normally closed. The snap disk
Stationary Point
responds to the variations in pressure and, if
Case
Pin
Terminal
pressure is abnormally high, the snap disk
moves down to push the pin down, causing the
Molding by Resin
Lead Wires
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:
- The condenser air filter is dirty, restricting air flow.
- The condenser blower is defective.
I001768
Operation Section
19
6. ELECTRICAL SYSTEM
6.1 Circuit Diagram and Control Box
AC460 V 3 φ 60 Hz
AP
G
RS T
MCC
TB1
G
460 V 230 V
HI
X4
H4
X1
1
F 2
1L1
3L2
2T1
4T2
5L3
7L4
6T3
8T4
A1
TNS
S1
R1
MCC
MDP
TB1
2
8
1
RPHR
G
RTH
THS
DS
3
HPRS
1
2
CF1
A
P
T B 1
T B 2
C
B
R
B
M F 1
M F 2
M
C
C F 1
C F 2
RPHR
T N S
Condensate Pump
A2
CF2
1
G
FDS ODS
1
345
MC
IOLC
2
HI
MF2 LO
G
IOLF
J8
J7
J6
J5
J4
J3
J2
J1
HI
MF1 LO
G
IOLF
J9
J10
Terminal Block
(Signal Connection)
J106
J201
J105 J108
RB
IOLF
IOLC
D
S
T H S
R T H
G
HPRS
M C C
M D P
F D S
O D S
F
Attachment Plug
Terminal Block
Terminal Block
Control Board
Relay Board
Condenser Fan Motor
Evaporator Fan Motor
Compressor Motor
Capacitor for Condenser Motor
Capacitor for Evaporator Motor
Phase Reversal Relay
Transformer
J101 J102 J103 J104
FUSE 25A
TB2
LL+
EE+
CB
Inner Overload Relay of Fan Motor
Inner Overload Relay of Compressor
Full Drain Warning Switch
Freeze Protection Thermistor
Room Thermistor
Grounding
High Pressure Switch
Relay for Compressor and Condenser Fan Motor
Condensate Pump Motor
Drain Float Switch
Drain Overflow Switch
Fuse (25 A)
Fuse
(for Transformer)
TB2
Fuse Holder
Terminal Block
(Reverse Phase Protector)
Dip Switch
Reverse Phase Protector
Relay Board
Relay Board Fuse
Fan Capacitor
(Evaporator)
TB1
Relay
Terminal Block
G
Fan Capacitor
(Condenser)
I001953
20
Operation Section
6.2 Basic Operation of The Office Pro 63 Electrical Circuit
• There are three basic components used to control the operation of the Office Pro 63 electrical
system:
- Transformer
- 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, high pressure switch and a microprocessor.
(1) Fan mode
High Fan Mode
• When the FAN MODE button on the control panel is pressed, the microprocessor turns on “FAN
HI” “COOL OFF” indication of LCD and activates both the fan on relay and fan mode relay. This
sends line voltage (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.
• When this button is pressed again, fan turns to low mode (see below). Press again, fan stops.
• High fan mode is automatically switched
depending on room temperature. When room
(High)
temperature is decreased down to 80 °F
(27 °C) or below, fan mode is switched to
HIGH. When room temperature is increased to
Condenser Fan
(LO)
88 °F (31 °C) or higher, fan mode is switched
from HIGH to LO.
Room Temperature
80 °F
(27 °C)
88 °F
(31 °C)
I001914
Low Fan Mode
• When the FAN MODE button on the control panel is pressed again, the microprocessor turns on
“FAN LO” “COOL OFF” indication of LCD and activates both the fan on relay and fan mode relay.
This sends line voltage (230 VAC) from the fan on relay 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.
• When this button is pressed again, fan stops.
Operation Section
21
(2) Cool mode
• In addition to fan mode (as described above), when the COOL ON/OFF button on the control
panel is pressed, the microprocessor turns on “COOL ON” indication of LCD and if the
temperature set point is less than the current room temperature, activates the compressor relay
(relay board) after 120 sec delay. This sends line voltage (230 VAC) to the J4 terminal (relay
board) and compressor auxiliary relay is excited. Then compressor and condenser fan motor
turn on (Cooling Operation).
• Condenser fan mode is automatically switched
depending on room temperature. When room
(LO)
temperature is approximately. 100 °F (38 °C)
or greater, fan mode is switched LO to HIGH.
When room temperature is approximately.
Condenser Fan
(High)
95 °F (35 °C), fan mode is switched HI to LO.
Room Temperature
95 °F
(35 °C)
100 °F
(38 °C)
I001915
22
Operation Section
6.3 Transformer
• A dry-type transformer rated 5 KVA is equipped
within the unit to provide step down voltage
Terminal Block
(Primary)
Terminal Block
(Secondary)
from 460 V single phase to 230 V single phase.
• The terminal connection of the primary side of
the transformer are labeled H1, H2, H3, and
H4. Terminals H2 and H3 are shorted together
to provide a series connection for 460 V
application.
Terminals
H1
and
H4
are
Coil
connected to 460 V power source to supply
power to secondary side.
• Terminals X2 and X3 of the secondary side are
also shorted together to provide 230 V output
<Wiring Diagram>
Short Circuit
Primary
(460 V)
H1
H3 H2
H4
Secondary
(230 V)
X4
X2 X3
X1
between terminals X4 and X1.
Specifications:
Distribution transformer
- Type: Dry type
- Rated VA: 5000 VA
- Power Requirement: 1 PH, 60 Hz
- Primary Voltage: 460 V
- Secondary voltage: 230 V
Short Circuit
I001954
Operation Section
23
6.4 Control Box
(1) Reverse Phase Protector
• The Reverse Phase Protector is operated at
Terminal Block
Reverse Phase Protector
nominal voltage of 440 VAC to 480 VAC.
The reverse phase protector is mounted on a
plug-in socket terminal block where it can
easily be plugged-in or removed during
service.
• The internal relay of a reverse phase protector
is energized and LED is on when the phase
LED
<Wiring Diagram>
sequence is correct. If the phases are reverse,
R
S
T Power Source
the out put relay will not energize.
• The
reverse
phase
protector
is
reset
automatically upon correction of the fault.
3
4
5
8
to J2
2 (Normally Closed)
to TB1 R1
1
Specifications:
- Rated Line Voltage: 440/480 V
I001955
- Rated Output: 8 A resistive at 240 V
- Mounting: Plug-in socket (8 pin, octal plug)
(2) Capacitors
• The capacitors are used to temporarily boost the power output available to the fan motor at
start-up.
• The specifications of each capacitor are listed below:
Capacitor Application
Voltage
Rating Capacitance
Evaporator Fan Motor
440 VAC
15 µF
Condenser Fan Motor
370 VAC
25 µF
24
Operation Section
(3) Relay board
• The relay board receives signals and outputs <Dip Switch>
from the control board that contains a
microprocessor. The relay board contains the
Dip Switch
compressor, fan on and fan mode (speed)
relays.
• It also contains a step-down transformer that
converts the line voltage (230 VAC) to 12 V.
• This 12 V is then converted from AC to DC and
Temperature Scale
Display Switch
(°C⇔°F)
Fan Mode Control
Switch
(STOP⇔OPERATE)
I001772
used for relay coil activation. The 12 V (DC)
power is sent to the control panel assembly where it is further reduced to 5 V 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 both
the set point and room temperature display from Fahrenheit to Celsius.
< NOTE >
The relay board must be serviced as a complete assembly. It has only one serviceable
component, the fuse. (see below)
(4) Relay board fuse
• This fuse provides protection against damage <Relay Board>
to the step-down transformer. It must be
Fuse
replaced with the exact type of fuse or an
equivalent.
Specifications:
- 2/10 A, 250 V
I001773
CAUTION
Failure to use the exact type of fuse could result in damage to the unit and/or to components. It
could also void the warranty of the unit.
Operation Section
25
(5) Fuse (For Transformer)
• This fuse provides protection against damage
to the transformer. The fuse is located in the
Fuse
secondary circuit of the transformer.
• It must be replaced with the exact type of fuse
Control Box
or an equivalent.
Specifications:
- Time delay type
- Class cc
I001956
- Rated volt: 600 V
- Rated amp: 15 A
- UL listed
6.5 Fan Motor
(1) For evaporator
• The fan motor is a single phase, induction type
Evaporator Fan Motor
two-speed motor.
Specifications:
- Rated Voltage: 230 V, 60 Hz
- Rated Output: High-590 W, Low-360 W
Ground (Green/Yellow)
J7 Low (Red)
CF22 (Brown/White)
CF21 (White)
J8 High (Black)
I001774
(2) For condenser
• The fan motor is a single phase, induction type
two-speed motor.
Condenser Fan Motor
Specifications:
- Rated Voltage: 230 V, 60 Hz
- Rated Output: High-1195 W, Low-932 W
Ground (Green/Yellow)
J5 Low (Red)
CF12 (Brown/White)
CF11 (White or Orange)
J6 High (Black)
I001775
26
Operation Section
6.6 Compressor Motor
• The compressor motor is a three-phase motor and is contained within the same housing as the
compressor.
Specifications:
- Rated Voltage: 460 V, 60 Hz
- Rated Output: 3890 W
< NOTE >
An internal overload relay is used to protect the fan motors and the compressor motor. This relay
is built into the fan motors and compressor motor. It interrupts the flow of current when there is an
over current situation or if abnormally high temperature builds up in the fan motors and
compressor motor.
Operation Section
27
6.7 Condensate Pump
• The Office Pro 63 is equipped with a condensate pump, which collects the water that forms on
the evaporator during normal cooling operation and eliminates the need for a drain tanks.
- When the water collects to level (A) in the
pump reservoir, the condensate pump begins
to operate and discharge the water. During
condensate pump operating period the
3/8 in (9.53 mm) I.D.
Drain Outlet Spout
with Check Valve
Motor Fan
Cover
1 in (25.4 mm)
Inlet Drain Hole
compressor cycles off.
Reservoir
Mounting Ear
Main Control Float
I001918
- When the water level drops below level (B),
the condensate pump stops and compressor
restarts after delay time has expired.
A
B
I001919
< NOTE >
• If for any reason the water level exceeds that of level (A) in the pump reservoir, an overflow drain
switch stops the compressor operation.
• If the fan mode control DIP switch has been set from the cool to the stop position, the fan also
turns off while the condensate pump is discharging the water.
Operation Section
- To insure proper drainage, locate the highest
vertical position, no more than 17 ft (5.2 m) at
460 VAC, and run the drain hose on a
downward slope at a minimum rate of 1/4 in
1/4 in (6.25 mm)
Taper Per Foot
(6.25 mm) per foot.
17 ft (5.2 m) Max
28
Condensate
Pump
Grommet
I001920
< NOTE >
The condensate pump maximum lift is 17 ft (5.2 m) at 460 VAC. Please check the drainage
performance after installation. It is important that the drainage line from the condensate pump is
free of kinks and is not pinched. Power fluctuation or low voltage could result in incorrect drainage.
Operation Section
29
6.8 Drain Switch
• The Office Pro 63 is equipped with a drain tank switch. When the drain tanks accumulates
approximately 8.0 gal (30 L) of condensate (water) in the drain tanks, the drain tank switch sends
a signal to the microprocessor. The microprocessor stops all operation of the unit, flashes the
"TANK FULL” LED, indicates "TANK FL” on the LCD and closes the contact of output signal.
• This system utilizes a 0.1 A, 125/250 VAC micro-switch for this function. When drain water
accumulates approximately 8.0 gal (30 L) in the drain tanks, 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. This causes the ground signal at the J103 connector of the
control panel assembly to go open. When the microprocessor detects this event, it shuts the unit
off, flashes the “TANK FULL” LED, indicates “TANK FL” on the LCD and closes the contact of
output signal.
• When the drain tanks is removed (or the drain tanks 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 close. This provides a ground to the microprocessor through the J103
connector.
Top Base Plate
Evaporator
Drain Switch
Drain Pan
NC
DS2
2
1
Drain Tube
DS1
C
To J103
Drain Tanks
Drain Water
Fulcrum
Spring
Base
Base Plate
I002230
30
Operation Section
(1) How to re-start the unit
• If the LCD indicates “PROGRAM ON”, press the COOL ON/OFF button to continue running the
program. If the LCD indicates “PROGRAM ON” continuously (program activated), no further
steps are necessary. If no program exists or the program was deactivated, press the FAN MODE
button or the COOL ON/OFF button. The unit returns to the previous temperature set point.
6.9 Automatic Restart after Power Interruption
• The program within the microprocessor of the Office Pro 63 contains a feature that automatically
restarts 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. All preset programs are retained in the memory in the event power loss occurs.
6.10 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 (optional) operation.
Specifications:
Time delay
- 120 ± 20 sec.
6.11 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 U/V buttons on the control panel. The adjustment range of the temperature set
point is 65 °F to 90 °F (18 °C to 32 °C).
Operation Section
31
6.12 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 left side of the relay board located in the control box.
• There are two settings:
(1) Cool to stop
• When the DIP switch is set in the downward 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 restarts the fan and
compressor automatically. However, if the unit has been off for less than 120 sec, the fan starts
before the compressor (time delay feature).
(2) Cool to operate
• When the DIP switch is set to the upward or OPERATE position, the microprocessor controls
the fan operation using control panel inputs only. The fan operates continuously during fan only
and cool modes. (This is the factory default setting.)
6.13 Temperature Scale Display Switch
• When the DIP switch is set in the down or “°C” position, the set point and room temperature are
displayed in degrees Celsius. “°C” is indicated on the LCD. When the DIP switch is set in the up
or “°F” position, the set point and room temperature are displayed in degrees Fahrenheit . “°F”
is indicated on the LCD. (This is the factory default setting.)
Operation Section
32
6.14 Warning Signal Connection (Output Signal Terminal L+ and L-)
• The controller is equipped with a warning signal output relay type (Form C, normal open dry
contact) which can be used to monitor the failure condition.
Relay contactor is closed when the following condition has occurred:
- Tank Full
- Temperature sensor fails
- High pressure switch error
• The relay output contactor is rated 2 A at 30 VDC or 2 A at 30 VAC (resistive load) and it is
compatible with various warning devices such as alarm speaker, light indicators, etc.
Connecting warning signal from controller
- Remove service panel from the rear of the unit.
- Squeeze the inner latches and push out the black cap from inside the panel. (See drawing of
cap and inner latch shapes.)
- Use recommended warning signal wire size from 16 AWG to 26 AWG or a solid wire, or 16
AWG to 22 AWG for a stranded wire with ring terminal for #6 stud size.
- Connect warning device to terminal L+ and L- according to its polarities.
6.15 Fire Alarm Control Panel Connection (Input Signal Terminal E+ and E-)
• The controller is equipped with a normal open input signal, which can be connected directly from
the fire alarm control panel. When receiving the signal from the fire alarm control panel, the unit
turns off and does not turn back until it has been reset.
Connecting fire alarm control panel to controller
- Remove service panel from the rear of the unit.
- Squeeze the inner latches and push out the black cap from inside the panel. (See drawing of
Cap and inner latch shapes.)
- Use recommended warning signal wire size from 16 AWG to 26 AWG for a solid wire, or 16
AWG to 22 AWG for a stranded wire with ring terminal for #6 stud size.
- Connect warning device to terminal E+ and E- according to its polarities.
<Cap>
Input Signal
Terminals
Latch
Output Signal
Terminals
I001888
Repair Section
33
7. TROUBLESHOOTING
7.1 Troubleshooting
• Before troubleshooting the system, the following inspection should be performed.
(1) Inspection of power source voltage
• Check the voltage of the power source.
- Three phase 460 V (60 Hz)
• Check the phase sequence of the power source.
< NOTE >
If the phase sequence is reversed, control panel display turns off. In this case, exchange any two
wires out of the three wires to correct the phase sequence.
• 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 condensate pump
• Remove any dirt or debris which may collect in the bottom of the reservoir tank.
• On a monthly basis, check the condensate drain hose for kinks, blockage or any other damage
that may obstruct condensate pump from draining properly.
• Make sure that motor's cover is closed to keep electrical parts free of dust, dirt and any other
foreign material.
• Condensate pump overflow switch can stop the compressor operation if the pump is
malfunction. To test the condensate pump overflow switch, pinch the drain outlet hose and pour
water into the reservoir inlet drain hole. Continue to fill the reservoir until the rising water lifts the
overflow switch and stops the operation. If the compressor continues to operate when the
reservoir is full, check your installation procedure. After testing is completed, release the drain
outlet hose to enable the condensate pump to empty its reservoir. Make sure the 9 in (230 mm)
section of hose is installed into the inlet drain hole of the pump reservoir.
Repair Section
34
(4) Inspection of drain tanks (optional)
• Make sure tank is fully drained.
< NOTE >
If the fan mode control DIP switch is set to the stop position, the entire unit (including fan
operation) turns off.
The following pages (page 34 to 42) are self-diagnostic codes and troubleshooting information.
Detailed information is contained in the OPERATION MANUAL supplied with the unit.
7.2 Self-Diagnostic Codes
• Self-diagnostic codes are displayed on the control board under the following conditions and
clear method is as follows.
LCD Display
Description
Drain tanks is full
Condition
When the drain tanks (optional) is
filled with drain water.
(“TANK FL” LED flashes and signal
Reset/Remedy
1) Drain away.
(LCD indicates “TANK”)
2) Press ON/OFF button.
output (J106) turns on.)
TU
AM
HI
Condensate pump
When condensate pump is
1) Fix the condensate pump.
problem
damaged or broken.
2) Reset the system.
F
FAN
ON
COOL
(J8 input of relay board turns to
To RESET: Press ON/OFF and
open and signal output (J106) turns
HI/LO buttons on the control box
on.)
simultaneously for 5 sec.
SET TEMP
Defect (short or open) When room thermistor (connecting Disconnect and reconnect the
of room thermistor
HI
F
FAN
ON
COOL
HI
SET TEMP
F
FAN
ON
COOL
SET TEMP
to J101) becomes short or open.
room thermistor.
(Signal output (J106) turns on.)
If it doesn’t work, then change it.
Repair Section
LCD Display
Description
Reset/Remedy
Defect (short or open)
When freeze protection thermistor Disconnect and reconnect the
of freeze protection
(connecting to J102) becomes short freeze protection thermistor.
thermistor
or open.
If it doesn’t work, then change it.
(Signal output (J106) turns on.)
F
HI
Condition
35
FAN
SET TEMP
ON
COOL
F
HI
FAN
SET TEMP
ON
COOL
Show running hours
Press ON/OFF and V buttons
After 5 sec., display goes back to
simultaneously for 3 sec, total
normal mode.
operation hours of compressor is
indicated by 6-digit (hours).
Example in left: 807 h
MO TU WE TH FR SA SU
AM
START
Show LCD and LED
Press HI/LO and U buttons
After 5 sec., display goes back to
all on mode
simultaneously for 3 sec.
normal mode.
PROGRAM
ON
STOP
CLOCK
(To check LCD segments and LED
PM
LOCKED
F
C
HI
FAN
LO
ON
COOL
OFF
F
C
display.)
SET TEMP
ROOM TEMP
TU
AM
Key lock mode (LCD
Press ENTER and SET CLOCK
Press ENTER and SET CLOCK
displays “LOCKED”.)
buttons simultaneously for 5 sec.
buttons simultaneously for 5 sec
again to cancel the key lock mode.
LOCKED
HI
F
FAN
ON
COOL
SET TEMP
Indication of model
Press ENTER and SET CLOCK
Reset to normal display
name
buttons simultaneously for 5 sec or
automatically after 5 sec.
turn on.
Detection of unit stop
Press input signal from fire alarm
1) After input signal turns off.
signal from fire alarm
becomes on.
2) Reset the system.
system
(Unit stops, output signal (J106)
To RESET: Press ON/OFF and
turns on and buzzer sounds.)
HI/LO buttons on the control box
simultaneously for 5 sec.
Repair Section
36
LCD Display
Description
Condition
Reset/Remedy
Indication of service
Press ON/OFF and U buttons
1) See page 36 and 37.
code
simultaneously for 3 sec. Indication
2) Press ON /OFF button.
contents is as follows.
LCD
Description
DF
Defrost status
FZ
OD
Value
Evap. out pipe 26⇔109F
temperature
(“26”⇔“X9”)
Outdoor
0 (“00”)
temperature
Change model setting For installing new controller PCB, if
1) While pressing U and V
a different model name appears
buttons, plug the power cord.
when the unit is reset or turned on,
<Condition>
change model name according to
LCD indicates current setting
the correct procedure.
model name and buzzer sounds.
2) After setting the model type by
pressing U and V button,
unplug the unit.
TU
Activation of high
When high pressure switch
Find the cause of high pressure to
pressure switch
(connected to J104) activates
address it.
(=J104 input turns to open) 3 times
Check the following.
in 24 h, “HP” is indicated and signal
Ambient air temperature
output (J106) turns on.
(65 °F (18.3 °C), 50 %RH⇔
When it activates 10 times in 24 h,
95 °F (35 °C), 60 %RH)
“FAIL HP” is indicated and buzzer
Air filter (if dirty, wash up.)
sounds.
Condenser fan motor (if not
AM
HI
F
FAN
ON
COOL
SET TEMP
working, replace.) Defect of high
pressure switch (if switch is open
when unit is off, replace switch.)
Reset the system.
To RESET: Press ON/OFF and
HI/LO buttons on the control box
simultaneously for 5 sec.
Repair Section
37
7.3 Troubleshooting Chart
• To accurately troubleshoot the problem, it is important to carefully confirm the nature of the
problem. Typical problems are:
- Insufficient cooling.
- Unit does not start (operate).
- Overflow of drain water.
- Abnormal noise or vibrations.
- Others.
(1) Insufficient cooling
• Cooling system problem generally results from electrical or mechanical components such as fan
motor, compressor, control switch.
< NOTE >
• There is a possibility of insufficient cooling due to clogging of the air filter. So make sure to first
check if the air filter is clogged or not.
• Check the power supply because of the possibility of power source failure.
• Check the installation site for operating temperature and installation space (unobstructed airflow).
Repair Section
38
Possible Cause
Symptom
Remedy
Checking Area
1. Usage conditions
Cause
Operation near usage limits.
(high temperature).
2. Dirt in condenser or
Compressor
operates.
Air volume
place.
Insufficient heat exchange.
Clean fins.
evaporator.
3. Frost in refrigeration cycle.
Clogging at the frost section. Replace clogged section.
4. No temperature difference
Insufficient refrigerant.
Check the leaking part,
between evaporator and
then repair and charge
condenser.
refrigerant.
1. Compressor coil resistance.
normal
Review the installation
Short or open circuit.
(0 ohm or ∞ ohm)
Replace compressor.
(In case of short, check
the compressor relay.)
Compressor
2. Compressor relay.
does not
operate.
3. Compressor relay on the
relay board.
Open circuit or insufficient
Replace compressor
contact.
relay.
Open circuit or insufficient
Replace relay board.
contact.
4. Voltage.
Low voltage.
Repair power.
1. Coil resistance of fan motor.
Short or open circuit.
Replace fan motor.
Open circuit or insufficient
Replace relay board.
(0 ohm or ∞ ohm)
No air.
2. Fan on-off relay on the relay
board.
3. Fan HI/LO change relay on
the relay board.
Insufficient
contact.
Open circuit or insufficient
Replace relay board.
contact.
1. Air filter.
Clogged air filter.
Clean air filter.
2. Evaporator.
Clogged evaporator or
Repair and clean fins or
crushed fins.
replace it.
3. Duct connection state.
Improper connection.
Repair duct connection.
4. Fan motor.
Insufficient rotation.
Replace motor.
5. Transformer.
Low voltage.
Replace transformer.
air volume
Insufficient
air volume.
(Secondary side)
Repair Section
39
(2) Unit does not start (operate)
< NOTE >
• In this case, there is a possibility of safety device activating due to the clogged air filter. So make
sure to first clean the air filter and then start up again to confirm if the problem lies with the air filter.
• Check the installation site for operating temperature and installation space (unobstructed airflow).
• Check the phase sequence of the power source.
If the phase sequence is reversed, the control panel display, and reverse phase protector LED in
the control box turn off.
Possible Cause
Symptom
Remedy
Checking Area
Cause
1. Voltage.
Power failure.
Repair power.
2. Phase sequence of the
Phase sequence is
Change any 2 of the 3 wires
reversed.
for power source wires.
Ground fault or defective
Repair ground fault section.
ground fault breaker.
Reset or repair breaker.
Fuse blown.
Repair shorting section.
power source.
3. Ground fault breaker trip.
4. Fuse.
Does not
Control
operate at
Panel
Replace fuse on the relay
all
display turns
board.
off.
Replace fuse of the
transformer secondary side.
5. Transformer.
Defective transformer.
Replace transformer.
6. Reverse phase protector.
Open circuit or insufficient
Replace reverse phase
contact.
protector.
Repair Section
40
Possible Cause
Symptom
Remedy
Checking Area
1. Display code “FL”.
Cause
Drain tanks (optional) are
Discharge the drain water.
filled with the drain water.
Improper drain switch
Check connection.
connection.
2. Display code “AS”.
Defective drain switch.
Replace drain switch.
Improper routing of drain
Repair drain hose, then reset
hose.
unit.
To RESET: Press ON/OFF
and HI/LO buttons on the
control box simultaneously
for 5 sec.
Defective condensate pump. Repair or replace
condensate pump, then reset
unit.
To RESET: Press ON/OFF
and HI/LO buttons on the
control box simultaneously
for 5 sec.
Control
panel
display
turns on
Control
3. Display code “RT”.
Panel
Missing jumper connector.
Connect jumper connector.
Improper room thermistor
Check connection.
connection.
display
Defective room thermistor
shows error
Replace room thermistor.
(short or open).
codes.
4. Display code “FT”.
Improper freeze protection
Check connection.
thermistor connection.
5. Display code “HP”.
Defective freeze protection
Replace freeze protection
thermistor (short or open).
thermistor.
Improper high pressure
Check connection.
switch connection.
Defective high pressure
Replace high pressure
switch (short or open).
switch.
See “Stops after running a while” of Troubleshooting on
page 41.
6. Display code “ALRM”.
Turn the input signal on and
continue it.
1) Check external input
signal.
2) Reset the system.
To RESET: Press ON/OFF
and HI/LO buttons on the
control box simultaneously
for 5 sec.
7. Display code “FZ”.
See “Stops after running a while” of Troubleshooting on
page 41.
Repair Section
41
Possible Cause
Symptom
Remedy
Checking Area
Cause
1. Fan on-off relay on the relay
board.
the relay board.
immediately panel
after
display
starting
normally.
Open circuit or insufficient
Replace relay board.
contact.
3. Fan motor insulation
Control
Replace relay board.
contact.
2. Fan HI/LO change relay on
Stops
Open circuit or insufficient
Insulation failure on fan
resistance.
Replace fan motor.
motor.
4. Compressor relay.
5. Compressor relay on the
relay board.
Open circuit or insufficient
Replace compressor
contact.
relay.
Open circuit or insufficient
Replace relay board.
contact.
6. Compressor insulation
resistance.
Insulation failure on
Replace compressor.
compressor.
7. Reverse phase protector.
1. Temperature of fan motor
(abnormally high).
Open circuit or insufficient
Replace reverse phase
contact.
protector.
Operation of safety device
Replace fan motor.
(IOLF) due to fan motor
malfunction.
2. Temperature of compressor
Stops after
running a
while
Control
(abnormally high).
normally.
Replace compressor.
(IOLC) due to compressor
panel
display
Operation of safety device
malfunction.
3. Refrigerant leakage.
4. Dirt on evaporator or
condenser.
5. Duct connection state.
Insufficient refrigerant or gas
Repair and charge
leakage.
refrigerant.
Insufficient cooling of
Clean evaporator or
evaporator or condenser.
condenser.
Improper connection.
Repair duct connection.
(3) Overflow of drain water
Possible Cause
Symptom
Remedy
Checking Area
Cause
1. Drain pan.
Cracks in drain pan.
Check and repair.
2. Water level in drain pan.
Clogged drain hose.
Check and replace.
3. Drain hole.
Reversed air flow from drain
Insert a trap on discharge
hole.
drain hose.
Reversed air flow from drain
Clean air filter.
Overflow from the unit.
4. Clogged air filter.
hole due to the excessive
negative pressure inside of
the unit.
42
Repair Section
(4) Abnormal noise or vibration
• To prevent abnormal noise or vibration, carefully determine the source of the problem and come
up with proper countermeasures to solve the problem so that it does not occur again.
< NOTE >
Internal dry-type distribution transformer may produce a humming noise up to 31 dB (A) at
maximum operated voltage (506 V) during stand-by state.
Possible Cause
Symptom
Remedy
Checking Area
1. Fan.
Cause
Fan interference.
Repair interfering section.
Fan deformation.
Replace fan.
Abnormal noise or
2. Compressor fixing nuts.
Looseness of nuts.
Tighten nuts further.
vibration.
3. Transformer fixing nuts.
Looseness of nuts.
Tighten nuts further.
4. Piping.
Pipe interference.
Repair interfering section.
5. Panel fixing screws.
Looseness of screws.
Tighten screws further.
7.4 Basic Inspection
• Perform the following inspection before disassembly.
(1) Inspection of plate fins
• To inspect the plate fins of either the evaporator
or condenser, the air filter must be removed.
After removal of the air filters, inspect the plate
fins for any dirt, dust, lint, or debris that may
have caused insufficient cooling performance
of the unit. If cleaning of the fins is necessary, it
is recommended that this service be performed
by a qualified service technician.
I001780
(2) Examination of operating environment
• Operating environments can vary depending on location, climate and surrounding conditions.
Installation location also can cause operational problems. Consult your reseller concerning
operational environment requirements.
Repair Section
43
(3) Inspection of cooling capacity performance
• 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 15, proceed with the remedy
suggested in the troubleshooting chart on page 37 to 42.
Thermometer
Cool Air Out
Thermometer
Evaporator Air In
I001922
44
Repair Section
8. DISASSEMBLY
8.1 Parts Construction
Upper Panel
Upper Front Panel
Control Panel
Blower housing
Condenser Fan
Air Outlet Grill
Front Right Panel
Rear Right Panel
Room Thermistor
Freeze Protection
Thermistor
Front Panel Filter Assy
Front Left Panel
Evaporator
Fan
Condensate
Pump
Drain Tank
Panel
Side Panel
Filter Assy
Drain Pan Assy
Pivoting
Caster
Drain Tanks
(Optional)
Rear Panel
Power Cord
Middle Frame
Sub-Assy
Pivoting Caster
Transformer Assy
Rear Left Panel
Service Panel
I001958
Repair Section
45
8.2 Disassembly
1) Remove drain tanks (optional).
I001783
Screws (7)
Screws (2)
2) Remove twelve (12) screws from upper front
Screws (3)
panel.
I001924
3) Slide upper front panel forward and remove.
I001925
4) Louver can be removed from upper front panel by
unsnapping the lock tap and removing the louver
from its pivots.
I001786
Repair Section
46
Screws (13)
5) Remove nine (9) screws from service panel and
thirteen (13) screws from rear left panel.
Screws (9)
I001926
6) Remove eight (8) screws from rear right panel.
Screws (8)
I001927
7) Remove fourteen (14) screws from front right
panel.
Screws (10)
Screws (4)
I001928
8) Remove fourteen (14) screws from upper panel.
Screws (8)
Screws (3)
Screws (3)
I001929
Repair Section
47
9) Remove nine (9) screws from rear panel.
Screws (9)
I001930
Screw (12)
I001959
10) Remove twelve (12) screws from front left panel.
48
Repair Section
8.3 Removal of Electrical Parts
(1) Control box
1) Remove nine (9) screws from service panel. (See page 46.)
2) Remove electrical parts.
- Relay: Remove four (4) screws from control box.
- Reverse phase protector: Pull out reverse phase protector from terminal block.
- Terminal block: Remove four (4) screws from control box.
- Terminal block (signal connection): Remove two (2) screws from control box.
- Terminal block (reverse phase protector): Remove two (2) screws from control box.
- Capacitor: Remove two (2) screws from control box.
- Fuse holder : Remove one (1) screw form control box.
Terminal Block
(Signal Connection)
Fuse
FUSE 25A
TB2
Fuse Holder
Terminal Block
(Reverse Phase Protector)
Dip Switch
Reverse Phase Protector
Relay Board
Relay Board Fuse
Fan Capacitor
(Evaporator)
TB1
Relay
G
Terminal Block
Fan Capacitor
(Condenser)
I001960
Repair Section
49
(2) Relay board
1) Remove nine (9) screws from service panel. (See page 46.)
2) Disconnect ten (10) connectors, and remove five (5) screws from relay board.
Temperature Scale Display Switch
Dip Switch
Fan Mode Control Switch
To Control Board (10 pin)
To Condensate Pump (2 pin)
To Comp. Driver Relay
To Evap. Fan Motor (HI)
To Comp. Relay
To Evap. Fan Motor (LO)
To Cond. Fan Motor (HI)
To Cond. Fan Motor (LO)
Relay Board Fuse
Power (#R1) On Terminal Block
Power (#T1) On Terminal Block
I001793
(3) Control board
1) Remove two (2) screws from the control panel
Screws (2)
stay.
I002179
Screws (3)
2) Remove three (3) screws from the control panel
stay.
I002180
50
Repair Section
3) Slowly slide control panel assembly out of box.
I002181
4) Disconnect the following connectors from the
B C D E
A
control board:
(A) J201 (10-pin) Wire Harness, Relay Board to
Control
(B) J101 (2-pin) Room Temperature Thermistor
(C) J102
(2-pin
with
black
tape)
Freeze
Protection Thermistor
F
G
I002182
(D) J103 (2-pin) Drain Tank Switch
(E) J104 (2-pin) High Pressure Switch
(F) J106 (2-pin) Output signal terminal
(G) J108 (2-pin) Input signal terminal
< NOTE >
Mark each of the 2-pin connectors with a
different color marker to ensure the correct
orientation when they are reconnected or label
all wire sets with tape. Numbering the wire sets
from (A) through (G).
5) Remove the five (5) screws from the control
board on the control panel assembly. Remove
the control board.
I001804
Repair Section
51
(4) Battery replacement of control board
• When the power is unplugged from the unit, and control board is automatically resetting clock
and program, it is time to change the battery on the control board to avoid resetting of clock and
program.
1) Disassemble control board. (See page 49 and
50.)
Control
Board
Battery
I001805
2) See diagram for battery removal.
Control Board
Holder
Battery (Old)
I001806
3) Insert new battery securely in the direction shown
Control Board
in the drawing.
Specifications:
- Type: 3 V CR2450 or equivalent
Holder
CAUTION
Battery (New)
When inserting the battery, make sure the
direction of polarity (plus/minus) is correct (as
I001807
shown).
52
Repair Section
(5) Fuse Replacement of Control Box
1) See diagram for fuse removal.
2) Insert new fuse securely.
Specifications:
- Time delay type
- Class cc
- Rated volt: 600 V
- Rated current: 15 A
I001961
- UL listed
WARNING
Disconnect power before remove fuse.
Repair Section
53
8.4 Removal of Blower Assembly
Control Panel Stay
Control Panel
Control Panel Stay
Evaporator Fan
Evaporator Fan Casing
Condenser Housing Box
Condenser
Fan Motor
Evaporator Fan Motor
Condenser Fan
Casing
Condenser Fan
Center Panel
I001932
Repair Section
54
(1) Removal of condenser fan and fan motor
1) Loosen the set screw using a hex key.
Set Screw
I001933
2) Remove six (6) nuts in the location shown.
Nuts (6)
I001934
3) Remove fan motor wire from three (3) ties.
Ties (3)
I001935
4) Lift fan motor up then pull rear motor backward
and remove the fan motor. Centrifugal fan drops
into condenser fan housing.
I001936
Repair Section
55
5) Turn the fan motor around and place on mounting
Nuts (2)
bracket. Secure condenser fan motor with two (2)
nuts.
I001937
6) Remove six (6) screws from ring.
Screws (6)
I001938
7) Loosen four (4) nuts that are securing the fan
Nuts (2)
casing. Lift the enclosure off its mounting. Slide
the condenser fan out through opening.
Nuts (2)
I001939
(2) Removal of evaporator fan and fan motor
1) Loosen the set screw using a hex key. Then
Evaporator
Fan
Set Screw
remove six (6) screws on the ring. Then remove
this ring and evaporator fan.
Ring
Screws (6)
I001940
Repair Section
56
2) Remove evaporator fan motor wire and two (2)
ties. Remove four (4) nuts from housing while
holding fan securely with one hand. Then remove
Nuts (4)
Ties (2)
evaporator fan motor.
I001941
8.5 Removal of Condensate Pump
1) Remove fourteen (14) screws from front right
panel. (See page 46)
2) Remove the two (2) drain hoses.
Drain Hose
3) Disconnect condensate pump connector.
Drain Hose
Connector
I001942
4) Remove two (2) screws from condensate pump.
Screws (2)
I001943
5) Remove tab from condensate pump.
OVE
REM
I001944
Repair Section
57
8.6 Removal of Transformer
Screws
Upper Cover
Side Cover
Side Cover
Nuts
Screws
Nuts
Bolts
Transformer Wire
Nuts
Transformer Assy Base
Transformer Base
Transformer
I001962
58
Repair Section
1) Remove the transformer wires and pipe connect
Transformer
Wire
ground wire. Then remove two (2) ties.
Ground Wire
Ties (2)
I001963
2) Remove two (2) bolts and two (2) nuts from
Nuts (2)
transformer assemble frame.
Bolts (2)
I001964
3) Slide the transformer assembly out of the unit
and remove.
I002165
4) Remove four (4) screws from transformer upper
cover.
Screws (4)
I002166
Repair Section
59
5) Remove four (4) screws from transformer side
covers. Then remove transformer wire.
Screws (4)
Transformer
Wire
I002167
6) Remove four (4) nuts from transformer.
Nuts (4)
I002168
60
Repair Section
8.7 Inspection of Capacitor (for Fan Motor and Compressor)
(1) Ohmmeter method
• Set the ohm-meter to the 10M range. Place the
two probes against the two terminals of the
capacitor. At first, the ohm-meter should
indicate small value, then the reading should
gradually
increase
towards
infinity.
This
indicates that the capacitor is charging. If the
reading indicates infinity right away (open) or
the ohm-meter fails to move from 0. (shorted),
I001808
replace the capacitor.
(2) Capacitance tester method
• Using a capacitance tester and the chart on page 23, test the capacitor for the value indicated.
If the value tested is not within 10 % of indicated capacitance, replace the capacitor.
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.
8.8 Inspection of Drain Switch
• Check for continuity between terminals 1 and 2
when drain switch is pressed. With drain switch
Top of Base Plate
depressed, there is no continuity between
Drain Switch
terminals 1 and 2. Replace drain switch if
continuity does not satisfy the above condition.
To J103
NC
DS2
2
1
DS1
C
I001809
Repair Section
61
8.9 Inspection of Fan Motor
(1) Condenser fan motor
• Measure resistance across the terminals of the
fan motor. (All terminals must be disconnected
Condenser Fan Motor
from the unit.)
• Between terminals (at 77 °F (25 °C))
- J6-CF11 Approx. 3.5 ohm
- J6-CF12 Approx. 6.0 ohm
- CF11-CF12 Approx. 9.1 ohm
• If the measured resistance is not equal to these
Ground (Green/Yellow)
J5 Low (Red)
CF12 (Brown/White)
CF11 (White or Orange)
J6 High (Black)
I001775
standard values, replace the fan motor.
(2) Evaporator fan motor
• Measure resistance across the terminals of the
Evaporator Fan Motor
fan motor. (All terminals must be disconnected
from the unit.)
• Between terminals (at 77 °F (25 °C))
- J8-CF21 Approx. 7.6 ohm
Ground (Green/Yellow)
J7 Low (Red)
CF22 (Brown/White)
CF21 (White)
J8 High (Black)
- J8-CF22 Approx. 10.4 ohm
- CF21-CF22 Approx. 17.7 ohm
• If the measured resistance is not equal to these
I001774
standard values, replace the fan motor.
8.10 Inspection of Compressor Motor
• Measure resistance across the terminals of the
compressor motor. (All terminals must be
C
T1
disconnected from the unit.)
• Between terminals (at 77 °F (25 °C))
- R-C Approx. 0.4 ohm
R
T3
S
T2
- C-S Approx. 0.6 ohm
- S-R Approx. 0.9 ohm
• If the measured resistance is not equal to these
standard values, replace the compressor. The
overload relay is internal to the compressor.
I001945
Repair Section
8.11 Inspection of Transformer
• Measure resistance across the terminals of the
H1
H4
transformer.
(All terminals must be disconnected from the
PRIMARY 460V
H4 H2
H3 H1
62
unit.)
• Between terminals (at 77 °F (25 °C))
H1
H3
H2
H4
X4
X2
X3
X1
SECONDARY 230V
X4 X2
X3 X1
- H1-H4 Approx. 0.3 ohm
- X1-X4 Approx. 0.3 ohm
- X1-H4 Approx. Open
X4
X1
I002169
• If the measured resistance is not equal to these
standard values, replace the transformer.
8.12 Inspection of Wiring Connection
• Refer to the Wiring Diagrams on page 19 and check for connection of each wire.
8.13 Inspection of Thermistor
• Using an Ohm-meter, 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 k ohm.
Repair Section
63
8.14 Inspection
• In most cases, the probable cause for insufficient cooling is a clogged system, leakage or an
incorrect amount of refrigerant. In such cases, inspect the system according to the following
procedure.
(1) 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.
(2) 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.
(3) Insufficient refrigerant
• In case the unit is judged to be deficient in cooling capacity, make sure to perform the inspections
in 64. 9.1 (1) and 64. 9.1 (2) to confirm the cause of trouble. Then, charge the system with
refrigerant to the specified amount.
Repair Section
9. REFRIGERANT SYSTEM REPAIR
9.1 Repair of Refrigerant System
• In case there is a leak, obstruction, or trouble in the refrigerant system of the Office Pro 63,
replace or repair the part in question. After replacing any component all connections must be
brazed.
(1) 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.
(2) Brazed fittings and fitting clearance
• In general, the strength of brazing filler metal is
lower than that of the base metal. So, the
a
shape and clearance of the brazed fitting are
Clearance
0.001~0.003 in
(0.025~0.075 mm)
quite important. As for the shape of the brazed
fitting, it is necessary to maximize its adhesive
a
64
area. The clearance of the brazed fitting must
be minimized to facilitate brazing filler metal to
flow into it by capillary action.
Clearance From The Pipe Fitting and Tubing.
I002225
(3) Cleaning 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 can 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.
CAUTION
Do not use chlorine cleaner.
Repair Section
65
(4) 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 (0.27 gal/min (1 L/min); adjust with the flow regulator) through the
pinch-off tube of the refrigerant.
< NOTE >
Take care not to allow dirt, water, oil, etc. to enter into the pipe.
(5) Vertical Joint
• Heat the whole brazed fitting to a proper
brazing temperature. Bring the brazing filler
45°
metal into contact with the fitting so that the
Vertical Down Joint
Brazing Filler Metal
Burner
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
Tube
I000564
essential to keep the whole fitting at a proper
brazing temperature.
Vertical Up Joint
Tube
Burner
45°
Brazing Filler Metal
I001725
Repair Section
66
9.2 Removal of Refrigeration Cycle Components
CAUTION
• Before any refrigeration cycle component can be replaced, it is necessary to recover the
refrigerant using standard recovery procedures and equipment.
• To prevent oxidation, dry nitrogen should be conducted (flow rate 0.27 gal/min (1 L/min)) through
the pinch-off tube during any brazing operation.
• During any component replacement involving brazing, shield nearby parts with a steel plate, etc.,
to protect them from the flame.
• Evaporator
• Capillary tube
• Condenser
• Compressor
• High Pressure Switch
< NOTE >
When replacement of the compressor, attach the two pipes (Pipe 1, Pipe 2) which are packaged
in Compressor Assy as following figure.
Pipe 2
D
Pipe 1
A
B
E
C
F
Part to Replace
Compressor
Condenser
Capillary Tube
Evaporator
Disconnect At
A&F
A&B
C&D
C&E
I002170
Repair Section
67
9.3 Charging the System with R-410A Refrigerant
• Always ensure that the refrigerant system has been properly evacuated before charging with the
specified amount of R-410A.
• Equipments is only for R-410A.
• Liquid charge (no gas charge).
• Make sure not to use more than 90 % of the initial weight of R-410A in the cylinder.
WARNING
• When handling refrigerant (R-410A), the following precautions should always be
observed:
- Always wear proper eye protection while handling refrigerant.
- Maintain the temperature of the refrigerant container below 104 °F (40 °C).
- 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.
1) Evacuate the system.
• 15 min or more.
Step 2
• 30 inHg (100 kPa) or more of vacuum.
2) Stop evacuating the system.
• Leave for 5 min.
When leak is found,
repair the connection
or components.
3) Check the vacuum.
Step 3
Connect to refrigerant source.
Step 4
Test the system for leaks.
Step 5
Step 6
Charge the system with R-410A.
• See specifications on page 13.
Remove manifold gauge.
I002171
68
Repair Section
(1) Connection of gauge manifold
1) Properly remove the crushed end of the pinch-off
Charging Hose
Side
Refrigerant
Cycle Side
tube at the high pressure side and the low
pressure side of the refrigerant cycle with a pipe
cutter.
2) Fit the process tube fitting to the pinch-off tube on
both sides.
Seal
Pinch-Off Tube
I002183
3) Connect the charging hoses (red-high pressure
Low Pressure
Valve (Closed)
High Pressure Valve
(Closed)
Red Hose
Green Hose
Process Tube Fitting
High Pressure
Side Tube
side) for the gauge manifold to the process tube
fitting.
< NOTE >
Connect the hoses using care not to mistake
the high pressure side for the low pressure side
and vice versa.
Vacuum Pump
(when stopped)
I000568
4) Connect the charging hose (green) at the center
of the gauge manifold to the vacuum pump.
(2) Evacuation
1) Open the high pressure valve (Hl) of the gauge
Valve Setting
Gauge
LO
HI
Closed Open
LO
HI
Closed Closed
30 inHg (100 kPa) or larger
Low Pressure
Valve
High Pressure Gauge
High Pressure Valve
High Pressure
Side Tube
Vacuum Pump
(in Operation)
manifold.
2) Turn on the vacuum pump to start evacuation.
(Evacuate the system for approximately 15 min.)
3) When the low pressure gauge indicates 30 inHg
(100 kPa) or larger, turn off the vacuum pump
and close the high pressure valves of the gauge
I002227
manifold.
Repair Section
69
(3) Checking vacuum
Valve Setting
LO
HI
Closed Closed
Pressure Gauge
1) Leave the high pressure valve and the low
Leave valves closed for 5
min or more. Pointer of
pressure gauge returning to
zero indicates there is a leak.
pressure valve of the gauge manifold closed for
five min or more, and confirm that the gauge
pointer does not return to zero.
2) If the gauge pointer returns gradually to zero
Return
there is a leak somewhere in the system (this
Pipe Brazing
could also include gauge manifold). Perform leak
I002184
check according to procedure indicated in the
next step. Once leak has been found and
repaired evacuate the system once more, and
confirm system holds vacuum.
Repair Section
(4) Checking gas leak
1) Remove the charging hose (green) from the
Valve Setting
vacuum pump, and connect the hose to the
LO
HI
Closed Closed
Air Purging
refrigerant cylinder (R-410A).
Charging Hose
Red
(Green)
To Process Tube Fitting
2) Loosen the nut on the gauge manifold side of the
Refrigerant
Cylinder R-410A
Open The Valve
of Refrigerant
Cylinder
charging hose (green).
3) Open the valve of refrigerant cylinder perform air
purging in the charging hose (green). Then
I001901
Low Pressure
Valve (Closed)
Refrigerant
Cylinder
Valve
(Open)
tighten the nut.
4) Open the high pressure valve of the gauge
Valve Setting
LO
HI
LO
HI
Closed Open Gauge Reading Closed Closed
Refrigerant
Cylinder R-410A
70
manifold. Charge the system with refrigerant until
57 psi
(390 kPa)
the low pressure gauge indicates 57 psi
Open High Pressure
Valve
Process Tube Fitting
High Pressure
Side Tube
I002228
(390 kPa). After charging is complete, close the
high pressure valve.
5) Open the valve of refrigerant cylinder perform air
purging in the charging hose (green). Then
tighten the nut.
6) Check carefully for gas leaks inside the
refrigerant system using the gas leak tester.
7) Repair any 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.
Repair Section
71
(5) Evacuation (repeat)
1) Close the valve of the refrigerant cylinder. Then
Valve Setting
Gauge
LO
HI
Closed Open
LO
HI
Closed Closed
30 inHg (100 kPa) or larger
Low Pressure
Valve
High Pressure Gauge
High Pressure Valve
remove the charging hose (green) from the
refrigerant cylinder, and connect it to the
refrigerant recovery machine.
< NOTE >
High Pressure
Side Tube
Vacuum Pump
(in Operation)
Keep the high pressure valve and the low
pressure valve of the gauge manifold closed.
I002227
2) Using procedure in the “Evacuation”, evacuate
the system until the low pressure gauge indicates
30 inHg (100 kPa) or larger. (For 15 min or more.)
3) After evacuation is complete, close the high and
the low pressure valves of the gauge manifold.
CAUTION
Make sure to evacuate the system twice or
more using the repetitive vacuum method.
Evacuate the system an additional time on
rainy or humid days.
Repair Section
9.4 Refrigerant Charging Work
(1) Refrigerant charging
1) Remove the charging hose (green) from the
Valve Setting
vacuum pump, and connect it to the refrigerant
LO
HI
Closed Closed
Air Purging
cylinder
Charging Hose
Red
(Green)
To Process Tube Fitting
(R-410A).
Refrigerant
Cylinder R-410A
Open The Valve
of Refrigerant
Cylinder
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
I001901
refrigerant cylinder. After air purging, tighten this
nut and close the valve of the refrigerant cylinder.
3) Securely place the refrigerant cylinder on a scale
Valve Setting
LO
HI Specified Amount
LO
HI
Closed Open
Closed Closed
of Refrigerant
with a weighing capacity of 70 lb (30 kg) that is
graduated by 0.2 oz (5 g).
High Pressure Valve
Valve of
Refrigerant
Cylinder
Process Tube Fitting
Refrigerant
Cylinder R-410A
72
High Pressure
Side Tube
Weight
I001903
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.
Standard Amount of Refrigerant: 4.41 lb
(2.00 kg)
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.
Repair Section
73
(2) Removal of gauge manifold
1) Crimp the pinch-off tube with a pinch-off tool.
Pinch-Off Tool
Pinch-Off Tube
2) Remove the gauge manifold and the process
To Gauge
Manifold Side
tube fitting. Crush the end of the pinch-off tube.
3) Braze the end of the pinch-off tube.
Charging Hose
To Refrigerant
Cycle Side
4) Ensure that a gas leak is not present at the
pinched off portion and the brazed end.
Process Tube Fitting
I002185
74
Repair Section
10. REASSEMBLY
10.1 Removal 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.
10.2 Compressor Mounting
• Mount the compressor on the frame, using
cushions, steel collars, spring washers, plate
Nut
Spring Washer
washers and nuts.
Plate Washer
Cushion
Steel Collar
I001818
10.3 Blower Assembly
1) Install blower fan for evaporator. Allow a
<Evaporator Blower Assy>
clearance of 0.12 in (3 mm) (minimum) on each
Min 0.12 in
(3 mm)
side of the evaporator fan.
Min 0.12 in
(3 mm)
CAUTION
• Tightening torque:
- 10.84 ± 2.17 ft•lbf (15 ± 2.7 N•m)
I002229
2) Install blower fan for condenser. Allow a
<Condenser Blower Assy>
clearance of 0.12 in (3 mm) (minimum) on each
Min
0.12 in (3 mm)
Min
0.12 in (3 mm)
side of the condenser fan.
CAUTION
• Tightening torque:
- 10.84 ± 2.17 ft•lbf (15 ± 2.7 N•m)
I001947
Repair Section
75
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 they were before removal.
10.5 Perform the Inspection
• Perform the inspection of cooling performance and check for abnormal noise or abnormal
vibration.
10.6 Caster Maintenance
• 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.
Repair Section
76
10.7 Schematic
<Wiring Diagram>
AC460 V 3 φ 60 Hz
AP
G
RS T
TB1
MCC
G
460 V 230 V
HI
X4
H4
X1
1
F 2
1L1
3L2
2T1
4T2
5L3
7L4
6T3
8T4
A1
S1
R1
TNS
MCC
P
G
RTH
THS
DS
3
HPRS
1
2
2
CF1
A
MDP
TB1
8
1
RPHR
Condensate Pump
A2
CF2
1
G
FDS ODS
1
345
MC
IOLC
2
HI
MF2 LO
G
IOLF
HI
MF1 LO
G
IOLF
J8
J7
J6
J5
J4
J3
J2
J1
J9
J10
J101 J102 J103 J104
J106
J201
J105 J108
RB
LL+
EE+
CB
Attachment Plug
IOLF
Inner Overload Relay of Fan Motor
T B 1
Terminal Block
IOLC
Inner Overload Relay of Compressor
T B 2
Terminal Block
D
Full Drain Warning Switch
C
B
Control Board
T H S
Freeze Protection Thermistor
R
B
Relay Board
R T H
Room Thermistor
S
TB2
M F 1
Condenser Fan Motor
G
M F 2
Evaporator Fan Motor
HPRS
High Pressure Switch
M
Compressor Motor
M C C
Relay for Compressor and Condenser Fan Motor
C F 1
Capacitor for Condenser Motor
M D P
Condensate Pump Motor
C F 2
Capacitor for Evaporator Motor
F D S
Drain Float Switch
RPHR
Phase Reversal Relay
O D S
Drain Overflow Switch
T N S
Transformer
C
F
Grounding
Fuse (25 A)
I002172
DENSO SALES CALIFORNIA, INC.
Long Beach, CA 90810
www.movincool.com
P/N: SV0003- 01
Second Issue: December 2008